Machinable insulating materials for high T
Macor
Macor Machinable Glass Ceramic was developed and manufactured by Corning Incorporated for use in the NASA space shuttle space program. After an extensive testing program by NASA and UCLA it became clear that Macor was more suitable than Silica Glass, Boron Nitride (BN) and Silicon Nitride in certain components and applications.
Over 200 parts of Macor MGC could and can be found on the now retired Space Shuttle Orbiter. Macor is still being used in the Aerospace
Industry and in several ongoing space programs around the world today. Machinable insulating materials for high T
Macor
For instance Ceramic to Metal bonding for pressure transducers. A few other examples are retaining rings at all hinge points, windows and doors. Larger pieces of Macor were used for NASA spaceborne gamma radiation deflector.
Machinable insulating materials for high T
Macor
Glass-ceramics are polycrystalline materials produced through controlled crystallization of base glass. Glass-ceramic materials share many properties with both glasses and ceramics. Glass-ceramics have an amorphous phase and one or more crystalline phases and are produced by a so-called "controlled crystallization" in contrast to a spontaneous crystallization, which is usually not wanted in glass manufacturing. Glass-ceramics have the fabrication advantage of glass as well as special properties of ceramics.
Machinable insulating materials for high T
Macor
Glass-ceramics usually have between 30% [m/m] to 90% [m/m] crystallinity and yield an array of materials with interesting properties like zero porosity, high strength, toughness, translucency or opacity, pigmentation, opalescence, low or even negative thermal expansion, high temperature stability, fluorescence, machinability, ferromagnetism, or high chemical durability, biocompatibility, bio-activity, ion conductivity, superconductivity, isolation capabilities, low dielectric constant and loss, high resistivity and break down voltage. These properties can be tailored by controlling the base glass composition and by controlled heat treatment/crystallization of base glass.
Machinable insulating materials for high T
Macor Glass-ceramics are mostly produced in two steps: First, a glass is formed by a glass manufacturing process. The glass is cooled down and is then reheated in a second step. In this heat treatment the glass partly crystallizes. In most cases nucleation agents are added to the base composition of the glass-ceramic. These nucleation agents aid and control the crystallization process. Because there is usually no pressing and sintering, glass-ceramics have, unlike sintered ceramics, no pores.
Machinable insulating materials for high T
Macor
●Machinable with ordinary metalworking tools ●Macor allows fast turnaround, no post firing required ●Holds tight tolerances, up to 0.01 mm ●Withstands high temperature, up to 1000°C (no load) ●Macor is clean, no outgassing and zero porosity. ●Rapid prototype services available
Machinable insulating materials for high T
Macor
Macor (machinable glass ceramic) has a continuous use temperature of 800°C and a peak temperature of 1000°C. Its coefficient of thermal expansion readily matches most metals and sealing glasses. It is non-wetting, exhibits zero porosity, and unlike ductile materials, won’t deform. It is an excellent insulator at high voltages, various frequencies and high temperatures. And, when properly baked out, it won’t outgas in vacuum environments.
Machinable insulating materials for high T
Macor
Macor can be machined to a surface finish of less than 0.5µm and polished to a smoothness of 0.01 µm. Configurations are limited only by available equipment and the experience of the machinist.
Machinable insulating materials for high T
Macor
Macor can also be joined or sealed-both to itself and to other materials-in a number of ways; metalised parts can be soldered together and brazing has proved to be effective method of joining the material to various metals: epoxy produces a strong joint, and sealing glass create a vacuum tight seal. Even a straight forward mechanical joint is possible. It can be thick film metalised using metal inks, or thin film metalised by sputtering. Possible metal coatings are Gold, Silver, Copper, Nickel, Platinum, Chrome and Tungsten.
Machinable insulating materials for high T
Macor thermal properties
Machinable insulating materials for high T
Macor mechanical properties
Machinable insulating materials for high T
Macor electrical properties
Machinable insulating materials for high T
Macor electrical properties
Machinable insulating materials for high T
Macor electrical properties
Machinable insulating materials for high T
Macor machining Key factors for successful machining are proper machining speeds and coolant. Macor can be machined with high-speed steel tools, but carbide tools are recommended for longer wear. Achieve the best results by using a water-soluble coolant especially formulated for cutting and grinding glass or ceramics. No post firing is required after machining.
Machinable insulating materials for high T
Macor composition Macor is a white, odourless, porcelain-like (in appearance) material composed of approximately 55% fluorophlogopite mica and 45% borosilicate glass. It has no known toxic effects: however the dust created in machining can be an irritant. Good housekeeping and appropriate machining techniques can avoid this irritation. The material contains the following compounds:
Machinable insulating materials for high T
Macor microstructure
Machinable insulating materials for high T
Macor components
Machinable insulating materials for high T
Shapal
Machinable insulating materials for high T
Shapal
Shapal is a machinable ceramic which combines a high thermal conductivity with a high mechanical strength with high strength. In particular, it has an excellent sealing ability to vacuum. It also has good heat resistance and an extremely low coefficient of thermal expansion.
Machinable insulating materials for high T
Shapal
Typical applications: Electronic components, especially where electrical insulation and heat dissipation are required. Also components where low dielectric constant and dissipation factor are required; fixturing parts where a low coefficient of thermal expansion is required.
