ROCAR® Silicon Carbide

CeramTec Czech Republic, s.r.o

Special Materials for Machines and Devices CeramTec Czech Republic, s.r.o.

Expert at ROCAR® – Advanced Ceramics Based on Silicon Carbide

A few years later, as production expanded, a second production line Production for sealing discs used in water faucets at CeramTec Czech Republic, s.r.o. was built. Currently, it represents started in 1994 when the mother one of the largest production company of CeramTec moved capacities in its branch. The core the production of technical, of the production is grinding, polishing, SiC-based ceramics from Selb (Germany) and oﬁ nal inspection of aluminium

to Šumperk (CR). oxide discs (Al2O3). Today, the plant in Šumperk with more than 300 employees is one of the largest subsidiaries of the German group of CeramTec, and it is the only plant that specializes in customizing advanced silicon carbide production under the brand name ROCAR®.

CeramTec – worldwide producer and supplier

AMERICA EUROPE ASIA The USA Germany China Brazil France Korea Mexico Great Britain Malaysia Italy India Poland Russia Scandinavia Spain The Czech Republic Silicon Carbide from ROCAR® Material for Special Applications

Slicon carbide belongs to the group of non-oxide ceramic materials, and is one of the hardest industrially-produced materials.

Silicon carbide gained its extraordinary hardness thanks to the homopolar bond between the atoms of silicon and carbon. This strong bond also causes its high elasticity and extremely low thermal expansion.

Silicon carbide also has high thermal conductivity and strength that is almost constant in a wide temperature range.

Regarding its electrical properties, silicon carbide belongs to the group of semiconductive materials.

Special Properties of Silicon Carbide

High heat resistance 1,350 / 1,800 °C. Corrosion resistance. Extremely high hardness. High strength in all temperature ranges (from – 100 °C to + 1,800 °C). Excellent thermal conductivity. Low thermal expansion. Low speciﬁ c density. specific density 6.4 g/cm3

heat fracture conductivity toughness 130 W/mK 9 MPa.m1/2

hardness bending as per Vickers strength SSiC HV 0.5 1,000 MPa 2,500 Al2O3

ZrO2 3,800 MPa compression strength Si3N4

Reaction Bonded Sintered Silicon Carbide Silicone Carbide RBSiC/SiSiC SSiC

In this material, the porous cavities of the original Sintered silicon carbide is created when pre- matrix structures of SiC are fi lled with metal pressed and very soft SiC granulate is sintered silicon during the so-called infi ltration fi ring at a temperature of more than 2,000 °C, when very process. Secondary SiC is created in this phase strong sintering bonds between the material grains and the material gains perfect mechanical properties are formed. and wear resistance. Firstly, there is lattice densifi cation, then the porosity Thanks to the minimal fi ring shrinkage, it can is lowered, and fi nally, sintering bonds between be used even for the production of large, the grains of SiC are formed. This fi ring process has complex components while achieving fi ne considerable product shrinkage of about 20 %. tolerances. The amount of silicon, however, limits the max. operating temperature to 1,350 °C The fi nal material is single-phase with higher and also the chemical resistance is limited up to pH 10. hardness, heat and chemical resistance than SiSiC.

Material Grades: Material Grades: ROCAR® SiG, ROCAR® SiF ROCAR® S1 ROCAR® Therm G, ROCAR® Therm F ROCAR® G5

10 3 9 copper 8 steel 7 thermal speciﬁ c 6 conductivity density

specific density g/cm density specific 5 material W/mK g/cm³ ® 4 ROCAR Therm G 180 3.1 ROCAR® Therm G steel 15 8 3 aluminium 2 aluminium-based alloys 230 2.8 1 copper 380 9 0 0 50 100 150 200 250 300 350 400

thermal conductivity W/mK Silicon Carbide from ROCAR® Material for Advanced Applications

Thanks to its balanced properties, Silicon Carbide ROCAR® ﬁ nds a wide range of use in many kinds of industries, power engineering, environmental protection, food industry, pharmaceuticals, and ballistic protection of people and vehicles.

