How to choose the right ceramic inserts wear parts foundry

The first question to ask yourself is: what are the benefits of using ceramic inserts in your machine? Ceramic tools can be an effective solution if you need high-speed cutting. In this case, ceramics are a real alternative for carbide. Ceramic inserts, however, are more expensive than carbide. The cost-performance ratio, or CPR, of ceramic tools is about three times higher than that of carbide.

In addition to dimensional stability, ceramic inserts can also be able to mold more difficult metals. Since ceramics are more resistant to high temperatures and molten materials, they eliminate the need for periodic mold surface refinishing. They also reduce the risk of thermal distortion and tolerance shifting. Which is better for your machine? Here are some benefits of ceramic inserts:

Wear-resistant inserts are embedded in the metal matrix. The ceramic inserts are composed of a porous ceramic pad containing 20 to 80% Al2O3 and 80 to 20% ZrO2, expressed in weights. The material is integrated into the metal matrix during casting. When the metal is cooled, the ceramic inserts remain in place and will be protected from external wear. This way, you’ll be assured of a long service life for your product.

When choosing the right ceramic inserts wear parts, you should know what your application requires. The ceramic inserts must be hard enough to hold the metal without becoming brittle. A high-hardness ceramic insert should be able to resist the lubrication of the metal. Ceramic inserts can also be held in a pig iron matrix to enhance its hardness. You can also choose a specific geometries for the ceramic inserts to solve this problem.

When choosing a ceramic inserts wear parts foundry, you should first consider the cost of the material. In general, CBN inserts are less expensive than carbide, but the machining costs are eight to 10 times higher. In addition, CBN inserts require tighter machine parameters. Cutting speeds that are ten percent too high can severely impact performance. Also, you should know the overall process and economics of the machining process. If a carbide insert has a long service life, this material can be an option to reduce tool costs.

The next step in choosing the right ceramic inserts wear parts is to find out which materials the casting is made of. While high-chromium steel is strong, it has a low impact toughness. Having a hardness that is close to that of manganese steel will increase the wear life of the casting. Moreover, the wear life of the casting is longer, which will increase the equipment’s uptime.

Choosing the right ceramic inserts for a casting requires careful planning and consideration of the material and workpiece. Hard-carbide inserts with positive rake geometries will cut HRSA stock, while ceramics with negative rake geometries will create a plowing action. Most difficult materials, such as titanium, are best machined dry as they require more coolant.

Advanced structural ceramics are often used in high-end applications, such as cutting tool inserts and mechanical seal rings. However, these advanced materials are not cheap and can only compete with traditional materials if conditions are optimal. For instance, high-quality metals and alloys may not be a great choice for most applications. But with a proper design and manufacturing process, you’ll be surprised how much better-looking and durable your product will be.

While carbon fiber and carbide have the lowest melting point, you’ll still need to choose a high-temperature alloy for toughness and abrasion resistance. The type of ceramic you choose depends on the application and its pressure. If the component is subjected to high pressure, the expansion coefficient should be high. This will minimize stresses and reduce the risk of breakage. You can also choose a high-pressure ceramic alloy.