Ceramic Industry February 2012

February 2012 | Volume 162 | Issue Number 2 www.ceramicindustry.com

R&D LAB EQUIPMENT and INSTRUMENTATION DIRECTORY

the expertise

CERAMITEC 2012 Technologies | Innovations | Materials

22 – 25 May 2012 New Munich Trade Fair Centre

The best gathering: Take advantage of the trade fair’s leading international role. As a global trade fair, CERAMITEC is the most international event of its kind and features the industry’s most extensive range of machines, equipment, systems, processes and raw materials for ceramics and powder metallurgy.

Contact: U.S. Office CERAMITEC 2012, Ms. Anika Niebuhr Ph: 646-437-1014 | [email protected]

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³ TABLEOFCONTENTS February 2012 | Volume 162 | Issue Number 2

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33

23

DEPARTMENTS

FEATURES

Inside CI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

³Heating up the Lab Purchasing a new lab/test furnace or kiln requires careful consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

International Calendar . . . . . . . . . . . . . . . . . 7 Ceramics in the News . . . . . . . . . . . . . . . . . . 8 People in the News . . . . . . . . . . . . . . . . . . . 10 Advanced Arena . . . . . . . . . . . . . . . . . . . . . 12 Buyers’ Connection . . . . . . . . . . . . . . . . . . . 36 What’s New . . . . . . . . . . . . . . . . . . . . . . . . . 36 Services Marketplace . . . . . . . . . . . . . . . . . 37 Classified Advertisements . . . . . . . . . . . . . 46 Advertiser Index . . . . . . . . . . . . . . . . . . . . . 46

ON THE COVER: Photo courtesy of Thermcraft, Inc.

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³Air Jet Sieving Air jet sieving is an efficient and effective method for drying fine bulk materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ³Analyzing Ceramics in Fuel Cells A critical factor in the successful use of fuel cells is verifying the composition of the ceramics used to form them. . . . . . . . . . . . . . . . . . . . . . . . 23 ³2012 R&D Lab Equipment and Instrumentation Directory Our exclusive annual quick-scan chart provides a handy resource for the selection of a range of laboratory equipment and instrumentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ³Nanonization: A New Word for a New Process A recent development in size reduction technology can improve the micronization process by a factor of 10. . . . . . . . . . . . . . . . . . 30

SPECIAL SECTION | BRICK & CLAY RECORD Crushing Abrasive Materials Selecting the right size reduction equipment will help improve product quality and reduce operating costs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GET CONNECTED! Visit www.ceramicindustry.com/connect

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CERAMIC INDUSTRY (ISSN 0009-0220) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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³ INSIDECI by Susan Sutton | Editor-in-Chief, Integrated Media

www.ceramicindustry.com 6075 B Glick Road • Powell, OH 43065 281-550-5855 (p) For subscription information or service, please contact Customer Service at: 847-763-9534 (p) • 847-763-9538 (f) • [email protected]

Tools of the Trade My house is over 100 years old, and I’m unfortunately not a “handy” person. This is not a good combination. Not only do I have no idea how to go about making the (seemingly neverending) repairs that are required, but I don’t even have the correct tools on hand when others come to lend a hand. Anyone who comes over to help always has to bring their own toolbox. Having the right tools available is vital to any endeavor, particularly when the project demands high accuracy and consistency. Manufacturers that are developing and producing high-tech ceramic products cannot operate effectively, efficiently or—most importantly—profitably if their equipment is out of date or in disrepair. The right lab/test furnace can mean the difference between a successful new product launch and a complete disaster. Important considerations when purchasing a new unit include temperature, expansion potential, geometry, and uniformity, among others. “Heating up the Lab” (pp. 16-18) has all of the details. Sample preparation is a key factor in any quality control program, and air jet sieving is proving to be an efficient step in the process. Read “Air Jet Sieving” (pp. 19-22) to find out how this method provides multiple benefits for the drying of fine bulk materials. High-tech products such as fuel cells require the use of high-quality, consistent ceramic materials. Multiple analysis techniques can be used to ensure positive results, but each technique brings its own benefits and challenges. Learn more about “Analyzing Ceramics in Fuel Cells” on pp. 23-25. I’m very excited to announce the debut in this issue of a new column by Dedalus Consulting’s Frank Kuzler. Focusing on advanced ceramics and glasses, the first installment of “Advanced Arena” discusses ceramic cutting tools and can be found on pp. 12-15.

EDITORIAL / PRODUCTION STAFF Amy Vallance, Publisher 281-256-8492 (p) • 248-283-6543 (f) • [email protected] Susan Sutton, Editor-in-Chief, Integrated Media 330-336-4098 (p) • 248-502-2033 (f) • [email protected] Teresa McPherson, Managing Editor 734-332-0541 (p) • 248-502-2102 (f) • [email protected] Kelsey Seidler, Associate Editor 614-789-1881 (p) • 248-502-2051 (f) • [email protected] Mike Holmes, Art Director 412-306-4358 (p) • 248-502-1075 (f) • [email protected] Bryon T. Palmer, Production Manager 248-244-6435 (p) • 248-502-9113 (f) • [email protected] Ralph Ruark, Senior Technical Editor Charles Semler; Sandra Spence; Frank Kuzler; Lynn Bragg; George Muha, Contributing Editors

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ONLINE EXTRA: Understanding Fuel Surcharges Columnist George Muha explains fuel surcharges and provides tips for negotiating rates.

R&D LAB EQUIPMENT AND INSTRUMENTATION DIRECTORY The online version of the R&D Lab Equipment and Instrumentation Directory is searchable by product or company, and includes extras such as hotlinks, spec sheets, and videos for select suppliers.*

EDITORIAL ADVISORY BOARD Jesse Hamilton, Director of Process Excellence, Dal-Tile International; William Babik, Technical Sales Manager, Nabertherm Inc.; Charles Semler, Ph.D., Refractories Consultant, Semler Materials Services; Gary Childress, General Manager, Orton Ceramic Foundation; Matthew Centa, Technical Support Manager - Ceramics & Glass, Rio Tinto Minerals; James E. Houseman, Ph.D., President, Harrop Industries, Inc.

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CORPORATE DIRECTORS Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Krywko Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Events: Scott Wolters Clear Seas Research: Beth A. Surowiec

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³INTERNATIONALCALENDAR

* Feb 7-10 Cevisama 2012 ³Valencia, Spain, http://cevisama.feriavalencia.com

Starbar and Moly-D elements are made in the U.S.A. with a focus on providing the highest quality heating elements and service to the global market.

* Feb 21-23 Composites 2012 ³Las Vegas, Nev., www.acmanet.org Feb 21-23 American Craft Council Wholesale Show ³Baltimore, Md., www.craftcouncil.org/wholesale * March 11-15 Pittcon ³Orlando, Fla., www.pittcon.org * March 24-26 DECO ‘12 ³Las Vegas, Nev., www.sgcd.org * March 26-28 St. Louis Section 47th Annual Symposium ³St. Louis, Mo., www.ceramics.org March 27-29 Westec ³Los Angeles, Calif., www.westeconline.com * April 17-20 Coverings ³Orlando, Fla., www.coverings.com

Over 40 years of service and reliability I Squared R Element Co., Inc. Akron, NY Phone: (716)542-5511 Fax: (716)542-2100

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 April 18-19 NanoManufacturing Conference & Exhibits ³ Boston, Mass., www.sme.org/cgi-bin/get-event. pl?--002081-000007-home--SME* May 8-10 Powder and Bulk Solids ³Chicago, Ill., www.powderbulksolids.com  May 15-17 CISILE 2012 ³Beijing, China, www.cisile.com.cn/en May 20-23 10th CMCEE International Symposium on Ceramic Materials and Components for Energy and Environmental Applications ³Dresden, Germany, www.cmcee12.de * May 22-25 ceramitec 2012 ³Munich, Germany, www.ceramitec.de May 28-31 Ceramics China ³Guangzhou, China, www.ceramicschina.com.cn June 13-16 KERAMIKA 2012 ³Moscow, Russia, 7-495-983-06-71 June 19-21 AAT Expo ³Rosemont, Ill. www.aatexpo.com * July 10-12 SEMICON West ³San Francisco, Calif., www.semiconwest.org * Look for Ceramic Industry magazine at these events! For a more detailed listing, visit our website at www.ceramicindustry.com.

CERAMIC INDUSTRY ³ February 2012

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³ INTHENEWS Bennu Glass to Set Up Manufacturing in Port of Kalama The Port of Kalama in Washington recently announced that wine bottle manufacturer Bennu Glass has acquired the assets at the port location previously owned by Cameron Family Glass Packaging and will be fully operational by mid-year. Bennu, which serves the wine industry in Washington, Oregon, California and western Canada, reportedly expected to hire up to 100 salaried and hourly personnel in the beginning of this year. At full capacity, the factory will produce over 100 million wine bottles per year. “To restart the factory, Bennu will make a significant investment in the existing facility at the Port of Kalama, which includes the installation of a new state-of-the-art oxygen fuel furnace,” said Jerry Lemieux, CEO of Bennu Glass. “The Port of Kalama offers exactly what we need to launch a successful manufacturing plant–diverse modes of transportation; a location close to an international airport at PDX; and a ready, skilled workforce.” For further information, visit www.bennuglass.com.

AGC to Establish Chinese Production and Sales Site Asahi Glass Co. Ltd. (AGC) has announced plans to establish a new production and sales site in China for cathode materials for the lithium-ion batteries (LiBs) used in mobile devices and electronic vehicles, as part of its enhanced efforts in the LiB materials business. AGC Seimi Chemical Co. Ltd., a subsidiary of the company, will convert a Chinese LiBs cathode materials manufacturer into its subsidiary, with production scheduled to begin around April 2012. This will approximately double the current production capacity of the AGC Group for cathode materials. Following the rapid increase in the global demand for LiBs, the market for cathode materials grew to 40,000 tons per year in 2010. The market is expected to expand to about 300,000 tons per year in 2020 due to a dramatic increase in the future demand for automotive use. The new AGC Seimi subsidiary will be the AGC Group’s first overseas production and sales site for LiB cathode materials. Visit www.agc.com for details.

Lifetime Brands Acquires Stake in GS Internacional Lifetime Brands Inc. announced it has acquired a 40% equity interest in GS Internacional S/A (GSI), a leading wholesale distributor of branded housewares products in Brazil. GS Interna8

cional markets dinnerware, glassware, home décor, kitchenware and barware to more than 7,000 customers, including major department stores, housewares retailers, and independent shops throughout Brazil. The company’s principal office and distribution facilities are located in Serra, State of Espirito Santo, which is close to Vitória, Brazil’s largest container port. GSI also maintains a showroom and offices in São Paulo. For further information, visit www.lifetimebrands.com or www.gsnet.com.br.

Saint-Gobain to Reward Innovation Saint-Gobain recently launched its fourth global Innovation Competition. Organized by the company’s NOVA Exter nal Ventur ing team, the competition reportedly rewards worldwide startup businesses that offer innovations in sustainable construction products, cash prizes and access to partnership opportunities with Saint-Gobain. NOVA External Venturing, an international team of Saint-Gobain representatives that identify and evaluate startup companies for strategic partnerships with all Saint-Gobain businesses, will award a first-place winner with $50,000 and second and third place winners with $25,000 and $10,000, respectively. Winners will also work with NOVA to explore a variety of working partnerships with Saint-Gobain, such as

February 2012 ³ WWW.CERAMICINDUSTRY.COM

licensing, manufacturing or commercial agreements, equity investment, or joint ventures. According to Rakesh Kapoor, director of Saint-Gobain Northboro (U.S.) R&D Center and NOVA External Venturing, companies that are poised for growth but lack the capacity to commercialize will gain invaluable advantages from participating in the NOVA Innovation Competition. For additional information, visit www.saint-gobain.com/ innovationcompetition2012.

NSG Announces Delay to Solar Glass Expansion in Vietnam The NSG Group recently announced that it has decided, after reviewing market demand in the current global economic environment, to delay the construction of the solar energy line previously announced to be built in Vietnam. A revised timetable for the project is reportedly under consideration. For more details, visit www.nsg.com.