Measuring wheel Tubes and piping Spiral nozzle for measuring the parameters for aggressive media with ﬂ ange of combustion products or combustion products for abrasive liquids

Seal Rings Journal Nozzles of Mechanical Seals Bearings

Thanks to its perfect Axial and radial pump Thanks to its excellent properties, silicon sliding bearings made chemical resistance carbide is a good using ROCAR® material and resistance material for tribological are good solutions, to abrasion, nozzles applications. and sometimes the only made from ROCAR® SiG We specialize possible solution, or ROCAR® S1 in the production for highly abrasive material are suitable of sealing rings or chemically aggressive for demanding for advanced media. The material operating conditions application – compressor of ROCAR® G5 that in the chemical or power seals, gas seals, sealings contains graphite engineering industry. for water turbines fi nds a wide range High-power spiral and ship propulsion of uses as graphite or tangential units (normal and jet), improves the friction spraying nozzles and other very properties and resistance with a long lifespan specifi c types of seal of the bearings are commonly installed rings. Monolithic in modes of insuffi cient in the desulfurization rings from ROCAR® lubrication, units of coal power for ship shaft seals and substantially plants. The nozzles are with a diameter of more decreases the friction supplied in fl anged that 1,000 mm are forces when starting or threaded versions. considered to be unique the pump. all over the world. Ballistic Machine Parts, Optical Thermal Protection Special Production Devices Technology

Very high hardness, Silicon carbide can It is convenient ROCAR® Therm G and F mechanical strength, be widely used to use silicon carbide materials, due to their low specifi c density, in mechanical from ROCAR® very high heat and affordable price engineering. In cases for supporting structures conductivity, are suitable make silicon carbide, when common materials of very precise optical for the construction especially the SSiC are overloaded and have apparatuses as it of heat exchangers version, a modern only a short lifespan, has negligible heat in the chemical industry, material used or they cannot be used expansion, low specifi c or cooling devices for constructing ballistic at all – e.g. chemical density, and high rigidity. and devices used protection for people, corrosion, abrasion, for indirect gas and liquid vehicles, and planes. high temperatures, heating. Burner tips or compression stress – made of silicon carbide these are typical are a popular solution situations when silicon in gas ovens. carbide can outdo Our coal burners the original materials that are stressed signifi cantly, even by high temperatures during combined load. and abrasive coal powder Materials from ROCAR® are used in the power are certifi ed by FDA engineering industry. for direct contact with food stuffs. Silicon Carbide from ROCAR® Production Process

We have optimalized Thanks to perfect mastery of our production technologies, we are able to produce our production processes components made of SiSiC up to a diameter for different materials of 1,000 mm and with a length of 950 mm. and achieved a high SSiC components are limited to a diameter of 700 mm and a length of 700 mm. standard of reliability over the years. We achieve optimal results in designing products and systems because of our experience and close cooperation with our customers. That is why we can minimalise production costs from the beginning.

Testing samples and prototypes are produced, tested, and developed for mass production in our development department. Serial Production Small Series Production (Single-Part Production)

BODY PREPARATION

DRY PRESSING ISOSTATIC PRESSING

DEBINDING PROCESS

GREEN MACHINING TURNING / MILLING

SiSiC SSiC INFILTRATION WITH SILICIUM SINTERING PROCESS (CA 1,600 °C) (CA 2,000 °C)

SANDBLASTING

HARD MACHINING (GRINDING, LAPPING, POLISHING) Silicon Carbide from ROCAR® Quality Management

The excellent characteristics of our materials and their applications are constantly optimalized in our laboratories, which enhances our technological advancement.

