Corrosion- and Wear-Resistant Zirconia Toughened Alumina Disc (Sheet) for Industrial Sealing Assemblies

ZTA Ceramic Disc Applications

• Mechanical Seals for Pumps, Compressors and Agitators

  ✅Key Advantages

  1. Improved edge robustness under cycling load – ZTA disc with fracture toughness around 5–7 MPa·m¹ᐟ² reduces micro-crack growth and chipping at the sealing edge in start-stop operation.
  2. Longer wear life in abrasive slurries – high hardness and dense microstructure help retain sealing face geometry in slurry and particle-rich media over extended running hours.
  3. High-temperature capability – ZTA ceramics maintain mechanical integrity up to about 1650 °C, enabling use near hot process zones and in elevated-temperature seals.

  ✅ Problem Solved

  In a chemical slurry pump line, alumina seal discs require replacement roughly every 6–8 months due to edge chipping and leakage. After switching to ZTA disc faces of similar dimensions, seal life in the same duty extended to 18–24 months, reducing unplanned maintenance stops by more than 50%. For a mid-size plant operating multiple pumps, this type of upgrade can save several days of downtime per year and lower annual spare-parts usage while keeping leakage control within specified limits.

• Industrial Valves and High-Pressure Flow Control

  ✅Key Advantages

  1. Stable sealing line in high-pressure service – flexural strength around 700–1000 MPa supports localized contact loads at the valve sealing diameter.
  2. Resistance to erosive jet and cavitation – ZTA discs show low wear when used as valve seats or throttling plates in high-flow, abrasive or cavitating fluids.
  3. Dimensional stability across temperature gradient – thermal expansion of about 8×10⁻⁶ /K is compatible with many metallic housings, limiting stress from temperature swings.

  ✅ Problem Solved

  A high-pressure process valve handling abrasive slurry previously used hardened metal discs, which experienced measurable seat wear within one year and required frequent lapping. After moving to a ZTA ceramic disc as the valve seat, dimensional inspection after one year showed only minor wear at the throttling edge, while field data indicated a reduction in leakage-related adjustments by roughly 30%. The improved stability allowed the plant to extend overhaul intervals and reduce the number of emergency valve interventions per year.

• Wear Pads and Support Discs in Process and Textile Machinery

  ✅Key Advantages

  1. High hardness for sliding contact – ZTA hardness around 1750–2100 Knoop supports low wear on sliding or rolling contact surfaces in guides and supports.
  2. Toughness against impact and vibration – compared to standard alumina discs, ZTA discs better tolerate local impact from misalignment or intermittent contact.
  3. Good thermal conductivity for cooled wear parts – thermal conductivity near 20 W/m·K supports heat transfer in cooled wear liners and pads.

  ✅ Problem Solved

  In a textile finishing line, conventional alumina wear pads on high-speed rollers showed surface cracking and required replacement during each major shutdown. ZTA discs used as wear pads kept surface quality within tolerance through two shutdown cycles, effectively doubling service life. Machine operators reported fewer line stops due to surface defects, and maintenance teams reduced pad replacement time by about 30% over a full year.

ZTA Ceramic Sheet Usage Instructions

• Installation of ZTA Discs

  1. Verify that the metal or polymer mating parts are free from burrs and embedded hard particles before installing the ZTA disc.
  2. Use compatible gaskets, O-rings or backing rings to avoid point contact on the ceramic disc.
  3. Tightening sequence for bolts should follow a cross pattern and be applied in multiple steps so the ZTA disc is loaded evenly.
  4. Do not force the disc into misaligned recesses; adjust the housing or shaft alignment instead of using the bolts to pull parts into place.

• Operation Guidelines

  1. Avoid running mechanical seals or valve discs dry for extended periods unless the design explicitly supports dry running.
  2. For new assemblies, monitor leakage or torque during the first hours of operation to detect abnormal loading on the ZTA disc.
  3. In systems with high solid content, consider upstream filtration or cyclones to reduce the impact of large particles on the ceramic face.

• Storage of ZTA Discs

  1. Store discs in their original cavity trays or soft-lined containers to prevent edge contact.
  2. Keep in a clean, dry area away from strong vibration and direct chemical exposure.
  3. For long-term storage, keep labels with drawing number and material grade attached to each inner box to maintain traceability.