AVX Suppliers Comply with Conflict-Free Program AVX Corp. announced that, as of December 1, 2011, all of its current tantalum powder and wire suppliers are fully compliant with the independently audited Conflict-Free Smelter Program. AVX says it plans to exclusively use tantalum powder and wire from conflictfree compliant smelters. AVX is reportedly the industry’s first manufacturer to reach this point, another major step forward in its ability to provide verifiable assurance to its customers that all AVX products contain only conflict-free tantalum, in accordance with the principles of the Dodd-Frank legislation and current OECD guidelines. OECD Due Diligence Guidance for Responsible Mineral Supply Chains from Conflict-Affected and High-Risk Areas can be used by any company potentially sourcing minerals or metals from conflict-affected areas of weak governance, and provides management recommendations to help companies respect human rights and avoid contributing to conflict through their

mineral or metal purchasing decisions and practices. For additional information, visit www.avx.com.

TricorBraun Acquires Trilogy Glass and Packaging TricorBraun recently announced it has acquired Trilogy Glass and Packaging Inc. of Santa Rosa, Calif. Trilogy will become part of TricorBraun WinePak, making it a $120 million division of TricorBraun that specifically services the wine industry. For additional information, visit www.tricorbraun.com or www. trilogyglass.net. 

Have News to Share with the Industry? Email news releases to Teresa McPherson at [email protected].

MTC Receives Trademark for Textured Alumina Morgan Technical Ceramics (MTC) recently announced it has received a U.S. trademark for its Sharkskin™ high-roughness textured alumina material, which is manufactured in Hayward, Calif. Sharkskin reportedly provides a high-roughness surface texture integral to the alumina base material. The roughened surface can improve process residue adhesion for film processes, primarily for physical vapor deposition (PVD), plasma-enhanced PVD and chemical vapor deposition (CVD). The improved adhesion can enhance equipment productivity by extending service life, reducing overall particulate defects and reducing the total number of preventative maintenance cycles per chamber. Used primarily for reactor domes, shields and cover rings, Sharkskin can serve as a foundation to help the twin-wire arc spray (TWAS) layer adhere better to the base ceramic, doubling TWAS adhesion. Sharkskin can also eliminate the need to re-grit blast parts after each cleaning, because the roughness is permanent and doesn’t degrade with multiple uses and cleaning. “Today’s thinner integrated circuits demand better film adhesion,” said Ed Tomasek, manager of new business development. “Advancements in process residue adhesion decrease chip defects and increase yields. Since adhesion is improved by roughening surfaces, Sharkskin offers an excellent option to replace or complement such traditional ceramic roughening methods as grit blasting or TWAS.” For more information, visit www.morgantechnicalceramics.com.

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The NSG Group recently announced that Mike Fallon, executive director and president, Automotive Worldwide, has decided to retire after 33 years of service with the company. He will leave the group in June 2012 after the ordinary general meeting of shareholders. Mohawk Industries Inc. recently announced that Brian Carson was appointed president of the Mohawk Flooring Business Unit and that John “J.T.” Turner Jr. was named president of the Dal-Tile Business Unit, effective January 2. Carson joined the company in 2006 after a 16-year career at Armstrong World Industries, where he held a number of senior leadership roles. He joined the Mohawk Flooring Business Unit as president of Hard Surfaces and was later promoted to vice president of Operations for the division. In early 2011, he assumed his current role as the business unit’s COO. Turner began his career with Dal-Tile in 1990, progressing through a series of leadership roles in Sales, Operations and General Management throughout the business. In 2005, Turner was promoted to senior vice president of Sales, and served in that role until being appointed senior vice president of Operations in 2008. He assumed his current responsibilities as COO of the business segment in early 2011. Carson and Turner will succeed Frank Peters, current president of the Mohawk Flooring Business Unit, and Harold Turk, current president of the Dal-Tile Business Unit. Both Peters 11:35:51 AMand Turk will continue with the company by leading strategic

Alfred University Professor Selected as Senior Member of SPIE Alfred University recently announced that S.K. Sundaram, Inamori professor of materials science in the Kazuo Inamori School of Engineering, is one of 166 worldwide researchers selected for senior membership in SPIE, an international society for optics and photonics. “Senior members are members of distinction who will be honored for their professional experience, their active involvement with the optics community and SPIE, and/ or significant performance that sets them apart from their peers,” according to the society. In order to be nominated as a senior member, a person must have been a member of the society for at least five years, and must have at least 10 years’ professional experience. Sundaram was chosen for his “achievements in millimeter wave material diagnostics and sensing.” Prior to joining the Alfred University faculty in January 2011, Sundaram was chief materials scientist at Pacific Northwest National Laboratory. He joined Pacific Northwest Laboratory in 1994 after earning his doctorate from the Georgia Institute of Technology. He became chief materials scientist at the lab in 2002, and has more than 16 years of scientific, technical and managerial experience.

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development activities in their respective segments. Asahi Glass Co. Ltd. recently announced several executive staff changes. Yoshiaki Tamura has been named senior executive officer, president of Electronics company and general manager of Display General Div., effective January 1. Kazuyoshi Watanabe has been appointed executive officer and general manager of Technology Development General Div., Electronics company, effective February 11. Shigekuni Inoue has been named executive officer and general manager of Electronic Glass General Div., Electronics company, effective February 11. In addition, the company announced that two officers will not return as of March 29: Yasutoshi Hirata and Nozomu Taguchi.

Attorney John C. Lemery has been appointed to the board of advisors of Blasch Precision Ceramics Inc., where he led the buyout team in securing the local ownership of Blasch from its parent company, Texas United, in 1995. Lemery has practiced law in the Capital Region for more than 40 years, and is an economic development specialist. Corning Inc. recently appointed Richard T. Clark, retired chairman and CEO of Merck, to its board of directors, effective immediately. Clark, who qualifies as an independent director, will also serve on the audit and compensation committees. Clark will hold office until Corning’s annual meeting of shareholders on April 26, at which time he will stand for election to a one-year term. Clark brings nearly four decades of experience with global markets and

manufacturing to Corning’s board. He became president and CEO of Merck in 2005 and chairman of the board in 2007. He transitioned from his CEO role in January 2011, and served as board chairman through November. H.C. Starck Group recently announced four new members to its executive board. John van Put will represent the Advanced Metals and Ceramic Powders (AMCP) business unit, and Dmitry Shashkov will act for the Fabricated Products (FPR) business unit. Together with CEO Andreas Meier and CFO Ludger Heuberg, they will form the company’s new management team. Axel Westerhaus, who had been on the executive board since 2007, has retired. 

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CERAMIC INDUSTRY ³ February 2012

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³ ADVANCEDARENA by Frank Kuzler, President, Dedalus Consulting

Why Ceramic Cutting Tools?

C

eramic materials have been used in the cutting industry for over 100 years. In fact, it did not take long for manufacturers in the metalworking industries to understand the benefits of using ceramics to increase productivity and efficiency in many applications. Ceramic cutting tools are constructed mainly from alumina (Al2O3) and silicon nitride (SiN). Recent advances have also introduced the use of silicon carbide (SiC) and ceramic matrix composites (CMCs) in order to enhance the performance of the cutting tool. Each of these ceramic materials has its own particular characteristics, but, in general, they all exhibit excellent hardness,

The manufacturing of ceramic tools also offers advantages over typical manufacturing of carbide tools in that they are typically prepared using powder metallurgy techniques and can be manufactured closer to near-net finish, thus saving the tool manufacturer hard machining costs. The main drawback of ceramic tools is that they are brittle and do not withstand thermal shock very well, which means that they are better applied to continuous, long-run applications.

World Market for Ceramic Tools In 2011, the global market for ceramic cutting tools was over $1 billion and equaled 8.5% of the total market for metalcutting tools (see Figure 1). From 2011 to 2016, the market will show above average growth of 6.8% annually (with year-toyear fluctuations). After a sharp decline in 2009 of over 30%, the global market for ceramic tools started a rebound in 2010 (see Figure 2). It is expected to reach pre-2009 levels in the second half of this year. Relative growth rates will be stronger than that of carbide, high-speed steel (HSS) and cermet tools, but lower than the growth rates for super-hard tools such as polycrystalline cubic boron nitride (PcBN) and diamond (PCD and single crystal). By 2016, the global market for ceramic cutting tools is expected to reach $1.5 billion.

Key Trends Figure 1. Ceramic cutting tools global market, 2007-2015 ($MM).

toughness and thermal conductivity. In fact, the advantages of using ceramic materials in manufacturing revolve around ceramic’s greater ability to withstand much higher temperatures than tools made from carbide or high-speed steel. Generally speaking, ceramic tools’ heat resistance exceeds 4000°F vs. about 1600°F for tools made from carbide powder. In addition, ceramic’s ability to operate at higher temperatures can result in a softening of the workpiece material, which allows for deeper and cleaner cuts. Thus, ideal machining temperatures (e.g., 2200°F for nickel alloys) can be accommodated by ceramic. However, these high temperatures are unattainable for carbide tools because they exceed the melting point of the cobalt binder.

Many general factors affect the demand for ceramic tools, including: • end-use market environment • competitive pressures from other tool types • customer preference and current workflow End users are currently scrutinizing tools for their ability to increase efficiency, reduce costs and save money. In conjunction with this greater sense of cost effectiveness, the implementation of new materials (including non-ferrous, hardened and composite) within many markets has driven a similar effort to reduce costs and/or decrease energy production in the ultimate product. The main driving markets behind this trend include automotive and aerospace, as well as developing markets such

Frank Kuzler is president and senior analyst at Dedalus Consulting Inc., a publisher of industrial market research and an independent consultancy. He has over 20 years of experience as an analyst and consultant, and is well-versed in interpreting regulatory environments affecting advanced technology markets. He specializes in advanced materials such as ceramics, diamond-based products, nanomaterials, cutting tools, abrasives, and carbides; electronic components such as RF and microwave, frequency-control devices (e.g., quartz crystals, oscillators, resonators), and surge protection components and devices; and photonics (e.g., germanium, IR optics, CCD and CMOS image sensors, photo diodes). Kuzler is also a member of the New York State Bar. He can be reached at (212) 709-8352 or [email protected]. Any views or opinions expressed in this column are those of the author and do not represent those of Ceramic Industry, its staff, Editorial Advisory Board or BNP Media.

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February 2012 ³ WWW.CERAMICINDUSTRY.COM

Figure 2. Ceramic cutting tools industry growth rates, 2007-2015 ($MM).

as medical and alternative energy. Thus, tool application has become much more specific. As mentioned previously, ceramic tools exhibit higher heat and wear resistance over carbide or HSS. This has led to greater use of ceramic tools in jobs that require longer run times and where the workflow would benefit from the softening of the material due to higher temperatures. For example, ceramic

tools are having a strong impact in the manufacture of aerospace parts made from hardened materials such as Inconel®, Waspalloy®, and Hastelloy®, as well as within the medical devices market where materials such as stainless steel, titanium, and biocompatible metals are used in implants and prosthetics. The limiting factors of the market for ceramic metal-cutting tools include strong competition from super-hard materials tools such as PcBN and PCD. The prices of these tools are continually dropping, and they are not only becoming more affordable, but they have higher wear resistance and can be used at higher speeds as well. However, it should be kept in mind that diamond tools (minus any specialized coating) can only be used on non-ferrous materials, and ceramic tools are still a better choice when short runs do not justify the higher tool price.

Ceramic Tool Types Ceramic grade tools are typically classified into three general categories: oxide, nitride and matrix ceramics. Oxide ceramics are alumina-based and are generally used in roughing and finishing applications of cast and gray irons. Increasingly, oxide ceramics are being used in dry machining applications at high

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ADVANCED ARENA

speeds. This is due to the advancements within materials science, including the incorporation of whisker-based materials. Nitride ceramics exhibit extremely high fracture toughness and are used for roughing and semi-roughing of cast irons under harsh conditions, such as

ditions. These are commonly referred to as SiC-whisker reinforced. Alumina reinforced with SiC whiskers is the toughest and most resistant to thermal shock of the oxide-based ceramics due to the extremely high tensile strength of the SiC whiskers. It offers the additional

Indexable tools make up over 75% of the demand for ceramic tools. when there is considerable starting and stopping that would typically increase fracturing. CMCs contain ceramics mixed with other hard materials like cemented and titanium carbides. They can also contain reinforcing whiskers and other materials to increase wear resistance and toughness under hot machining con-

benefit of being able to be run without coolant, thus making dry machining a common application while also being able to offer an increase in machining rates up to 800%. These benefits lead to increases in efficiency. For example, many machinists would slow cutting speed if temperatures were to approach maximum

O

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February 2012 ³ WWW.CERAMICINDUSTRY.COM

carbide limits. It is the opposite for ceramic tools, which excel in higher temperature conditions.

