Polishing Ceramic Coatings & White Alumina Ceramics
Advanced technical ceramics are a class of materials that have significantly transformed various fields and industries, ranging from automotive sensors and control systems to computers and touchpads, as well as power plant engines and turbines. The unique properties of these ceramics make them ideal for use in demanding environments, but they also pose significant challenges in terms of machining and cleaning.
Traditionally, ceramics were made from materials like aluminium oxide and silicon carbide, which were used for lapping and polishing them. However, the hardness and brittleness of ceramics made the process extremely difficult, time-consuming, and expensive. To overcome these challenges, precision surface finishing solutions have been developed to improve the machining and cleaning of technical ceramics.
Kemet International has been a pioneer in the field of precision surface finishing solutions for over 85 years. One of the most significant challenges faced by the company was the efficient lapping and polishing of ceramic materials with highly reflective surfaces. This was a challenging task because the traditional lapping materials like Boron Carbide produced a non-reflective surface that was impossible to measure optically.
In the early 1970s, Kemet International developed a breakthrough solution that combined composite lapping plates and diamond abrasives. This innovative solution allowed for more efficient lapping and polishing of ceramic materials with highly reflective surfaces, enabling 100% quality control. Kemet International was among the first to tackle these challenges, and this development revolutionised the field of ceramic lapping and polishing.
Today, Kemet International offers a comprehensive process program that includes diamond slurries for both twin plate and open face lapping systems, Kemet composite plates for specific types of ceramics, and specially formulated cast iron plates. The company has expanded its offerings to meet newer applications, such as ceramic coatings on aerospace bearing assemblies, which require special-purpose machines and process consumables.
However, lapping and polishing ceramic components, particularly white alumina-based ceramics, can create challenges in terms of cleaning the parts. Cast iron used as a lap tool can contaminate the surface of these components with oils and metal particles, making it difficult to return them to their original pure white appearance. Fortunately, Kemet International's Cleaning Division offers turnkey process and equipment solutions for cleaning small batches or thousands of parts, with each solution tailored to meet the specific needs of their customers.
Kemet International's cleaning solutions include ultrasonic cleaning, spray cleaning, and vacuum solvent cleaning. The company's ultrasonic cleaning solutions use high-frequency sound waves to agitate a cleaning solution, creating small bubbles that remove contaminants from the surface of the ceramic parts. The spray cleaning solutions use a high-pressure spray of cleaning solution to remove contaminants, while the vapour degreasing solutions use a solvent vapour to dissolve and remove contaminants.
In addition to its standard cleaning solutions, Kemet International also offers customised cleaning solutions for specific customer requirements. These solutions can include specialised cleaning chemistries, equipment modifications, and customised cleaning procedures.