Nowadays we have Based on the ISO 9001 Thanks to our advanced advanced, quality system processes and monitored cost-effective, and ISO 14001 procedures, we produce development, environmental protection, customized mass production and production we use the latest techniques with the same accuracy technologies. of company management. as small series production and sample parts. Microstructures

ROCAR® SIG ROCAR® SIF

ROCAR® S1 ROCAR® G5 Silicon Carbide from ROCAR® Excellent Properties

Silicon carbide is extremely hard and shows excellent corrosion and heat resistance. Its perfect friction properties and high heat conductivity make it an ideal tribological material, especially for mechanical seals. IC 2 c density c Brand Material Speciﬁ Closed porosity (approximately) strength Bending °C 20 at Compression strengt Young‘s modulus elasticityof Vickers hardness HV 0.5 Fracture toughness K Weibull modulus Poisson‘s ratio Material characteristics General properties Mechanical properties Units g/cm3 Vol. [%] MPa MPa GPa MPa m1/2 DIN DIN DIN DINV DINV DIN DINV DINV Test values EN 623-2 EN 843-1 51067T1 ENV 843-2 ENV 843-4 51109 ENV 843-5 ENV 843-2 ROCAR® SSiC 3.15 2 410 3,500 430 2,300 4.1 > 10 0.17 S1

® ROCAR G5 SSiC 3.00 2 240 2,000 360 2,100 2.6 > 10 with 5% graphite

ROCAR® two-phase SiSiC / RBSiC 3.07 0 340 3,500 380 4> 140.17 SiG mat. 1) ROCAR® two-phase SiSiC / RBSiC 3.07 0 350 3,500 395 4> 140.17 SiF mat. 1)

Silicon carbide ROCAR® two-phase SiSiC / RBSiC 3.07 0 340 3,500 380 4> 140.17 Therm G mat. 1) ROCAR® two-phase SiSiC / RBSiC 3.07 0 350 3,500 395 4> 140.17 Therm F mat. 1)

1) HV 0.2 1200 (Si) / 2700 (SiC) 2) None of the materials has open porosity (water absorption 0 %) Tribological conditions in a disc / disc system: Wear – relation of low / high range: comparison of pairs made of different comparison of different materials materials

Wear High range 0.5 Friction coefficient µ Rv Aluminium oxide steel Silicon carbide 0.4

0.3 Rubalit® A1996 – ROCAR® S ROCAR® S1 – ROCAR® S1 0.2

ROCAR® Si – ROCAR® Si 0.1 Low range t 0246810 400 800 1,200 1,600 2,000 2,400 Hardness HV steel SiO2 Al2O3 SiC

SSiC SiSiC SSiC is resistant to most chemical media. For SiSiC material, the originally porous cavities As no metal silicon is present in the structure, are fi lled during the fi ring process with metal it can be used at temperatures up to 1,800 °C silicon. Because of the negligible shrinkage without any impact on its mechanical properties. in the fi ring process, complex components with Our new ROCAR® S1 is optimalized for mass small tolerances can be produced. Its maximum production using the dry-pressing process, operating temperature is 1,350 °C. Nevertheless, which enables high process reliability at lower it is not suitable for strong alkali media due production costs. to the content of metal silicon. Heat conductivityHeat °C 20–100 at heat linear of Factor expansion °C 20–200of heat linear of Factor expansion 20–400of °C heat linear of Factor expansion 20–600°C of heat linear of Factor expansion °C 20–1,000of capacity Heat °C 20–100 Cp capacity Heat °C 1,000 Cp °C Resistivity 20 at Resistivity°C at 400 Resistivity°C at 800 temperature Maximum for use in oxidizing environment temperature Maximum for use in reducing inert environment or No. material CeramTec Thermal and electrical properties W/mK 10–6 K–1 10 –6 K–1 10 –6 K–1 10 –6 K–1 KJ / kgK KJ / kgK  cm  cm  cm °C °C DIN DIN DIN DIN DIN DINV DINV IEC IEC IEC EN 821-2 EN 821-1 EN 821-1 EN 821-1 EN 821-1 ENV 821-3 ENV 821-3 672-1 672-1 672-1