Solid vs. Indexable Tools Ceramic tools are offered in both solid and indexable types. Solid tools dominate in drilling applications where inserts are used in milling and turning applications. Solid ceramic tools are being more widely employed in highspeed machining, particularly drilling. The benefits of this tool type include high output, dry machining, decreased production and cycle times, high production per machine tool, and greater flexibility when using single-spindle machine tools. Indexable tools make up over 75% of the demand for ceramic tools. Indexable tools offer cost savings due to their ability to change out only the insert and not the entire tool. They offer comparable tool life to solid tools, along with savings on individual tool cost. Ceramic inserts are used mainly in finishing, turning of hardened material and super-alloys, and in the finishing of stainless steels. In 2011, milling made up the majority of the demand for ceramic inserts, comprising 60.8% of the total market. Turning made up the second largest market at 36.7%, while drilling was only 2.2% of the total. In solid tooling, however, the mix was level among milling, turning and drilling demand. When looking particularly at ceramic inserts, the main drivers include greater application in the finishing of hard-tomachine materials after roughing has been completed with carbide tools. In addition, advanced grades are being developed for hard turning applications; however, difficulties continue in achieving the cutting edges necessary for many hard turning applications. In 2011, silicon nitride- and aluminacoated inserts made up a combined percentage of demand for ceramic inserts at 39.5%. SiC whisker and SiN follow next, comprising 17.3% and 15.4%, respectively.

Trends in Ceramic Tooling Over a forecast period of five years, ceramic tools will continue to find their place in the application matrix, especially as greater emphasis is placed on specificity in machining. Advances in materials development, along with the preparation of ceramic tools, will increase the efficacy and the wear resistance of ceramic tools. Some key advances include: • New material compositions will be developed based on high-purity ceramic powders (particularly Al2O3), as well as continued enhancement using SiC carbide whiskers and matrix composites. These improvements continue to increase the versatility of ceramic tools and broaden the scope of applications in which they can be effectively and competitively employed.

CI02094Thermcraft.indd 1

• Optimized powder processing will lead to finer grain size (< 100 nm), which will lead to finer

ditional and time-consuming grinding. • The improvement of coated ceramic tools will be essential in more gen-

The improvement of coated ceramic tools will be essential in more general applications. cutting edges and greater tool wear resistance. The development of the finer grain size has led to some issues in tool construction, but some of these have been offset by the use of composites that increase the strength of the tool. The benefit of the finer edge size and wear resistance leads to close to near-net finishing in the workpiece material, which reduces cycle times and the need for finishing through tra-

eral applications where longer run times will justify the added expense of ceramic tools.  Editor’s note: The information in this article is based on the following reports from Dedalus Consulting: “Cutting Tools: World Markets, End-Users & Competitors: 2010-2015 Analysis & Forecasts” and “Indexable Inserts—World Markets, Applications & Competition: 2010-2015.”

1/13/09 1:07:34 CERAMIC INDUSTRY ³ February 2012PM15

³ Purchasing a new lab/test furnace or kiln requires careful consideration.

Heating UP THE LAB

by James Brocklehurst, Regional Sales Manager, and Derrick Wilson, Marketing Manager, Thermcraft, Inc.

M

any factors should be considered when purchasing a new electrical resistance-heated lab/test furnace or kiln. One of the first factors should be the desired operating temperature that will be used most often. Many new lab and test furnace purchasers often assume that one furnace can operate through a very broad temperature range, such as 10001800°C. While this is certainly possible, requesting such a range can lead to sticker shock, which can be discouraging to new furnace purchasers. Upon further consideration, the user may realize that 95% of their lab/test processes only require a maximum temperature of 1100°C, which would be more realistic and certainly more cost effective at purchase time. Lab and test furnaces can be divided into three temperature ranges according to their heater technology. The first range, based on wire heating element 16

technology, extends to a maximum of 1300°C, although some special use applications can reach up to 1400°C. The second group is based on silicon carbide (SiC) heating elements and generally has a useful upper range of 1550°C. The third group uses molybdenum disilicide (MoSi2) heating elements that can easily reach 1750°C and, with care, can be used to up to 1800°C. Of course, as the temperature increases, so does the cost. A rough rule of thumb is that if a furnace with a maximum temperature of 1300°C costs one unit, a furnace with maximum temperature of 1550°C will cost two to three units, and a furnace with a maximum temperature of 1750-1800°C will be three to four units. (This rough order of costing assumes the same general heated chamber geometry for each unit.)

Expansion Potential Another point to consider when buying a new lab/test furnace or kiln is future

February 2012 ³ WWW.CERAMICINDUSTRY.COM

expansion. It makes sense to order a furnace with specific working dimensions for existing projects. However, if planning indicates that future projects will require a larger unit, it might be wise to consider a larger unit for the initial purchase (depending on timeframes and cost restrictions). Unfortunately, due to a range of variables, it is impractical to estimate how much more a larger unit will cost without getting an actual price quote. In some instances, doubling the working volume adds less than twice the cost and delivery time; in other instances, the cost could more than double and the delivery could be significantly extended. If future projects dictate that a higher temperature unit will be required, several additional factors must be evaluated. The external size of the unit can increase with temperature because

of the need for more insulation. For this reason, the current existing normal operating temperature parameters should be studied with respect to issues of maintenance, reliability, and temperature uniformity as compared to a higher temperature unit. Furnaces are designed to operate most efficiently and give the best uniformity at their specified operating temperature. Purchasing a 1600°C rated furnace based on possible future applications and then using it for daily operation at 600°C only creates operational issues related to process control and temperature uniformity. This would be the equivalent to someone buying an F1 racecar to drive to the supermarket, with the remote possibility that they may have a chance to drive in the Monte Carlo Grand Prix someday. Capital costs, reliability, low speed performance, and maintenance issues might make a used VW a wiser purchase.

the application requires repeated access to the internal heated chamber, a split tube is the best option. The solid tube unit offers a generally flatter section of radial uniformity and costs typically 20% less. Sometimes the process requires that samples be shielded from direct radiation from the heaters. In this case, the

Uniformity

Box vs. Tube The next point to consider should be furnace geometry. Should you purchase a box unit or a tube unit? While a box unit is great for loading samples in a batch operation, a tube unit is generally better for continuous applications such as gas conditioning or material characterization testing that can take place inside of a process tube. Each style also has additional options to consider. Box units feature several types of doors, such as a simple front door (either vertical or hinged side swing). Special process applications might require a bottom-loading or elevator-type unit in which the samples are loaded on a base that is then raised into the bottom of the furnace. Elevator units can typically be made more uniform and can be loaded “hot.” In addition, if designed correctly, they have a faster recovery time and can be more efficient. Some drawbacks include a significantly higher purchase price and possible higher maintenance costs due to moving parts. With tube furnaces, options include either a solid tube or a split tube type. If

used as a carrier that is loaded ahead of time then placed in the furnace for processing. In other cases, rather than having a flat uniform temperature in the working area, it is required to have a known temperature gradient across the work area. A tube furnace would be the most beneficial and simply adjusted solution under those circumstances.

Box units feature several types of doors, such as a simple front door (either vertical or hinged side swing).

solid tube unit can be designed with a diffuser built in as an integral part of the heating structure, while the split tube will have to have a separate unit installed and supported. This diffuser will also somewhat negate the advantages of quick access to the samples being processed, unless the diffuser is

Uniformity is another issue that must be addressed when looking at a new lab/test furnace or kiln. A general rule of thumb states that the center 80% of the working dimensions of a furnace will exhibit a ±5° temperature variation. Should a greater uniformity be required, several options exist. For lower temperature units (approximately 700°C or lower), stirring fans or recirculating air heating systems would be necessary. For higher temperatures the furnace may need to be larger in order to achieve the required temperature uniformity or “flat zone,” perhaps a different heater configuration may be recommended, or the addition of multiple heat zones may provide the solution. Unfortunately, no hard or fast rule covers all situations. It is often the case that the design requirements are specific to the user’s uniformity and operating requirements. Process requirements may dictate the need for forced or controlled cooling. Many options are available, ranging from the introduction of cooled gases to vents, fans or a combination of all the above—including special programming of the temperature controllers to achieve a controlled cool-down cycle.

Furnace vs. Kiln The terms furnace and kiln are basically industry-specific jargon. The word kiln is most often used in ceramic processing and the cement industry, while furnace is used most often in metallurgical processing, general heating, and material characterization applications. Depending on the industry, the exact same unit can either be referred to as a kiln or a furnace. Generally speaking, the terms can be used interchangeably.

CERAMIC INDUSTRY ³ February 2012

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HEATING UP THE LAB

to the elements due to interaction of the nitrogen and compounds used in the silicon carbide and molybdenum disilicide heaters. Should the atmosphere be some sort of “forming gas” or explosive in nature such as hydrogen, various safety features will be required and the use of a retort may be needed. A retort is simply a sealed containment vessel that serves to protect the furnace from attack while containing hazardous compounds. A retort can significantly add to the purchase price of the unit, as well as additional operational, safety and maintenance issues.

Aesthetics

If the application requires repeated access to the internal heated chamber, a split tube is the best option.

Controls

Atmosphere

Another important consideration is the type of controls desired. Will a standard single set-point temperature controller work? With these controllers, the unit ramps at an uncontrolled rate to a set process temperature and stays there until manually shut down. Or will a programmable unit be required? Programmable units allow for adjustable ramp rates with hold times, soak times, and shut down after completion of the process. In addition, a data logging and/or computer interface may be desired, or an over-temperature control to ensure that the unit does not self-destruct. Of course, with increasing degrees of sophistication and technology, the price will also increase. Thanks to advances in technology and electronics, many of these options are significantly less expensive than they were just a few years ago and, in some cases, one controller can perform many different functions.

Another consideration should be the atmosphere that will be used in the unit, as this can have a significant bearing on purchase and maintenance costs. In general, if the unit is going to be operating in an air atmosphere, no special considerations are required. Should the process generate off-gassing of volatile compounds, efforts must be made for venting and possibly protecting the inside of the furnace from chemical attack, depending on the types of gases released. If an atmosphere is required, and it is a simple “blanketing gas” such as nitrogen or argon, then a gas inlet and exhaust port might be necessary in an otherwise standard furnace. The spent gas can then be safely exhausted from the work area via an exhaust hood or exhaust manifold piping. It should be noted that when using nitrogen with the higher temperature classes, special care must be taken to prevent damage

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Finally, cosmetic issues should be considered. Will the vendor’s standard color scheme work, or must the unit be painted a special color to match existing equipment or standards? Instead of a painted exterior, is it necessary for the unit to have a stainless steel exterior? While many companies offer both versions based on style and unit type, the stainless units often carry a premium. In addition, converting a standard painted unit to a stainless exterior will cause significant increases in cost and delivery.

Planning is Key Standard products are available from most vendors of lab/test furnaces and kilns, and some manufacturers offer standard units as well as fully customized units that can be specified and engineered to exact customer requirements. Careful consideration of the topics covered in this article will put you ahead of the curve when the time comes to begin the search for your new lab/test furnace or kiln.  For more information, contact Thermcraft, Inc. at 3950 Overdale Rd., Winston Salem, NC 27107; call (336) 784-4800; email [email protected]; or visit www.thermcraftinc.com.

³ Air jet sieving is an efficient and effective method for drying fine bulk materials.

Air Jet

Sieving by Kyle James, Vice President of Sales, Retsch Inc., Newtown, Pa.

A

In contrast to other methods, air jet sieving is usually carried out with only one sieve. The sieve is placed on the unit with the sample material and covered with a lid. A powerful industrial vacuum cleaner generates a strong jet of air, which disperses the particles on the sieve through the slotted nozzle rotating below the sieve mesh. With each rotation, the particles are dispersed and distributed over the complete sieve surface.

