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Expands design flexibility by bonding (adding) instead of removal machining (subtracting)

This new technology is a processing method whereby two or more green bodies are stacked, sintered, and bonded together into a monolithic body. Since the interfaces of the green bodies are sintered, it makes a dense boundary. The strength of bonded parts ends up equivalent to the bulk parts.

Features

  • Enables Shapes Difficult to Achieve with MachiningThis bonding method allows for more complex shapes, where the tools of conventional machining cannot reach physically.
  • Superior Design FlexibilityFlexible design by bonding (adding) instead of removal machining (subtracting)
  • Unified Bonding BoundaryDense and highly reliable bonding technology with no loss of mechanical strength or thermal conductivity.

Manufacturing Process

Machine the pre-sintered green bodies. Align the surfaces where the bonding agent is applied, and bond by sintering under load. Then grind to the final shape.

 
  • Green Machining

    Green Machining
    Green body Green body
  • Apply bonding agent

    Apply bonding agent
    Prepare bonding agent
  • Align the Joint surface

    Align the Joint surface
    Load
  • SinteringGrinding

    Sintering  Grinding
  • mix boding agent

Design Samples

Complex internal shapes that are impossible to grind with tools from the outside are possible. In addition, some shapes which were conventionally achieved by machining a large portion of bulk body, for example, shapes with protrusions, can be formed by bonding, which will prevent material loss and will also reduce production time.

Samples

  • Rotor

    Rotor

    Φ160 x 95t (mm)

  • Internal Channel

    Internal Channel

    Φ100 x 20t (mm)*Cut model for reference of internal structure.

  • Bent Pipe

    Bent Pipe

    Φ200 x 200 x 30t (mm)

  • Table

    Table

    60 x 40t (mm)

Unified Bonding Boundary

SEM image
(x500)

Bonded interface

Ceramics at bonding boundary also become dense.

Material Lineup

Material
Material Code
Alumina Cordierite Silicon Carbide
AO479M CO220O SC120O
Color - Ivory Gray Black
Density g/cm3 3.9 2.5 3.15
Mechanical Characteristics Vickers Hardness HV9.807N GPa 15.7 8.0 23.0
Flexural Strength (3-point Bending) MPa 370 190 450
Young’s Modulus GPa 370 140 430
Poisson’s Ratio - 0.23 0.31 0.16
Thermal Characteristics Coefficient of Linear Thermal Expansion 40-400℃ × 10-6/K 7.2 (*) 1.5 3.7
40-800℃ 8.0 (*) 2.1 4.4
Thermal Conductivity 20℃ W/ (m・K) 32 4 190
Specific Heat Capacity J/ (g・K) 0.78 0.71 0.68

(*) <|0.05|(23℃)、<|0.02|(22℃)

Green Bonding processes of Cordierite and Silicon Carbide are under development. Please feel free to contact us for more details.

Values are based on typical material properties and
may vary according to product configuration and manufacturing process.