115 3 3.6 4.1 4.6 0.6 1.103 < 10 1,500 1,800 333

104 4.1 4.4 4.5 4.9 0.7 1,500 1,800 350

115 3.4 4.1 4.4 4.9 0.7 1.3 < 1 0.024 0.034 1,350 1,350 678

120 3.8 4.3 4.5 4.9 0.7 1.3 < 1 0.035 0.055 1,350 1,350 780

180 3.9 4.2 4.3 4.7 0.8 0.018 0.027 0.037 1,350 1,350 685

190 4.1 4.3 4.4 4.8 0.8 0.055 0.062 0.053 1,350 1,350 785

Values and properties of ceramic materials: Typical values were used to present the individual materials. The crystal structure of these materials, statistical deviations in composition, and the inﬂ uence of production processes can cause changes in parameters, so the values mentioned above are only informative, common values, and they cannot be guaranteed. Corrosion Resistance SiSiC and SSiC

SiSiC SSiC Solution Medium concentration in % 20 °C 50 °C 20 °C 50 °C Acetone Concentrated ++++ Aluminium chloride10 ++++ Formic acid Concentrated ++++ Ammonia Concentrated + (+) + + Ammonium chloride25 ++++ Ammonium fl uoride 20 (+) 0 + + Ammonium nitrate50 ++++ Benzene Concentrated ++++ Boric acid Cold saturated solution++++ Calcium oxideCold saturated solution++++ Citric acid 50 ++++ Chromosulfuric acidConcentrated ++++ Iron (lll) chloride45 ++++ Iron (ll) sulfate25 ++++ Glacial acetic acidConcentrated ++++ Ethanol Concentrated ++++ Ethyl acetateConcentrated ++++ Fluorhydric acid Concentrated, 40 (+) 0 + + Fluorhydric acid + nitric acid Concentrated, 3:1 0 0 + (+) Urea Cold saturated solution++++ Potassium hydroxide 30 0 0 + (+) Potassium hydroxide20 (+)0+0 Potassium chlorideCold saturated solution++++ Potassium chromate35 ++++ Potassium nitrate20 ++++ Potassium permanganate5 ++++ Aqua regia Concentrated, 3:1++++ Copper (ll) chloride40 ++++ Copper (ll) sulfate20 ++++ Lithium hydroxide 10 + (+) + + Magnesium sulfate4 ++++ Methanol Concentrated ++++ SiSiC SSiC Solution Medium concentration in % 20 °C 50 °C 20 °C 50 °C Mixed acid Concentrated, 1:1++++ Sodium carbonate15 ++++ Sodium chlorideCold saturated solution++++ Sodium fl uoride 4 + (+) + + Sodium hypochlorite12,5 % of free Cl++++ Sodium tetraborate20 ++++ Sodium peroxide10 ++++ Trisodium phosphate10 ++++ Sodium sulfi de50 ++++ Sodium thiosulfate40 ++++ Sodium hydroxide 10 (+) 0 + (+) Sodium hydroxide30 00+0 Oleic acid Concentrated ++++ Oxalic acid Cold saturated solution++++ Phosphoric acidConcentrated, 85++++ Phthalic acidAlcohol solution++++ Propionic acidConcentrated ++++ Mercury (ll) nitrate10 ++++ Nitric acid Concentrated, 65++++ Salt acid Concentrated, 36++++

Fuming sulfuric acid 30 of free SO3 ++++ Sulfuric acidConcentrated, 98++++ Sulfuric acid50 ++++

Sulfurous acid 5–6 of free SO2 ++++ Silver nitrate10 ++++ TetrachloroethyleneConcentrated ++++ Carbon tetrachlorideConcentrated ++++ Hydrogen tetraﬂ uoroborate Concentrated (+) (+) + + Hydrogen peroxide30 ++++ Tartaric acid10 ++++ Zinc chloride60 ++++

+ = no corrosion (+) = corrosion possible 0 = corrosion occurs CeramTec International

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CeramTec Czech Republic, s.r.o. Žerotínova 62 787 01 Šumperk Czech Republic

Phone +420 583 369 111 Fax +420 583 369 190 E-mail [email protected]