The jet of air causes a continuous new orientation of the particles on the sieve surface. Particles with sizes smaller than the sieve apertures are sucked in by the vacuum cleaner or—if the optional cyclone is used—collected in a laboratory bottle. When using sieves 25 mm high, the inflowing air causes the particles to impact on the lid, which helps to destroy agglomerates. The nozzle rotating below the sieve usually has a fixed speed, but varying this speed can be helpful. Sensitive sample materials, for example, should be sieved with a low speed to minimize stress on the material. This stress can be further reduced by using a 50-mm-high sieve so that the impact of the sample against the lid is less forceful. For samples that tend to agglomerate, sieving with high speed is more effective. The impact frequency of the parti-

Figure 1. Sample of ZrO2 powder sieved at 20 rpm.

Figure 2. Sample of ZrO2 powder sieved at 55 rpm.

ir jet sieving is often the method of choice for the dry sieving of materials with particle sizes below 40 microns. However, it is also a faster alternative to the vibratory sieving of materials of up to 250 microns.

Principles of Operation

CERAMIC INDUSTRY ³ February 2012

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AIR JET SIEVING

Figure 3. The open mesh function enables the nozzle to first move forward by 20° and then backward by 10°, instead of rotating uniformly.

Figure 4. Gauze of a 45-micron sieve after sieving quartz sand without (left) and with (right) the open mesh function.

cles against the lid is substantially increased, and even strong agglomerates are dissolved after short sieving times.

Application Example Two identical samples of ZrO2 powder were sieved at different speeds (see Figures 1 and 2).* Parameters included: • sieve—203 mm diameter, 25 mm height according to ISO 3310-1, 63 μm aperture size

• • • •

material—20 g of ZrO2 powder with agglomerates speed—20 rpm (sample 1) and 55 rpm (sample 2) sieving time—10 seconds and 2 minutes negative pressure—approximately 35 kPa Figures 1 and 2 (p. 19) clearly show that a high speed is beneficial to break down agglomerates. It is also possible to regulate the negative pressure generated by the vacuum cleaner, which allows variation of the impact speed of the particles. This, together with the selection of the sieve height, greatly improves the sieving of sensitive materials.

Reproducibility and Performance Fine-meshed sieves are particularly susceptible to so-called near-mesh particles, which block the sieve gauze. This has a negative effect on the sieve results and can also lead to premature wear of the sieve. An open mesh function (OMF) can help maintain the performance of the sieve and subsequently improve the reproducibility of results while minimizing time and effort for cleaning. This function enables the nozzle to move according to the principle “two steps forward, one step back,” which means the nozzle first moves forward by 20° and then backward by 10°, instead of rotating uniformly (see Figure 3). Near-mesh particles are therefore blown very effectively from the gauze, as no material lying on the sieve surface obstructs the air jet. Figure 4 shows the gauze of a 45-micron sieve after sieving quartz sand with and without the OMF. Some sieve apertures are blocked with particles where the sieving was done without the OMF, while the sieve apertures where the OMF was activated are completely free. By gently cleaning the sieve, this special feature helps to improve the reproducibility of the sieve analysis and increase the lifetime of the sieves.

Particle Size Distributions Although only one sieve can be used with the air jet sieving unit, it is still possible to determine particle size distributions. Two different methods can be used (see Figure 5). In the standard method, the complete amount of material to be sieved is placed on the sieve with the finest mesh size. After sieving and 20

February 2012 ³ WWW.CERAMICINDUSTRY.COM

Figure 5. Sieve analysis with the standard method (top) and the Swiss method (bottom).

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CERAMIC INDUSTRY ³ February 2012

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AIR JET SIEVING

weighing the fraction, the oversize is placed on the next larger sieve and sieved again. This procedure is continued until the complete sample is separated into fractions. Alternatively, the “Swiss” method requires that the sample is first divided into the number of size classes to be determined. Each part is then sieved individually with the corresponding sieve. This method can only provide reliable results if the sample division is carried out representatively to keep the particle size distribution in all part samples identical. The best results are obtained by rotary sample dividers, which divide the initial material into six, eight or 10 identical part samples. For the standard method, less sample material is required, whereas the Swiss method is more exact. Software-based evaluation not only facilitates and accelerates the data processing, but also eliminates user errors during data transfer and calculation. The software guides the user through the entire sieving process. It controls the sieve shaker and reads the weighing data to generate a protocol in accordance with standards.

Field Experience The German company Alpha Ceramics GmbH uses the air jet sieving machine AS 200 for the production of spray-

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February 2012 ³ WWW.CERAMICINDUSTRY.COM

granulated pressed powders from technical ceramics. Alpha Ceramics develops and produces well-engineered materials and products for spray granulation, pressing and fast-firing technologies. When pressed granules are compacted to components, it is crucial that the particle size distribution of the molding compound contains as little dust as possible. Therefore, spherical

“The introduction of this quality control measure proved to be uncomplicated and effective…” granules are produced from one or several raw materials with a particle size of below 2 microns by spray granulation. These granules allow the air to escape during the compaction process and can be automatically filled into the mold due to their flowability (i.e., they are “pourable”). Insufficient venting during compacting causes compression of the enclosed air, which expands when the pressed product is ejected from the mold and causes fissures in the product. Although Alpha Ceramics has been conducting particle size analyses of the finished spray granules for years, the interpretation of the ascertained particle size range has repeatedly caused the company to consider alternative methods to determine the “dust content” of the pressed granules. The operation of the analysis instrument was simplified, along with the interpretation of the results, with the introduction of the air jet sieving machine for quality control. If 50 g of material is sieved with a 45 μm sieve for 8 minutes with open mesh function, at least 49 g must remain on the sieve (which corresponds to a maximum of 2% dust content). If the percentage of fine particles is higher, the spray drying process parameters need to be corrected. “The introduction of this quality control measure proved to be uncomplicated and effective and, not least due to the easy handling of the instrument, was immediately accepted by all employees,” said Robert Kremer, Alpha Ceramics’ technical director.

Ensuring Quality Air jet sieving is an important method of quality control for fine bulk goods. Modern technologies and the possible variations of sieving parameters, in combination with reliable evaluation software, ensure reproducible sieving results over a long period of time.  For additional information, contact Retsch Inc. at 74 Walker Lane, Newtown, PA 18940; call (267) 757-0351; fax (267) 7570358; email [email protected]; or visit www.retsch-us.com.

Analyzing

Ceramics in Fuel Cells

by David Kluk, Technical Manager, NSL Analytical Services, Cleveland, Ohio

³ A critical factor in the successful use of fuel cells is verifying the composition of the ceramics used to form them.

F

uel cell technology was first demonstrated in the 1960s as a way to produce electricity by converting the chemical energy in fuels (e.g., hydrogen, methane, butane, or even gasoline and diesel) into electrical energy. This is accomplished by taking advantage of the natural tendency of oxygen and hydrogen to react. While this may seem like a simple concept, producing a commercially viable fuel cell has been the focus of intense research and development ever since. Now, as energy issues have become more acute, fuel cell technology seems on the verge of large-scale commercial implementation. At first, fuel cells appear to be simple devices, containing no moving parts and only four functional components: electrolyte, cathode, anode and interconnect. They are vibration free; therefore, the noise pollution associated with power generation is also eliminated. Fuel cells are also are clean, reliable and almost completely nonpolluting.

Much development has focused on solid oxide fuel cells (SOFCs) because they can convert a variety of fuels into electricity at higher efficiency (40-60% alone; up to 70% in a pressurized hybrid system) than engines and modern thermal power plants (30-40%).

Multiple Requirements For SOFCs to be commercially viable, cost-effective materials and processing must be developed. The first successful SOFC used platinum as both the cathode and anode, but less expensive alternatives are available today. Tem p e r a t u re a n d a t m o s p h e re requirements drive material selection for all the components. Materials must limit reactivity and interdiffusion between the components. The thermal expansion coefficients of the components must match as closely as possible to minimize thermal stresses that could cause cracking and mechanical failure. The air side of the cell must operate in an oxidizing atmosphere, and the fuel side must operate in a reducing atmosphere. Finally, to

produce sufficiently high current densities and power output, fuel cells must run at extremely high temperatures. The cathode must meet all the requirements noted above while also being porous to allow oxygen molecules to reach the electrode/electrolyte interface. In some SOFCs, the cathode accounts for over 90% of cell weight and provides structural support for the cell. The most commonly used cathode material is lanthanum manganite, which is typically doped with rare earth elements to improve conductivity. Most often, it is doped with strontium and called lanthanum strontium manganite (LSM). The electrolyte allows oxygen ions to migrate to the fuel side of the cell. This material must have high ionic conductivity and no electrical conductivity. It also must be dense enough to prevent gases from short-circuiting through it. Electrolyte materials include yttriastabilized zirconia (YSZ), doped cerium oxide and doped bismuth oxide. Of these, YSZ has emerged as the most suitCERAMIC INDUSTRY ³ February 2012

23

CERAMICS IN FUEL CELLS

able because it allows operation at up to 1000°C, stabilizes the zirconia in the structure at high temperatures and provides oxygen vacancies at one vacancy per mole of dopant. Cerium oxide can operate at lower temperatures (under 700°C), allowing the use of less expensive materials for the other components. However, cerium oxide is susceptible to reduction on the fuel side. The anode must meet the same requirements for electrical conductivity, thermal expansion and porosity as the cathode. It also must survive in a reducing atmosphere. These requirements make metals such as nickel the most widely used materials. However, nickel’s thermal expansion is too high to pair it

with YSZ, and it tends to lose its porosity at operating temperatures. These problems have been solved by making the anode from a nickel-YSZ composite. Finally, the interconnect must survive the high operating temperature of the cells and the severe environments. It also must meet the same requirements as the other components: 100% electrical conductivity, no porosity, compatible thermal expansion, and inertness with respect to the other fuel cell components. For YSZ SOFCs operating at about 1000°C, the preferred material is lanthanum chromium oxide (LaCrO3) doped with a rare earth element to improve conductivity.

Analysis Challenges A SOFC must sustain on/off thermal cycling without cracking, which would degrade its functional performance. Therefore, high fracture toughness is 24

essential to prevent premature failure and sustain structural integrity during operation. This high fracture toughness, however, also makes preparing samples for analysis difficult, and special proprietary techniques must be used to ensure accurate analysis. In addition, three other factors can affect the accuracy of the analysis. Each factor affects the analysis in different ways, and, unless samples are prepared carefully, the analysis can produce inaccurate readings of part composition and the impurities present. These factors include the types of ceramics in the part, the individual elements and the concentration ranges. The first two factors can cause interelement interferences that can lead to

false readings of the actual element concentrations. These interferences can be compensated for by applying wellknown correction factors to the measurements. The third factor controls the type of analysis that can be used. A number of analytical tests can be used to verify the composition and purity of ceramic materials. Each has benefits and limitations that must be considered before selecting the appropriate method. For bulk analysis to determine the concentration of the major chemical constituents of the ceramic material, X-ray fluorescence (XRF) and inductively coupled plasma optical emission spectroscopy (ICPOES) are used. To determine the presence of elements in trace amounts, particularly impurities, DC arc and inductively coupled plasma/ mass spectrometry (ICP/MS) are used.

February 2012 ³ WWW.CERAMICINDUSTRY.COM

XRF XRF determines element concentration by analyzing the emission of secondary (or fluorescent) X-rays from a material that has been excited by high-energy X-rays or gamma rays. The radiation can be analyzed either by sorting the photon energies emitted (energy-dispersive analysis) or by separating the radiation wavelengths (wavelengthdispersive analysis). Once sorted, the intensity of each characteristic radiation is directly related to the amount of each element in the material. Samples for XRF are made into pressed powders or fused glass beads. Pressed powders consist of the sample mixed with a small amount of binder and pressed into a pellet. If the sample has uniform particle

size, elements can be detected at the parts per million (ppm) level. One challenge of using pressed powders is acquiring matching material with known concentrations to calculate the final concentration. These may not be available for the element of interest and the ceramic material matrix. Fused beads overcome this problem because measurement standards can be created synthetically for comparison. Beads are created by mixing the sample with a flux and heating to form a glass bead. The main drawback of fusion beads is that the sample material is diluted by the flux, limiting detection accuracy to about 0.1-0.5%, depending on the fusion technique. ICP ICP instrumentation introduces an aqueous solution into an extremely hot plasma gas. The intensity of the light emitted is compared to previously measured standards of known element

concentration, and a concentration is computed. One advantage of ICP analysis is the ability to match the sample solution to a synthetically created standard once the sample has been dissolved by various digestion techniques. Also, concentrations from trace to major levels can be quantified using the same sample preparation technique. DC Arc Using DC arc analysis to determine trace elements involves vaporizing a 20- to 50-mg solid sample in a highintensity DC arc that creates a 5000°C corona. As in ICP analysis, the intensity of the light emitted is compared to standards of known concentration, and a concentration is computed. Measurement accuracy ranges from parts per billion (ppb) to 0.2%.