• Cleaning of ZTA Discs

  1. Clean sealing faces with soft lint-free cloth and neutral detergent or alcohol-based cleaner; avoid aggressive mechanical abrasion.
  2. Do not use steel brushes or hard abrasives directly on the ceramic faces.
  3. For stubborn deposits, soak in the appropriate solvent recommended for the process media before wiping.

• Common Misuse Points and Practical Fixes

  1. Over-tightening against a rigid seat
  Issue: Excessive preload on a flat ZTA disc against a rigid metallic seat can cause micro-cracks at the edge.
  Fix: Use specified torque values, introduce compliant gaskets or backing rings, and check surface flatness before assembly.

  2. Thermal shock from rapid quenching
  Issue: Moving a hot ZTA disc assembly directly into cold liquid can induce thermal stress and lead to cracking.
  Fix: Follow controlled cooldown procedures; avoid sudden temperature changes beyond recommended rates stated in equipment instructions.

  3. Contamination trapped between sealing faces
  Issue: Hard particles trapped on the ZTA disc face can scratch the surface and accelerate wear.
  Fix: Flush systems thoroughly during start-up and after maintenance; keep assemblies covered and clean before installation.

Zirconia Toughened Alumina Ceramic Disc (Sheet) FAQ

1. Q: How does a ZTA sheet differ from a standard alumina disc?
   A: A ZTA disc is a zirconia toughened alumina ceramic disc where zirconia particles are dispersed in an alumina matrix to increase fracture toughness and flexural strength compared with pure alumina discs, which helps reduce chipping and premature cracking in seals and valves.
2. Q: Where is a ZTA ceramic disc most commonly used in mechanical seals?
   A: A ZTA ceramic disc is typically used as the stationary seal face or as a mating rotating disc in cartridge seals, single mechanical seals or double seals for pumps, compressors and mixers handling water, chemicals or slurry.
3. Q: What media are suitable for a zirconia toughened alumina disc?
   A: A zirconia toughened alumina disc can operate in many water-based liquids, hydrocarbons, process gases and a range of chemical solutions where metallic seal faces or valve plates suffer from corrosion or galling; extremely aggressive acids or alkalis still require case-by-case evaluation.
4. Q: How does the toughness of a ZTA sheet affect seal life?
   A: The fracture toughness of a ZTA disc, typically about 5–7 MPa·m¹ᐟ², allows the sealing edge to absorb more mechanical and thermal shock than standard alumina, helping to reduce edge chipping and extending the service life of the seal assembly in cycling or abrasive duties.
5. Q: Can a Zirconia Toughened Alumina ceramic disc replace silicon carbide or alumina seal faces directly?
   A: In many applications, a ZTA ceramic disc can replace alumina or silicon carbide discs with the same envelope dimensions, but checking thermal expansion, counterface material and contact pressure is important before direct substitution to avoid unexpected stress or mismatch.

Customer Reviews About ZTA Disc

• ⭐️⭐️⭐️⭐️⭐️
  We moved several critical pump seals from metal and alumina faces to ZTA discs. After one year of operation, leakage incidents dropped noticeably and we see much less edge damage during inspections.
  -- Michael Turner – Maintenance Manager, Northshore Chemical Pumps
• ⭐️⭐️⭐️⭐️⭐️
  The zirconia-toughened alumina discs supplied by ADCERAX have given us stable sealing performance in our high-pressure control valves. Dimensional consistency from batch to batch has made assembly more predictable.
  -- Laura Schmidt – Product Engineer, EuroFlow Valve Systems
• ⭐️⭐️⭐️⭐️⭐️
  ADCERAX supported our drawing-based ZTA disc project with clear tolerances and sample runs. Pricing has been competitive while still meeting the flatness and surface finish our mechanical seal line needs.
  -- David Kim – Purchasing Manager, Pacific Rotating Equipment
• ⭐️⭐️⭐️⭐️⭐️
  By using ZTA ceramic discs as wear plates in mixing equipment, we extended service intervals and reduced unplanned stoppages. The discs arrived well-protected and ready to install without extra rework.
  --Sofia Alvarez – Operations Supervisor, Andes Process Services