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Liuyang High-Tech Industrial Area, Changsha China
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This advanced composite technology involves dispersing fine, high-purity ZTA ceramic particles uniformly throughout a ductile cast iron or steel matrix during the casting process. ZTA ceramics offer extreme hardness (HV 1400-1600) and outstanding resistance to abrasion, erosion, and corrosion. The metallic matrix provides crucial toughness, impact strength, thermal conductivity, and machinability. This synergy creates components ideal for applications involving moderate to severe abrasion combined with impact, thermal shock, or corrosive elements, outperforming standard alloys and monolithic ceramics.
Enhanced Abrasion/Erosion Resistance: Hard ZTA particles significantly improve the surface hardness and wear resistance of the base metal, protecting against sliding abrasion and particle erosion.
Improved Fracture Toughness: The ductile metal matrix prevents catastrophic brittle failure, a common drawback of solid ceramics, by absorbing impact energy and blunting crack propagation.
Good Thermal Shock Resistance: The metal matrix helps dissipate heat and accommodates thermal expansion differences better than solid ceramics, reducing cracking risks under thermal cycling.
Corrosion Resistance: ZTA ceramics are chemically inert, enhancing the component's resistance to certain corrosive environments compared to plain metals.
Machinability & Weldability: The metallic base allows the composite to be machined (using carbide tooling) and welded in certain cases, facilitating fabrication and repair.
Cost-Effective Performance: Offers a superior balance of wear life and toughness compared to many alternatives, often at a lower cost than solid ceramic solutions for complex shapes.
Slurry pump components (impellers, casings, liners, throatbushes) handling abrasive and corrosive mixtures.
Valve components (seats, trim, bodies) in mining, power generation, and chemical processing.
Wear plates, chute liners, and hoppers in moderately abrasive material handling with impact.
Agricultural equipment parts subject to soil abrasion (e.g., tillage tools, combine components).
Food processing equipment requiring wear and corrosion resistance.
Parts exposed to combined wear and moderate corrosion (e.g., ash handling systems).
Q: How does ZTA infusion compare to hard chromium plating or ceramic coatings?
A: ZTA infusion creates a wear-resistant zone that extends throughout the thickness of the component, not just a thin surface layer. This provides much longer life under abrasive conditions and is immune to spalling or peeling like coatings. It also offers better impact resistance.
Q: Is the wear resistance uniform?
A: Yes, because the ceramic particles are uniformly dispersed within the matrix, wear resistance is consistent throughout the material volume, not just on the surface. As the matrix wears slightly, fresh ceramic particles are exposed.
Q: Can these components handle heavy impacts?
A: While significantly more impact-resistant than solid ceramics, the toughness depends on the specific matrix alloy (ductile iron being tougher than high-Cr iron). They are suitable for moderate impact; for severe impact, TIC rod reinforcement or bi-metal might be better choices.
Q: What are the limitations of ZTA infused castings?
A: Primarily cost (higher than standard alloys) and limitations in achieving theabsolute maximumwear resistance possible with TIC or solid ceramics. They represent an optimal balance for many demanding applications.
Q: Are these parts repairable by welding?
A: Welding can be challenging due to the ceramic particles. Specialized procedures (using Ni-based electrodes) might be possible on the metallic matrix areas, but welding directly over ceramic-rich zones is not feasible. Consult the manufacturer.