The main advantage of DC arc analysis is that it does not dilute the sample, which minimizes the potential for contamination (provided no additional preparation is required). However, because the sample size is so small, material homogeneity is critical for accurate results. In addition, fine particle size is required to ensure accuracy, so the material may have to be crushed and blended prior to preparing a sample. This process can potentially introduce contaminants. ICP/MS ICP/MS is a highly sensitive type of mass spectrometry that can determine element concentrations below one part per trillion. Coupling mass spectrometry with ICP allows for low-level detection in ceramics, from parts per billion to 0.1%. Unlike ICPOES, the ICP/MS instrument detects and quantifies the

specific atomic mass of an element vs. the measuring of photons at specific wavelengths. As in ICP analysis, light intensity is measured to determine the presence or absence of specific elements. Advantages of ICP/MS include the ability to identify and quantify a large group of elements, and measurement standards are readily available. The drawback to ICP/MS is that the ratio of sample to diluent can cause analysis errors and uncertainty. Also, because the sample must undergo digestion to break down the material, contamination is a potential problem.  For additional information, contact NSL Analytical Services at 4450 Cranwood Parkway, Cleveland, OH 44128; (216) 438-5200; fax (216) 438-5050; email [email protected]; or visit www. nslanalytical.com.

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CERAMIC INDUSTRY ³ February 2012

25

Kilns





Dust Collectors/Control

Furnaces

Firing/Drying

Dryers

Presses

Sieves

Mixers

Mills

Grinders/Media

Blenders

Company

Balances

R&D LAB EQUIPMENT AND INSTRUMENTATION DIRECTORY

Sample Prep

Forming and Finishing

Rapid Prototyping Equipment

Batching and Materials Handling

Pug Mill/Extruder

2012

Applied Test Systems Inc. 154 E. Brook Ln., Butler, PA 16002 (724) 283-1212, Fax: (724) 283-6570 www.atspa.com

Carbolite Inc. 110 S. Second St., Watertown, WI 53094 (920) 262-0240, Fax: (920) 262-0255 www.carbolite.us



Centorr Vacuum Industries 55 Northeastern Blvd., Nashua, NH 03062 (603) 595-7233, Fax: (603) 595-9220 www.centorr.com



Datapaq Inc. 187 Ballardvale St., Wilmington, MA 01887 (978) 988-9000, Fax: (978) 988-0666 www.datapaq.com

Eirich Machines Inc. 4033 Ryan Rd., Gurnee, IL 60031 (847) 336-2444, Fax: (847) 336-0914 www.eirichusa.com







EXAKT Technologies Inc. 7002 N. Broadway Ext., Oklahoma City, OK 73116-9006 (405) 848-5800; (800) 866-7172, Fax: (405) 848-7701 www.exaktusa.com



Expert System Solutions S.R.L. Viale Virgilio 58/L, Modena, Italy 41123 +39 059 8860020, Fax: +39 059 8860024 www.expertsystemsolutions.com

Glen Mills Inc. 220 Delawanna Ave., Clifton, NJ 07014 (973) 777-0777, Fax: (973) 777-0070 www.glenmills.com











Hockmeyer Equipment Corp. 6 Kitty Hawk Ln., Elizabeth City, NC 27909 (252) 338-4705, Fax: (252) 338-6540 www.hockmeyer.com



L & L Special Furnace Co. Inc. 20 Kent Rd., P.O. Box 2129, Aston, PA 19014-1494 (610) 459-9216, Fax: (610) 459-3689 www.hotfurnace.com









L&L Kiln Mfg. Inc. 505 Sharptown Rd., Swedesboro, NJ 08085 (856) 294-0077, Fax: (856) 294-0070 www.hotkilns.com/industry

Linseis Inc. 109 North Gold Dr., Robbinsville, NJ 08691 (800) 732-6733; (609) 223-2070, Fax: (609) 223-2074 www.linseis.com

Matrix Enterprises 858 Maple Ln., Waterville, OH 43566 (419) 878-0001, Fax: (419) 878-4241 www.matrix-ent.com

26

February 2012 ³ WWW.CERAMICINDUSTRY.COM/SERVICESDIRECTORY

 Red checkmark listings indicate display advertisers in this issue.



  



 















CERAMIC INDUSTRY ³ February 2012

Other Instrumentation

X-Ray Diffraction Instruments

Viscometers

Thermomechanical Analysis

Thermal Duffusivity

Thermal Conductivity

Thermal Analysis/DTA

Surface Area Analyzers

Spectroscopy Instruments

Environmental/ Safety Products

Rheometers

Powder Testing

Particle Size Analyzers

Nondestructive Testing

Hardeness Testers

Glass Testing

Dilatometers

Differential Scanning Calorimeter

Other Lab Equipment

Vacuum Cleaners

Exhaust Hoods/Fans

2012 R&D LAB EQUIPMENT AND INSTRUMENTATION DIRECTORY Instrumentation













27

Presses







Dust Collectors/Control

Sieves



Kilns

Mixers



Furnaces

Mills



Dryers

Grinders/Media



Firing/Drying

Sample Prep

Blenders

Company

Balances

R&D LAB EQUIPMENT AND INSTRUMENTATION DIRECTORY

Forming and Finishing

Rapid Prototyping Equipment

Batching and Materials Handling

Pug Mill/Extruder

2012













Micromeritics Instrument Corp. 4356 Communications Dr., Norcross, GA 30093 (770) 662-3633, Fax: (770) 662-3696 www.micromeritics.com

Mohr Corp. P.O. Box 1600, Brighton MI 48116 (810) 225-9494, Fax: (810) 225-4634 www.mohrcorp.com

NETZSCH Instruments NA LLC 129 Middlesex Tpke., Burlington, MA 01803 (781) 272-5353, Fax: (781) 272-5225 www.netzsch-thermal-analysis.com

NETZSCH Premier Technologies LLC Grinding & Dispersion Div., 125 Pickering Way Exton, PA 19341, (484) 879-2020, Fax: (610) 280-1299 www.netzsch.com







Oxy-Gon Industries Inc.



42 Old Route 28, P.O. Box 40, Epsom, NH 03234-0040 (603) 736-8422, Fax: (603) 736-8734 www.oxy-gon.com

PAUL O. ABBE



735 East Green St., Bensenville, IL 60106 (800) 524-2188; (630) 350-3012, Fax: (973) 256-0041 www.pauloabbe.com









PTX-Pentronix Inc.



Subsidiary of Gasbarre Products 41160 Joy Rd., Plymouth, MI 48170 (734) 667-2897, Fax: (734) 667-4350, www.ptx.com

Scientific Dust Collectors



4101 W. 126th St., Alsip, IL 60803-1901 (708) 597-7090, Fax: (708) 597-0313 www.scientificdustcollectors.com

Shimadzu Scientific Instrument Inc. 7102 Riverwood Dr., Columbia, MD 21046 (410) 381-1227; (800) 477-1227, Fax: (410) 381-1222 www.ssi.shimadzu.com



TevTech LLC























100 Billerica Ave., North Billerica, MA 01862 (978) 667-4557, Fax: (978) 667-4554 www.tevtechllc.com

Thermcraft, Inc. 3950 Overdale Rd, Winston-Salem, NC 27107 (336) 784-4800, Fax: (336) 784-0634 www.thermcraftinc.com

Thermcraft, Inc. - LAB-TEMP 3950 Overdale Rd., Winston-Salem, NC 27107 (336) 784-4800, Fax: (336) 784-0634 www.thermcraftinc.com

Thermcraft, Inc. - Marshall Furnace 3950 Overdale Rd., Winston-Salem, NC 27107 (336) 784-4800, Fax: (336) 784-0634 www.thermcraftinc.com

Union Process Inc. 1925 Akron Peninsula Rd., Akron, OH 44313 (330) 929-3333, Fax: (330) 929-3034 www.unionprocess.com

28





February 2012 ³ WWW.CERAMICINDUSTRY.COM/SERVICESDIRECTORY

 Red checkmark listings indicate display advertisers in this issue.

  



 

  

 

 







 

  

 

 



 





CERAMIC INDUSTRY ³ February 2012

Other Instrumentation

X-Ray Diffraction Instruments

Viscometers

Thermomechanical Analysis

Thermal Duffusivity

Thermal Conductivity

Thermal Analysis/DTA

Surface Area Analyzers

Spectroscopy Instruments

Environmental/ Safety Products

Rheometers

Powder Testing

Particle Size Analyzers

Nondestructive Testing

Hardeness Testers

Glass Testing

Dilatometers

Differential Scanning Calorimeter

Other Lab Equipment

Vacuum Cleaners

Exhaust Hoods/Fans

2012 R&D LAB EQUIPMENT AND INSTRUMENTATION DIRECTORY Instrumentation

 





29

Unlike conventional dry jet mills, the new system uses superheated steam as the grinding gas.

Nanonization: A New Word for a New Process ³ A recent development in size reduction technology can improve the micronization process by a factor of 10. by Stephen Miranda, Sales Director, NETZSCH Premier Technologies, LLC; and Thomas Schneider, Marketing Manager, NETZSCH-CONDUX Mahltechnik

M

icronization is a word long associated with the miniaturization of particles by jet milling to a range of 2-200 microns (μm). For most dry grinding processes, 2 μm is the practical limit of the technology. However, a recent development in the technology of size reduction through dry grinding can improve this process by a factor of 10. The new process uses superheated steam as the grinding gas in a fluidized bed jet mill. A steam jet mill can produce dry powders with median particle 30

sizes in the range of 130 nanometers (nm), with 100% of the distribution finer than 400 nm. This patent-pending technology is so novel that it could inspire the coining of a new process name: nanonization.

Searching for Solutions The drive to improve product performance and develop new products is huge, but it is often the littlest things that make the most difference. The quest for innovation has driven many ceramic industry researchers to look

February 2012 ³ WWW.CERAMICINDUSTRY.COM

to nanoparticles (materials ground to 0.2 μm and finer in size) to enhance product performance or unlock new applications for ceramic materials. Production of nanoparticles was achieved years ago, with myriad benefits. Nanoparticles are used to improve reactivity, provide increased surface area, and reduce material consumption, particularly with rare and high-value ingredients. Media milling technology—the use of grinding beads (media) to break down larger particles into smaller ones—currently plays a significant role in many areas of ceramic processing. Media milling processes typically involve dispersing the materials into a suspension; using media mills for grinding or dispersing; and then drying the suspension to recover the nanoparticles. Each successive step in the process is energy intensive and can result in product contamination and wear on the equipment. Since dry processing is limited in its capacity to produce particles in the nanometer size range, wet processing is used. This keeps many materials from being produced in efficient commercial-scale manufacturing and limits innovation. The demand for finer dry powder products in the submicron or nanometer scale has led to the development of a new milling technology that allows real comminution in this range. “Nanonization” of solids in a dry process provides the added benefit of being energy efficient and economical. Unlike conventional dry jet mills, the new system uses superheated steam as the grinding gas. Using superheated steam as the grinding gas in simple spiral or loop jet mills without an integrated air classifier has been a common practice for decades. Until now, it was not possible to produce materials with a well-defined upper particle size limitation. The new system includes an integrated air classifier for the separation of the exact par-

Table 1. A variety of products has been tested in both R&D labs and commercial installations.

Figure 1. The new system has produced d50 of 130-140 nm.

ticle sizes. These two factors make steam fluidized bed jet milling commercially viable.

