Sintering Furnaces for Ceramic Matrix Composites (CMCs) ...

Oxide composites can provide an alternative to SiC/SiC composites due to lower manufacturing costs and improved thermal stability in the presence of oxygen at high temperatures. Pyrolysis and Sintering processes are used to fill the ceramic matrix in between the fibers. The sintering process of ceramic composites doesn't require an oxygen free atmosphere, but tight temperature control and temperature uniformity inside the furnace for heating and cooling yield better results. Keith Company also builds pyrolysis furnaces (carbonization furnaces) for carbon composites which requires less than 100ppm oxygen in the vessel. Sintering process are done at temperatures between 900degC [degF] and degC [degF].

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Powdered metal processing allows the production of products with properties that can surpass alloyed materials, and many products can be pressed and fired to yield products that are near net shape. This is achieved by mixing metal, ceramic powders, or both, with a binder. This mixture can then be pressed into the desired shapes. For larger parts, the mixture is filled into molds, as in the infiltration casting process used to manufacture Polycrystalline Diamond Composite (PDC) drill bits for deep well drilling.

The sintering process of powdered materials is conducted at elevated temperatures (usually above °F) and, depending on application, in an inert, reducing, or oxidizing atmosphere. The sintering process of powdered metals is intimately related to ceramic sintering. Automated powdered metal sintering furnaces can overcome challenges such as process contamination, limited processing capabilities, reliability and operating costs. Automated systems such as a pusher furnace or kiln can sinter parts in boats while being moved through the heating system. The heating system consists of a preheat section, a heating section and cooling section. Typically, gas fired systems feature a muffle with a protective atmosphere while electric fired systems, such as a sintering furnace for semiconductor manufacturing, do not require muffles to protect the ware.

Furnaces and Kilns for sintering metals and ceramic composites

Contact Keith Company to the powder processing furnace your application requires, or to learn more about any of our powdered metal sintering furnaces.

Sintering furnaces are widely available for a broad range of processing and manufacturing applications in which a material must be carefully densified through sustained stages of heating. Mineralogical deposits are commonly formed through natural sintering, where atomic diffusion causes particles in geological samples to fuse into high-density ore. Understanding of this reaction has informed modern powder metallurgy processes, allowing for the formation of finely-tuned compact metal products with elements featuring extreme melting points, such as tungsten (W).

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Working Principle of Sintering Furnaces

Sintering furnaces for powder metallurgy most commonly use a solid-state sintering methodology, which involves compacting a metal in powder form into a thermally-resistant mold and heating it for extended periods. The powder must not be heated to the point of melting, instead it must be kept under sustained temperatures to encourage powder particles to diffuse into one another, forming crystalline bonds. This results in a solid material mass with exceptionally dense, high-strength mechanical properties.

Considering powder metallurgy is usually concerned with bonding high-strength metals that feature extremely high melting points, sintering furnaces must be developed with heating chambers capable of reaching refractory temperatures with high degrees of temperature control and heating uniformity. Tungsten (W), for example, features the highest melting point of all pure metals; °F (°C). To create formable tungsten alloys, tungsten powder can be fused with powdered nickel (Ni), which greatly reduces the sintering temperature to °F (°C).

Extended sintering of metal alloys at temperatures exceeding °F requires exceptionally energy efficient batch sintering furnaces equipped with refractory heating elements and incredibly thermally-resistant insulation. These components enable high-temperature sintering for various powder metallurgy reactions and optimize furnace throughout by effectively insulating machinery from its own rigorous production conditions.

Sintering Furnaces from Thermcraft

Thermcraft are international-leading developers, manufacturers, and suppliers of exceptional thermal processing equipment for a broad range of commercial and industrial applications. We have developed multiple sintering furnaces for various processes, with several heated zone chambers and heating ranges of up to °F (°C).

Alongside our range of pre-configured furnaces, we offer bespoke thermal processing equipment which is unique to clients&#; specifications. We are experienced in manufacturing both large-scale sintering furnaces and smaller, analytical units for laboratory purposes. Our equipment is fully customizable, with automation processes, atmospheric controls, and more available upon request.

If you would like any more information about our sintering furnaces, please do not hesitate to contact us.

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