Machinable insulating materials for high T
Shapal
●Vacuum components ●Electronic components where electrical insulation and heat dissipation are required ●Components where a low coefficient of thermal expansion required. ●Electronic components where low dielectric constant and dissipation factors are required. ●Heat sinks ●Crucibles for vacuum deposition ●Special refractory parts such as protective tubes ●A wide range of industrial and structural components
Machinable insulating materials for high T
Shapal
●Vacuum components ●Electronic components where electrical insulation and heat dissipation are required ●Components where a low coefficient of thermal expansion required. ●Electronic components where low dielectric constant and dissipation factors are required. ●Heat sinks ●Crucibles for vacuum deposition ●Special refractory parts such as protective tubes ●A wide range of industrial and structural components
Machinable insulating materials for high T
Shapal
Machinable insulating materials for high T
Macor VS Shapal
Machinable insulating materials for high T
Macor VS Shapal
Machinable insulating materials for high T
PEEK Polyether ether ketone (PEEK) is a colourless organic polymer thermoplastic in the polyaryletherketone (PAEK) family, used in engineering applications.
Machinable insulating materials for high T
PEEK Polyaryletherketone (PAEK) is a family of semi-crystalline thermoplastics with high-temperature stability and high mechanical strength.
Generally speaking, PAEK can have continuous operating temperature of 250 °C (482 °F) and under short-term loads can function up to 350 °C (662 °F). When burned it has the least toxic and corrosive fumes. It also has a low heat output when burned, so it qualifies for use in interior aviation applications. It also has good overall chemical resistance.
Machinable insulating materials for high T
PEEK It has a tensile strength of 85 MPa (12,300 psi) and a Young's modulus of 4,100 MPa (590,000 psi). Its yield strength is 104 MPa (15,100 psi) at 23 °C (73 °F) and 37 MPa (5,400 psi) at 160 °C (320 °F). It does not break in an un-notched Izod impact test.
Machinable insulating materials for high T
PEEK PAEK plastics are characterized by phenylene rings that are linked via oxygen bridges (ether and carbonyl groups (ketone)).
Machinable insulating materials for high T
PEEK The ratio and sequence of ether to ketones mainly affects the glass transition temperature and melting point of the polymer. It also affects its heat resistance and processing temperature. The higher the ratio of ketones the more rigid the polymer chain, which results in a higher glass transition temperature and melting point. The processing temperatures can range from 350 to 430 °C.
Machinable insulating materials for high T
PEEK Plastics that fall within this family include:
●PEK ●PEEK ●PEKK ●PEEKK ●PEKEKK
Machinable insulating materials for high T
PEEK applications One major engineering application is oil drilling components, such as seals, compressor rings, valve parts, gears, bearings, and wire coatings. It is also used in the chemical pump industry because it can withstand the temperature, stress, and has the corrosion resistance. In the automotive industry it is used to make gears and thrust bearings in transmissions.
Machinable insulating materials for high T
PAEK applications Due to its excellent resistance to hydrolysis it is used in medical devices because it does not break down when sterilized. PEKEKK is used to make surgical implants, such as artificial hips.
Machinable insulating materials for high T
PEEK PEEK is a semicrystalline thermoplastic with excellent mechanical and chemical resistance properties that are retained to high temperatures. The Young's modulus is 3.6 GPa and its tensile strength 90 to 100 MPa. PEEK has a glass transition temperature at around 143 °C (289 °F) and melts around 343 °C (662 °F). The thermal conductivity increases nearly linearly versus temperature between room temperature and solidus temperature. It is highly resistant to thermal degradation as well as attack by both organic and aqueous environments. It is attacked by halogens and strong Bronsted and Lewis acids as well as some halogenated compounds and aliphatic hydrocarbons at high temperatures. It dissolves completely in concentrated sulfuric acid at room temperature.
Machinable insulating materials for high T
PEEK applications Because of its robustness, PEEK is used to fabricate items used in demanding applications, including bearings, piston parts, pumps, HPLC columns, compressor plate valves, and cable insulation. It is one of the few plastics compatible with ultra-high vacuum applications. PEEK is considered an advanced biomaterial used in medical implants. It is extensively used in the aerospace, automotive, and chemical process industries.
Machinable insulating materials for high T
PEEK applications
Machinable insulating materials for high T
PPS Polyphenylene sulfide (PPS) is an organic polymer consisting of aromatic rings linked with sulfides. Synthetic fiber and textiles derived from this polymer are known to resist chemical and thermal attack. PPS is used to make filter fabric for coal boilers, papermaking felts, electrical insulation, specialty membranes, gaskets, and packings.
Machinable insulating materials for high T
PPS Polyphenylene sulfide is an engineering plastic, commonly used today to make high performance components. PPS can be molded, extruded, or machined to high tolerances. In its pure solid form, it may be opaque white to light tan in color. Maximum service temperature is 218 °C. PPS has not been found to dissolve in any solvent at temperatures below about 200 °C.
An easy way to identify the plastic is by the metallic sound it makes when struck.
Machinable insulating materials for high T
Thermoconductive PPS (Idemitsu)
Machinable insulating materials for high T
PPS applications
Machinable insulating materials for high T
PPS applications
Machinable insulating materials for high T
PPS Polyphenylene Sulfide (PPS) - A crystalline polymer having a symmetrical, rigid backbone chain consisting of recurring p- substituted benzene rings and sulfur atoms. A variety of grades suitable for slurry coating, fluidized-bed coating, electrostatic spraying, as well as injection and compression molding are offered. Polyphenylene sulfides exhibit outstanding chemical resistance, thermal stability, dimensionally stability, and fire resistance. PPS's extreme inertness toward organic solvents, and inorganic salts and bases make for outstanding performance as a corrosion-resistant coating suitable for contact with foods.
Machinable insulating materials for high T
PPS
●Tensile Strength 0.50 N/mm² ●Notched Impact Strength 1.50 Kj/m² ●Thermal Coefficient of expansion 70 x 10-6 ●Max Cont. Use Temp. 200 °C ●Density 1.34 g/cm3