Benefits Steam can be provided to a jet mill at very high pressures compared to air. Higher grinding pressures yield higher jet speeds. At a pressure of 40 bar absolute, the jet speed is nearly 1,200 m/sec. (Higher pressures are both possible and beneficial.) Compared to air’s near maximum of 600 m/sec, the kinetic energy at the nozzles is approximately four times higher. This increased grinding energy results in much finer size reduction in the milling process, sending finer particles to the classifier. As a medium for dynamic classification of particles, steam allows a finer cut size than air. The properties of steam, which has a lower dynamic viscosity and lower density than air, as well as a higher speed of sound than air, makes possible a higher flow velocity within a classifier wheel. Thus, the acceleration forces acting on the material being separated are higher, and the possible cut sizes are finer. Since finer particles are already available due to higher jet energy, this is a decisive step in the production of

nanometer-sized particles by means of dry grinding. Higher jet energy can also result in significant increases in capacity and improved energy efficiency. Jet speeds of up to 1,200 m/s, along with the increase of the kinetic impact energy, can lead to significant increases in mill throughput. For example, throughput for an aluminum oxide powder with a fineness of 2.3 μm (d99) is more than tripled. Similar results with other materials have been realized. For materials of the same particle size and with equivalent gas flow rates, throughput rates are increased by two to three times, depending on the friability of the materials. A variety of products has been tested in both R&D labs and commercial installations (see Table 1). For example, the production of finely ground amorphous graphite with a d99 of less than 4 μm by conventional dry milling has, in the past, been problematic. The new system has produced particle sizes significantly below d99 ~ 1.0 μm. Another interesting example is in the range of oxide ceramics. Aluminum oxide with conventional dry milling can result in a fineness of about 2.3 μm (d99). The new system has pro-

Product

Fineness d50

d99

Alumina

0.13

0.35

Barium

0.13

0.34

Iron oxide

0.07

0.37

Glass frits

0.57

1.89

Amorphous graphite

0.16

0.58

Limestone

0.54

1.87

Silicon carbide

0.24

1.04

Wollastonite

0.3

2.6

Zirconium oxide

0.44

2.59

duced d50 of 130-140 nm with a d99 of 0.34 to 0.35 μm—results that could previously only be achieved through wet grinding (see Figure 1). These results have led researchers and engineers to rethink applications and materials. With new materials come new markets and expanding opportunities.

The Secret of Success Steam jet milling provides the ability to grind solids to higher fineness because of higher kinetic energy. However, the precise control of the milling process itself is only possible when a grinding mill has an internal classifier. The classifier controls the particle size by preventing the material from leaving the grinding system until the particle size reaches the correct fineness. The performance of a conventional classifier with air is limited to a d97 of approximately 2 μm. This, of course, varies with the material properties (e.g., specific gravity). Steam also provides the solution to controlling the classification of superfine particles generated with this process. Two forces act on particles in a classifier field: mass force and drag force. Mass force tends to move particles to the coarse fraction, while drag force tends to move particles to the fines fraction. As previously mentioned, steam has a much lower dynamic viscosity and density than air, as well as a higher speed of CERAMIC INDUSTRY ³ February 2012

31

NANONIZATION sound than air. Steam gas properties propertties of influence both mass force and dr drag rag force and allow for the production ction of o finer particle sizes. The higher speed of sound nd in steam results in a significantly antly higher peripheral velocityy of the gas flow within the classiassifier. This increases the acceleraeration of the particles in the classifier field. For example, iff the peripheral velocity increases from 200 to 300 m/s, the equivalentt effect of the mass force on the particle ticle is a relationship of the square off the difdifference. Therefore, in this example, ample, the mass force on the particles is incre increased eased by a factor of 2.25, moving the he cut ssize to a finer range. The reduced dynamic viscosity scosity also reduces the drag force on the particle. Drag force tends to move the particle to the fine fraction. Reducing the drag force lessens the tendency to drag coarser particles to the fine fraction, also moving the cut size to the finer range. Combined, these two

32

February 2012 ³ WWW.CERAMICINDUSTRY.COM

A classifier wheel.

factors reduce reduc the median particle size of the pr product roduc by a factor of 0.3 times finer or m more. This means if an air jet mill iss capable of producing particles at capa 1.0 μ μm, now it is possible to make that same product 0.3 μm or finer.

In the Future Th needs of ceramic compaThe nies ni and suppliers selling into the th ceramic industry that are developing dry materials in the dev nanometer size range can be met nan with steam jet milling technology. Additional developments in grindAddit A ing in ng are always possible and ongoing, but steam jet milling is currently the pinnacle in dry ggrinding technology.  For more information, contact NETZSCH Premier Technologies, LLC at 125 Pickering Way, Exton, PA 19431; call (484) 879-2020; fax (610) 280-1299; or email [email protected].

CRUSHING Abrasive Materials

³  Selecting the right size reduction equipment will help improve product quality and reduce operating costs. by Chris Nawalaniec, National Sales Manager, Stedman, Aurora, Ind.

M

anufacturers in the brick, ceramic and glass industries have to deal with notoriously difficult challenges in material size reduction. What makes glass and ceramics tough, durable products presents difficulties during the preparation of raw materials. Recycling process scrap and end-of-life disposal are important in considering the size reduction requirements.

fit all. Selecting the best type of equipment for your process will affect plant profitability.

Evaluating Size Reduction Needs Five basic questions should be asked to begin an evaluation of a size reduction process. If you begin your project by defining these variables, you will be off to a good start: • What is the material to be crushed?

Test plants help quantify customers’ unique size reduction needs.

The basics of size reduction are simple. Size reduction is simply putting energy into material to make large pieces smaller. Hundreds of machines— ranging from simple to complex—exist to accomplish this objective in many industries and for many materials. A variety of machinery choices are available simply because one size does not

• What is the size range of the feed to the crushing machine? • What is the desired production rate (Kg/HR, TPH, PPH)? • What is the moisture range of the raw material? • What is the size range desired of the material after crushing? It is important to find a good part-

ner with a broad range of size reduction expertise. The best suppliers will provide the following: a variety of size reduction machine types; a full-service test plant and toll crushing capability; after-thesale field service; a good understanding of the size reduction processes’ ability to influence the whole process; and a commitment to the industry.

Machine Types Companies that offer a limited size reduction product range (i.e., only one or two types) will logically be more limited in the solutions they can provide. The temptation exists to offer suboptimal solutions by stretching to meet size reduction processing objectives. For example, maximum feed size can limit machinery selection and applicability. Most machines are limited by the largest feed accepted. A larger machine or a different machine style altogether may have to be selected to accommodate bigger pieces in the raw material feed stream vs. the tonnage determining the machine style needed. Reduction ratios vary by machinery type, so this can be another area where a manufacturer can be led astray. For instance, if a glass recycler wants to crush to an intermediate fine product, machines can be selected with reduction ratios of: • 2:1—roll crusher, jaw crusher • 10:1—vertical shaft impactors • 20:1—cage mills, hammermills • 200:1—ball mills Which piece of equipment should be used? Until the five questions listed above are answered and the entire process is understood, the answer will not be clear. Testing your material is the best way to proceed in your evaluation. CERAMIC INDUSTRY ³ February 2012

33

ABRASIVE MATERIALS

The choice of size reduction equipment impacts more than just particle size. Other factors affected by the size reduction process may not be as obvious, but they can have significance. For instance, additional factors can include: • Ability to use one machine vs. two or three • Operating costs vs. acquisition cost tradeoffs • Particle shape and the effect on product quality • Particle shape and the effect on operating costs • Total energy required for a system

Some North American companies have continuously operated test facilities for over 80 years and continue to test for over 100 customers a year. This service will always be in demand due to unique customer requirements. Testing provides data on a core material processing step—size reduction— and helps to quantify the cost of ownership for the equipment. For a nominal testing fee, producers can tap into the size reduction equipment manufacturer’s knowledge base. Testing produces information on the following: • Pre-processing and post-crushing particle size distribution • Moisture • Power consumption per unit processed (e.g., KW/MT) • Wear cost estimate due to metal replacement parts

Testing and Toll Crushing The best size reduction equipment companies operate test plants. Each year, these facilities help quantify the unique size reductions that customers need.

Hi-Vac Proud ®

Thhere’s There’s ’ a feeling feeling you get when whh n you ou own any Hi-Vac product. Maybe be it’s the confidence you gain knowing wing that your Hi-Vac product will perform efficiently and flawlessly ssly every day. Maybe it’s your pride de in knowing that your decision to buy Hi-Vac helps create a cleaner, safer, healthier, more productive environment. All you ou know is that when it comes to the highest quality, most respected industrial vacuum systems on the market, you are 100% Hi-Vac Proud. Industrial Vacuum Systems

www.hi-vacproducts.com

800.752.2400 34

After-the-Sale Service Plant personnel with size reduction equipment should ask themselves: “When did I last see someone from the crusher manufacturer?” If you don’t know or can answer “never” to this question, how good is your size reduction business partner? Factory-trained service and parts sales personnel are part of the value proposition for your equipment selection process. Staying engaged with the crusher manufacturer will help maintain profitability by having professional advice available to keep the crushing systems running in good order. In addition, as machine designs and features are introduced, knowing the original equipment manufacturer helps plant process and maintenance stakeholders evaluate new features that can improve output, lower operating costs, or improve product quality.

Application Example ®

Want to feel that Hi-Vac Pride for yourself? Visit us online at

• Machinery selection confirmation Toll crushing is a service for a fee. Toll crushing customers include those undergoing new product development or process improvement/development. Toll crushing customers are also those companies that have an intermittent need for crushed materials (e.g., sending material quarterly for crushing) or have limited capital to purchase equipment. Toll crushing can allow a relationship to develop between companies before the end user invests capital in buying equipment. In the proper circumstances, toll crushing can be a valuable, worthwhile service.

ENVIRONMENTAL PRODUCTS FOR A CLEANER WORLD www.hi-vac.com

740.374.2306

[email protected]

February 2012 ³ WWW.CERAMICINDUSTRY.COM

Brick plant grinding rooms prepare clays, shales and scrap brick for blending and, ultimately, thermal processing in kilns to produce residential- and commercial-grade brick. Historically, grinding was achieved in three size reduction machines. New features were introduced by a company that solved several problems that are pervasive in ceramic raw material preparation: • High-moisture raw materials

special section | brick & clay record

• • • •

High-plasticity materials Abrasive Large feed size Need for a consistent particle size distribution after crushing • Improved particle shape properties Producers in the brick industry quickly adopted the new technology and realized a step-change decrease in material preparation operating costs. Quantifiable benefits include: • Ability to eliminate two crushing machines and related material handling equipment from the process, thereby lowering cost of ownership • Consistent output production rates with varying moisture of incoming raw material • Consistent output particle size • Reduction in extruder power consumption due to improved particle shape

• Increase in extruder die life due to improved particle shape • Significant reduction in direct costs due to wear parts • Reduction in maintenance and repair costs

and consideration of these points may help guide you in the best direction objectively. You will want your partner to be there when you need them.

Conclusion Industry Commitment Is your size reduction equipment manufacturer dabbling in your industry or are they committed to your industry? Well-maintained crushers should be expected to last 20-30 years. A healthy business partner will belong to and be active in your industry trade association, develop products and features to help solve industry problems, maintain a current website on their products and services, and exhibit at industry trade shows. Taking a step back when evaluating your choices in size reduction

Don’t ignore the importance size reduction has on profitability and product quality. Take time to objectively evaluate the systems, equipment, and personnel needed to crush, screen, convey, and store your raw materials. You may be surprised at the improvement opportunities that exist in your plant.  For more information, contact Stedman at 129 Franklin St., Aurora, IN 47001; call (800) 262-5401 or (812) 926-0038; fax (812) 926-3482; email sales@stedman-machine. com; or visit www.stedman-machine.com.

CERAMIC INDUSTRY ³ February 2012

35

³ WHAT’SNEW

³ BUYERS’

CONNECTION Glass Furnace Emissions

UltraCat Catalyst Filter Controls NOx at 350°F to 700°F Particulate to less than 0.1 lbs/ton of glass

s /NESYSTEMFOR0- ./x 3/2 (#L ORANYCOMBINATION s ,OWTEMP./x CONTROLBYCATALYST EMBEDDEDlLTERS ELIMINATESCOSTLY STAND ALONE3#2 s /VERCONTROL OF./x 3/2 (#L

Call or email today 0HsKEVINMOSS TRI MERCOM

Since 1960

www.tri-mer.com

LANCASTER PRODUCTS Industrial Mixer The new model K-3.5 mixer has been added to this company’s K-Series line of counter-current high-intensive industrial mixers. With a working volume of 6 cu ft (170 liters), the mixer is designed primarily for limited or prototype production. This particular K-3.5 mixer was recently delivered for use in mixing precision-glass batch, where the highest quality batch mix is crucial. The mixer can also be used for catalysts, proppants, refractories, ceramics and other applications. Visit www.lancasterprd.com.

©

Factory Headquarters: Owosso, Michigan

2012 Tri-Mer Corp.

MORGAN TECHNICAL CERAMICS

The 104-page catalog includes Puratronic® high-purity base metal salts, which are reportedly the leading choice of pharmaceutical and electronic companies as the basic building blocks for many manufacturing processes. In addition, the catalog lists the REacton® brand line of high-purity rare earth compounds, as well as Alfa Aesar’s line of ultra-dry anhydrous materials. Visit www.alfa.com.

HENKEL Ceramic Coating

A new two-part, sprayable ceramic coating designed to protect metal surfaces on industrial equipment from

Biocompatible DLC Coatings

A range of Diamonex® diamond-like carbon (DLC) biocompatible coatings is now available that can be used for medical implants, including left ventricular assist device (LVAD) heart pumps and artificial joints. The coatings reportedly offer excellent adhesion and wear resistance and can extended component life. The range of optimized DLC coatings reportedly provides a super-hard, low-friction coating with properties approaching those of natural diamond. Applied to both LVAD housing and rotor elements, the coatings can provide a medical barrier and wear-resistant coating that lengthens the life of the device. In addition, the low coefficient of friction (0.03-0.25) also increases the mechanical efficiency by minimizing friction at startup and during operation. According to the company, the co atings can provide excellent adhesion and wear-resistant protection for both artificial hip and knee replacements. Visit www.morgantechnicalceramics.com.

Contact Amy Vallance 281.256.8492 • [email protected]

TRUST IN RESEARCH

ALFA AESAR

wear, abrasion and corrosion is now available. Packaged in a reusable dualcartridge dispenser, Loctite® Nordbak® 7255™ sprayable ceramic coating can be sprayed onto metal components to create smooth, low-friction surfaces that improve equipment efficiency. The coating can reportedly be quickly and evenly applied to large surfaces and complex or intricate areas that are difficult to coat. It can be used on tank linings, mixing vessels, pump housings, impellers, chutes, troughs and centrifuge components. The solvent-free, thixotropic formulation can be used in overhead applications, and reportedly adheres well to a range of metal surfaces. Visit www. henkelna.com/nordbak. 

High-Purity Inorganics Catalog

www.clearseasresearch.com

CSR2012_Ads_7.875x10.5.indd 1 Untitled-1 1

36

12/19/11 AM 12/19/11 11:33 1:21 PM

This company, a Johnson Matthey company, has published a new “High Purity Inorganics Catalog,” which lists over 1,200 high-purity inorganic materials, including base metal compounds, rare earth compounds, and ultra-dry materials for airand moisture-sensitive applications.

February 2012 ³ WWW.CERAMICINDUSTRY.COM

Have Product News to Share with the Industry? Email news releases to Teresa McPherson at [email protected].

³ SERVICESMARKETPLACE ³CONSULTING & ENGINEERING SERVICES

³RECYCLING SERVICES

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A-Ten-C, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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³CONTRACT MANUFACTURING SERVICES C-Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Coalition Technology Co., Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CoorsTek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

³CONSULTING & ENGINEERING SERVICES

³FINISHING & MACHINING SERVICES Advanced Ceramic Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Bullen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 EBL Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Ferro-Ceramic Grinding, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Machined Ceramics, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 O’Keefe Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 PremaTech Advanced Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Sonic-Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

³FIRING & DRYING SERVICES Allied Kiln Service Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 American Isostatic Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 HED International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Ipsen Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 I Squared R Element Co., Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 SBL Kiln Services, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 TevTech, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

³GLASS SERVICES Ceradyne VIOX, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Fuse Tech/Hot Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Glass Inc. International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 SEM-COM Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Specialty Glass, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

³INDEPENDENT AGENTS Tape Casting Warehouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Taylor Tunnicliff Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

³LABORATORY & TESTING SERVICES Activation Laboratories Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Geller Microanalytical Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 JTF Microscopy Services, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Micron Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Netzsch Instruments NA LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 NSL Analytical Services Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Quantachrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 West Penn, Spectrochemical Labs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Phone: 480-895-9830 FAX: 480-895-9831 e-Mail: [email protected]

Dr. Charles E. Semler President/Consultant SEMLER MATERIALS SERVICES 10153 E. Elmwood Dr. Chandler, AZ 85248

High Shear Compaction— Superior Tape Forming Process • Full thickness single layer tapes: • HSC efficient high-volume 0.1 mm to greater than 13 mm process compatible with any powder: ceramic, glass, metal • Aqueous binder systems— extreme thickness control or plastic Ragan Technologies Inc. • Improvement over roll compac- • Tape Development > Toll 978-297-9805 Manufacturing > Turnkey tion —Isotropic tapes are [email protected] Installations never brittle & fire flat www.ragantech.com

³MAINTENANCE/SERVICES Ceramic Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

³PROCESSING SERVICES AVEKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 CCE Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Powder Processing and Technology, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Powder Technology, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 TAM Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Union Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Michael S. Gzybowski Intellectual Property Attorney 734.302.6046 [email protected]

Suite 200 | 524 South Main Street | Ann Arbor, MI 48104 usebrinks.com

CERAMIC INDUSTRY ³ February 2012

37

³CONSULTING & ENGINEERING SERVICES / CONTRACT MANUFACTURING SERVICES / FINISHING & MACHINING SERVICES ³CONTRACT MANUFACTURING SERVICES

Ruark Engineering, Inc.

Precision Ceramic Components

Customer Oriented Expert Kiln Assistance • • • •

CONTINUOUS IMPROVEMENT OF KILN OPERATIONS KILN UPGRADE AND MODIFICATIONS NEW KILN PROCUREMENT SPECIALIZED TRAINING ON SITE

Ralph Ruark, PE 10506 Cypress Point Drive Bradenton, FL 34202

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P: 941-730-2253 F: 941-360-3211 [email protected] http://www.ruarkengineering.com ]^\]"kdajbZ bVcj[VXijgZg

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Master Tapecaster Development Service Center

CoorsTek is the largest US-owned technical ceramics manufacturer in the world. Call 303-271-7006 or email [email protected] for expert assistance on your next project. Visit us on the web www.coorstek.com

Our new “state-of-the-art” tapecasting laboratory is designed for precision testing, development and contract toll casting services. If you want to make the best tapecast product on the planet...

CALL US TODAY: 1-800-433-5456 P. O. B ox 2 4 6 Ringoes, NJ 08551 Te l : 6 0 9 - 4 6 6 - 1 9 0 0 Fa x : 6 0 9 - 4 6 6 - 3 6 0 8 We b : www.hed .c o m E-ma il: info @hed .c o m

³CONTRACT MANUFACTURING SERVICES

³FINISHING & MACHINING SERVICES

EBL PRODUCTS, INC. PIEZOCERAMICS Serving our customers for over 50 years PRECISION CUSTOM DESIGN for:

• • • •

38

February 2012 ³ WWW.CERAMICINDUSTRY.COM

piezoceramic tubes piezo composites lead zirconate titanates matching layers & wearplates

EBL Products, Inc. 22 Prestige Park Circle, E Hartford CT 06108 Phone: 860-291-2537 • Fax: 860-291-2533 www.eblproducts.com [email protected]

³FINISHING & MACHINING SERVICES

WORLD LEADER IN PRECISION CERAMICS

YOUR OU U ULTRASOURCE SOU C FOR MACHINING HARD & BRITTLE MATERIALS

Over a Quarter Century of Precision Ceramic Machining Process Development, has resulted in hundreds of satisfied customers. Put our experience and knowledge to work for you and become one of our satisfied customers.

www.bullentech.com

719-687-0888 • [email protected] • www.okeefeceramics.com

28 Years of Precision Ceramic Grinding

1301 Miller Williams Rd. Eaton, Ohio 54320 USA Phone: (937) 456-7133 • Fax: (937) 456-2779 Email: [email protected]

Contract Machining Company and Ceramic Component Supplier

• Custom forming of technical ceramics * Built to customer print * • Prototype, short run and high volume production quantities • Multiple C.N.C. Capabilities

• ISO 9001:2000 & AS9100B • CAD/CAM CNC Machining • Extensive Material Inventory • Material/Technical Support • Over 40 Years of Service Specializing in BN, SiC, Macor, Si N , Al O , ZrO , Quartz, Ferrites and other related materials 3

Phone: 714-538-2524 Fax: 714-538-2589 Email: [email protected] Website: www.advancedceramictech.com

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PremaTech Advanced Ceramics is a highly respected, world leader in advanced custom machining and grinding for the Semiconductor, Aerospace & Defense, Research, Life Sciences and Commercial industries. For all your ceramic needs, please call 508.791.9549 NEW Lapping & Polishing Capabilities Advanced Ceramic Machining & Components Engineering and Design Support Grinding of Hard and Ultrahard Materials: Alumina, Boron Nitride, Ferrite, Quartz, Silicon Carbide, Silicon Nitrides and Zirconia

ISO 9001-2008 Certified ITAR & CCR Registered WBENC Certified

www.prematechac.com

CERAMIC INDUSTRY ³ February 2012

39

³FINISHING & MACHINING SERVICES / FIRING & DRYING SERVICES ³FINISHING & MACHINING SERVICES

³FIRING & DRYING SERVICES

TOLL FIRING SERVICES

• Sintering, calcining, heat treating to 1700°C • Bulk materials and shapes • R&D, pilot production • One-time or ongoing EQUIPMENT

• Atmosphere electric batch kilns to 27 cu. ft. • Gas batch kilns to Columbus, Ohio • 614-231-3621 57 cu. ft. www.harropusa.com e-mail: [email protected]

³FIRING & DRYING SERVICES BUS.: (608) 783-4455 ALLIED FAX: (608) 783-4420 KILN EMAIL: [email protected] SERVICE INC. TIMOTHY J. TOBIN

New Kiln Design and Manufacturing Roller Hearth - Shuttle - Car Bottom - Tunnel • Refractory/Fiber • Electrical

• Installations • Combustion

• Instrumentation • Profile/Balancing

www.alliedkilnservice.com 1349 Moorings Dr. • La Crosse, WI 54603

TOLL FIRING and CERAMIC REFRACTORIES

• Multiple kilns and furnaces for optimal firing options • Screening, surface area, and bulk density testing available • Custom and standard ceramic refractories • Alumina and Fused Silica formulas • Shapes include saggers, tiles, crucibles, kiln furniture [email protected] • (815)239-2385 ext. 105 www.ipsenceramics.com

I SQUARED R ELEMENT CO., INC. AKRON, NY USA

• Custom Designed Silicon Carbide & Molybdenum Disilicide Heating Elements for Your Application • Engineering Assistance & Trouble Shooting • Customized Accessories

Visit our Web Site: www.isquaredrelement.com Phone: (716) 542-5511 • Fax: (716) 542-2100 40

February 2012 ³ WWW.CERAMICINDUSTRY.COM

ISOSTATIC PRESSING Specializing in

HIP, CIP, Service and Equipment Visit us on the Web: www.aiphip.com Call toll free: 800-375-7108

American Isostatic Presses 1205 S. Columbus Airport Rd. Columbus, Ohio 43207 Phone (614) 497-3148 Fax (614) 497-3407

TEVTECH, LLC MATERIALS PROCESSING SOLUTIONS Custom Vacuum Furnaces & Hot Zone Refurbishment for Sintering • CVD • Purification • Brazing

100 Billerica Ave., N. Billerica MA 01862 Tel. (978) 667-4557 • Fax. (978) 667-4554 www.tevtechllc.com

TOP GUN HIGH FIRE KILN

SERVICESMARKETPLACE

³FIRING & DRYING SERVICES / GLASS SERVICES / INDEPENDENT AGENTS ³GLASS SERVICES

ADVANTAGE!

Expert Engineering and Consulting Services. Specializing in high temperature kiln and furnace designs. Technical solutions for improving your fuel efficiencies. Field service and operator training. Complete system upgrades and retrofits.

CALL US TODAY: 1-800-433-5456

Electronic and Specialty Glass Frits & Powders

UNIQUE/PERENY KILNS AND FURNACES • PRO-CAST TAPECASTING SYSTEMS

• • • • • • • • • •

P. O. B ox 2 4 6 Ringoes, NJ 08551 Te l : 6 0 9 - 4 6 6 - 1 9 0 0 Fa x : 6 0 9 - 4 6 6 - 3 6 0 8 We b : www.hed .c o m E- ma il: info @hed .c o m

³GLASS SERVICES

Standard compositions Custom melt capacity Glass development Calcinations Toll processing Test sample availability Production volumes Tailored particle sizes Press-ready granulation ISO 9001:2008

ALBERT LEWIS PRESIDENT

GLASS

INCORPORATED INTERNATIONAL 14055 LAURELWOOD PL • CHINO, CA 91710 email: [email protected] website: www.glassint.com Phone 909-628-4212

GLASS TECHNOLOGY Design • Development • Manufacturing

6701 Sixth Ave. S. Seattle, WA 98108 (206) 763-2170 E-mail: [email protected] www.viox.com

Fax 909-628-2771 ³INDEPENDENT AGENTS

SEM•COM

COMPANY, INC.

SPECIALTY & ELECTRONIC GLASS MANUFACTURING We provide the following services:

Q GLASS MELTING Q GLASS FABRICATION Q COMPOSITION DEVELOPMENT Q CONSULTING Contact us for further information:

Ph: 419-537-8813 Fax: 419-537-7054 E-mail: [email protected] www.sem-com.com

Refractory Repair Specialists • Ceramic Welding & Periscope Surveys • Port & Checker Cleaning • Hot Refractory Sawing & Drilling • Furnace Overcoating • Hot & Cold Refractory Repair

CERAMIC INDUSTRY ³ February 2012

41

³INDEPENDENT AGENTS / LABORATORY & TESTING SERVICES ³INDEPENDENT AGENTS

³LABORATORY & TESTING SERVICES

USA McCuen & Associates Ph: 330 482-1074 Fax: 330 482-4560 Email: [email protected] www.davemccuen.com

BULLERS RINGS • Improve Kiln Yields • Reduce Loss • Improve Production Profits • Guarantee Consistent Firings

UK Taylor Tunnicliff Limited. Normacot Road Longton Stoke-on-Trent ST3 1PA

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³LABORATORY & TESTING SERVICES

Your Partner in Ceramics Analysis Experiennced analysis of Advanced Experienced Advaanceed ceramic cerramicc m materials atterialss in including ncluudin ing alumina, magnesia, zirconia, carbides, nitrides, and oxides.

Powder and Porous Materials Characterization Laser diffraction particle size BET surface area Density DVS

Specialized Testing Capabilities Compositional Analysis Elemental and Chemical Analysis Microscopy and SEM Thermal Analysis

www.labqmc.quantachrome.com [email protected] 1-800-989-2476

Analytical Expertise Trace Level Analysis Bulk Composition Thermal Conductivity Contaminants Inclusions Failure Analysis

www.nslanalytical.com

NSL Analytical Services, Inc. 4450 Cranwood Parkway, Cleveland, Ohio 44128 4OLL&REEsMRJS$RWPEREP]XMGEPGSQ

Trust

|

Technology

|

Turnaround

JTF Microscopy Services, LLC Microscopy, Petrographic Analysis, Training & Consulting • Glass defect analysis and source identification • Furnace refractory failure investigations • Glass technology support services related to glass defect issues • Training seminars – on-site, on your own equipment

• Raw material contaminant identification • Trouble-shooting and correction of microscope equipment problems • Consulting for equipment purchases: microscope, camera & sample preparation • Expert witness services in legal actions

phone: 607.292.6808 • mobile: 607.731.8863 email: [email protected] • website: www.jtfmicroscopy.com

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February 2012 ³ WWW.CERAMICINDUSTRY.COM

³PROCESSING SERVICES

Thermal Analysis Materials Testing • Thermal Gradient • Custom Testing • Clay Testing

• Dilatometry • ASTM Testing • Glass Testing

SERVICESMARKETPLACE

³LABORATORY & TESTING SERVICES / MAINTENANCE SERVICES / PROCESSING SERVICES

• Firing Facilities • Refractories Creep • DTA/TGA

Columbus, Ohio • 614-231-3621 www.harropusa.com e-mail: [email protected]

G E L L E R M I C R O A N A LY T I C A L LABORATORY Analytical Services & NIST Traceable Magnification Standards SEM/X-ray, Electron Mircoprobe, Surface Analysis (Auger), Metallography, Particle Size Counting, and Optical Microscopy for Ceramics and Composite Materials Specializing in quantitative analysis of boron, carbon, nitrogen, oxygen, etc. in micrometer sized areas. Elemental mapping, diffusion studies, failure analysis, reverse engineering and phase area determinations. I SO 9001 & 1 7 0 2 5 Ce r t i f i e d Put our years of experience to work on your specimens! 426 Boston St. Topsfield, MA 01983 Tel: 978-887-7000 Fax: 978-887-6671 www. gellermicro.com Email: [email protected]

• Mill Lining Installation • Field Service & Installation • Thickness Testing • Mill Doors & Gaskets

Ceram

ic Maintenance Services, In

MILL LINING INSTALLATION GRINDING MEDIA

c.

Providing Quality Service for Over 25 Years

• Grinding Media • Buy/Sell Used Process Equipment

PO Box 119 • Conneaut PA 16316 • Cell: 412-818-1379 Email: [email protected] • www.ceramicservicesonline.com

³PROCESSING SERVICES

Your Source for Powder Processing We specialize in: • Spray Drying • Wet and Dry Milling • Calcining and Sintering Typical Applications: • Catalysts • Electronics • Ceramics • Fuel Cells For more information, please contact Alan Sukovich at 219-462-4141 x224 or [email protected] 5103 Evans Avenue | Valparaiso, IN 46383

www.pptechnology.com

Holding off on capital purchases? Union Process still has several low cost options for you to get the job done economically and efficiently using the finest size reduction equipment on the market.

TOLL MILLING

³MAINTENANCE SERVICES

• Ball & Pebble Mill Parts

LOWER COST MILLING SOLUTIONS

Save on capital equipment, personnel and space. Let Union Process toll grind your product in our Pilot Plant.

REBUILDING Got a used Attritor in need of an update? Talk to Union Process about our 8-step refurbishing process using all OEM parts.

"EFORE !FTER

SPARE PARTS Make sure your Attritor is performing at peak efficiency. Order critical OEM spare parts today. Union Process stocks many parts ready for immediate shipping.

Partner with Union Process.

0HONEsWWWUNIONPROCESSCOM

Expanding the Possibilities for Size Reduction CERAMIC INDUSTRY ³ February 2012

43

³PROCESSING SERVICES / RECYCLING SERVICES / REFRACTORY SERVICES / SPRAY DRYING ³PROCESSING SERVICES

'978318300463')77-2+ 7TIGMEPM^EXMSRMR%MV'PEWWM½GEXMSR ERH.IX1MPPMRK 7QEPPXS0EVKI4VSHYGXMSR0SXW ˆ.IX1MPPMRK4VIGMWIXSTWM^IGYXQMRMQEP½RIW ˆ%MV'PEWWM½GEXMSR'YXWJVSQQMGVSRWXSQMGVSRW ˆ1IGLERMGEP1MPPMRK*VSQQMGVSRWXSQIWL ˆ:MFVEXSV]7GVIIRMRK1MRYWQIWLXSTPYWQIWL ˆ&PIRHMRK(V]ERHHV]PMUYMHFPIRHW )[MRK%ZI7 &YVRWZMPPI12 4L *E\

-736)+-78)6)( [[[TS[HIVXIGLRSPSK]MRGGSQ

WEPIW$TS[HIVXIGLRSPSK]MRGGSQ

8SPP*VII ENGINEERED PARTICLES Custom Particle Processing featuring: • • • • •

Spray Drying Particle Coating & Surface Modification Wet & Dry Ball Milling Bead Milling Research & Development

Our approach: • • • •

Innovation Collaboration Exceptional Customer Service Quality

[email protected] ISO 9001: 2008 Registered 2045 Wooddale Drive Woodbury, MN 55125 For more information visit: www.aveka.com 651-730-1729 | FAX 651-730-1826 or Call Toll Free: 1-888-317-3700

³ RECYCLING SERVICES

RECYCLE! Eliminate Disposal

Wanted: ceramics, refractories, abrasives, kiln furniture, SiC and hi alumina ceramic scrap

A-TEN-C, INC.

Call: 412-821-5566 • [email protected] • www.ceramicrecycling.com

³ REFRACTORY SERVICES

Refractory Repair Specialists • Ceramic Welding & Periscope Surveys • Port & Checker Cleaning • Hot Refractory Sawing & Drilling • Furnace Overcoating • Hot & Cold Refractory Repair

³SPRAY DRYING

! e r e h d a r u o place y

CONTACT Amy Vallance @ 281-256-8492 or [email protected] to place yours today.

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February 2012 ³ WWW.CERAMICINDUSTRY.COM

TOLL DRYING SPRAY DRYING Moisture & Particle Size Control • Dry Blending • Powder Cooling • Wet Milling SPIN FLASH DRYING Press Cake or Paste • Continuous Drying • No Post Grinding

The Most Experienced Custom Dryer of Ceramics, Chemicals and Metals GENERAL SPRAY/CVP DRYING SERVICES INC. Ph: 908-353-2477 • Fax: 908-353-0060 E-mail: [email protected] www.generalspraydrying.com

SERVICESMARKETPLACE

³BUY & SELL ³BUY & SELL

With a MobileTag go from Print to Web ³ Simply snap a photo of the mobile tag with your Smartphone, and you can conveniently go from a page in our magazine to a webpage.

CERAMIC INDUSTRY ³ February 2012

45

³BUY & SELL

NEW 50, 100 & 200 GALLON DUAL SHAFT MIXERS IN STOCK • Stainless Steel Wetted Parts • Constructed for Vacuum • Jacketed for Heating or Cooling

³BUY & SELL

Quality & Service First

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and more time using it

www.ceramicindustry.com/databook

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Detroit Process Machinery TOM SUHY: 586-469-0323 www.detroitprocessmachinery.com

BUY & SELL MACHINERY 586-790-1717 • [email protected] WWW.AADVANCEDMACH.COM

HIGHEST QUALITY! USA Tel: 631-234-0500 • Fax: 631-234-0691

BUY & SELL MACHINERY

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CONTACT Amy Vallance @ 281-256-8492 or [email protected] to place yours today.

³ ADVERTISERINDEX ADVERTISER

PAGE NO.

* Applied Test Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 www.atspa.com Ceramic Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

ADVERTISER

PAGE NO.

Lucifer Furnaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 www.luciferfurnaces.com * Midwestern Industries Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

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www.midwesternind.com

Ceramitec 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Mohr Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

www.ceramitec.de

www.mohrcorp.com

Clear Seas Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 www.clearseasresearch.com * Charles Ross & Son Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 www.mixers.com Coverings 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 www.coverings.com * FLSmidth Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 www.flsmidth.com * Harrop Industries Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 [email protected] * HI-VAC Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 www.hi-vac.com * I Squared R Element Co., Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 www.isquaredrelement.com * Keith Company Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 www.keithcompany.com

* Netzsch Premier Technologies LLC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 www.e-thermal.com PTXi Int’l Expo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 www.powdershow.com * Starkey Machinery Incorporated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 www.starkeymachinery.com * Sunrock Ceramics Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 www.sunrockceramics.com Thermcraft Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 www.thermcraftinc.com * Tokuyama America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 www.tokuyama-a.com Tri-Mer Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 36 www.tri-mer.com * UK Abrasives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 www.ukabrasives.com

* LignoTech USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 www.lignotech.com * See our ad in the 2011-2012 Ceramic Industry Data Book & Buyers’ Guide. This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and Ceramic Industry assumes no responsibility for its accuracy.

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