Oxide-Resistant Zirconia Ceramic Refractory Plate for Material Sintering Systems

Application-Specific Performance of ADCERAX® Zirconia Ceramic Refractory Plate

ADCERAX® Zirconia Ceramic Refractory Plate plays a critical role in advanced thermal processing where component adhesion, dimensional instability, and surface contamination must be tightly controlled. Tailored for repeatable furnace cycles, its application value is best seen in material-specific sintering scenarios that demand both structural reliability and chemical neutrality.

• Zirconia Ceramic Refractory Plate in Multilayer Capacitor (MLCC) Sintering

  ✅Key Advantages

  1. High Planarity Retention at Elevated Temperature
  Maintains surface flatness within ±0.5 mm across 500 mm even after three consecutive sintering cycles at 1250–1600 ℃. This stability preserves dielectric layer alignment and prevents lamination deformation during MLCC processing.
  2. Chemical Inertness Toward BaTiO₃-Based Dielectrics
  No visible interaction layer forms between the plate and ceramic substrate after 10 hours of sintering at 1300 ℃, confirmed by SEM–EDS analysis. This prevents discoloration and maintains electrical uniformity.
  3. Reduced Surface Adhesion and Contamination Risk
  Surface energy below 0.35 J/m² minimizes sticking of dielectric pastes, leading to a > 10 % increase in first-pass yield for automated inspection lines.

  ✅ ️Problem Solved

  A Japanese MLCC manufacturer experienced 14 % yield loss due to adhesion and microcracks caused by alumina setters reacting with BaTiO₃ layers. After switching to ADCERAX® Zirconia Ceramic Refractory Plate, no barium–zirconium interfacial compound was detected, and the yield improved to 98.6 % within two production batches. The switch also reduced plate replacement frequency by 40 %, cutting annual maintenance downtime by 72 hours across three sintering furnaces.

• Zirconia Ceramic Refractory Plate in Ferrite Core Magnetic Sintering

  ✅Key Advantages

  1. Resistance to MnZn and NiZn Oxide Vapors
  Demonstrated < 0.2 % mass loss after 8 hours at 1450 ℃ in MnZn ferrite atmospheres, preventing the chemical erosion and glaze formation seen on alumina boards.
  2. Stable Geometry under Continuous Furnace Loading
  Maintains shape deviation under 0.3 mm across 400 mm span after 50 furnace cycles, ensuring uniform sintering pressure across multiple ferrite layers.
  3. Extended Service Life in Corrosive Environments
  Survives 3–5× longer than cordierite plates under identical operating conditions, reducing replacement intervals from biweekly to once per quarter in continuous belt furnaces.

  ✅ ️Problem Solved

  A Korean ferrite-core producer operating a 1450 ℃ continuous tunnel furnace reported frequent bonding between magnetic blocks and alumina setters, with an 18 % regrind rate. After implementing ADCERAX® Zirconia Ceramic Refractory Plate, surface adhesion was eliminated across 12 furnace runs, and product edge chipping decreased by 92 %. Equipment maintenance cycles extended from 10 days to 45 days, improving furnace utilization by 27 %.

• Zirconia Ceramic Refractory Plate in Cobalt-Based Powder Metallurgy Sintering

  ✅Key Advantages

  1. Inert Behavior toward Co/Ni Alloy Systems
  Exhibits zero measurable reaction layer (< 0.1 µm) after 3 cycles at 1480 ℃ under argon, verified by metallographic cross-section. This prevents compositional drift and contamination of superalloy surfaces.
  2. Reduced Post-Sintering Surface Correction
  Average surface roughness of sintered parts decreased from Ra 1.8 µm to Ra 0.6 µm, cutting finishing time by 35 % per batch.
  3. Dimensional Stability under Vacuum or Inert Gas
  Maintains flexural integrity with > 25 MPa strength retention after repeated thermal cycling, ensuring precise tooling geometry and batch repeatability.

  ✅ ️Problem Solved

  A German aerospace components supplier producing Co–Cr dental blanks and turbine inserts faced contamination from silica plates, leading to 5 % hardness variance and visible interfacial residues. Replacing them with ADCERAX® Zirconia Ceramic Refractory Plate eliminated measurable contamination, stabilized hardness within ±0.3 HRA, and achieved full compliance with EN ISO 22674:2020 surface-quality standards. The customer reported a 20 % reduction in post-sintering polish time and a threefold extension of plate service life.

Usage and Maintenance Guidelines for Zirconia Ceramic Refractory Plate

To ensure maximum service life and consistent performance, Zirconia Ceramic Refractory Plate must be handled, inspected, and maintained under appropriate operating standards. The following guidance addresses key precautions during pre-use, in-use, and post-use stages based on practical field experience in high-temperature sintering processes.

• Pre-Use Visual Inspection Before Each Furnace Cycle

  1. Check for visible cracks or surface erosion before loading parts. Even minor surface defects may lead to early failure during thermal cycling.
  2. Inspect for chipping or edge damage caused by prior handling or thermal shock events. Replace units showing delamination or corner loss.
  3. Confirm flatness and contact surface condition using a straightedge or feeler gauge, especially for MLCC or precision ceramics sintering.

• Handling Practices During Loading and Unloading

  1. Avoid impact with tools, trays, or metal parts. Even micro-cracks from handling may propagate under thermal load.
  2. Use dedicated lifting or insertion tools when placing or removing plates inside furnace structures. Hand-drop or tilting must be avoided.
  3. Maintain vertical stacking alignment during multi-layer loading to avoid mechanical point-load stress.

• In-Process Protection Against Thermal and Chemical Risks

  1. Do not overload the plate beyond designed surface weight limits. Maximum load should remain < 65 g/cm² for stable mechanical performance.
  2. Monitor furnace temperature ramp-up rates to avoid thermal shock. Recommend slope is < 5 ℃/min across 200–600 ℃.
  3. Prevent chemical vapor accumulation from volatile sintering materials. Use cover layers or shields if possible.

• Post-Use Cleaning and Plate Preservation

  1. Remove adhered powders or glaze residues using soft brushes or low-speed abrasive tools. Avoid metal scraping tools.
  2. Inspect and record surface changes after each use. Track cumulative degradation for replacement planning.
  3. Store in dry, cushioned trays away from moisture and hard impact zones, preferably in original packaging materials.

FAQs: Technical Insights into Zirconia Ceramic Refractory Plate

1. Q1: How does the Zirconia Ceramic Refractory Plate prevent part adhesion during high-temperature sintering?
   A1: The plate offers a chemically inert surface that resists reactions with dielectric and metal oxides. This ensures no bonding or sticking with MLCCs, ferrites, or cobalt alloys. It helps reduce post-sintering rework and maintains part surface integrity.
2. Q2: Why is thermal shock resistance important in a Zirconia Ceramic Refractory Plate?
   A2: During rapid heating or cooling, inferior materials often crack or deform. Zirconia plates exhibit thermal shock resistance > 40 cycles (25–1500 ℃), maintaining stability across multiple furnace cycles. This improves process uptime and reduces unexpected breakage.
3. Q3: What makes the Zirconia Ceramic Refractory Plate suitable for Mn-Zn and Ni-Zn ferrite sintering?
   A3: Volatile oxides from ferrites attack alumina and cordierite setters. This plate’s zirconia-rich phase structure offers superior resistance to such attacks. It prevents chemical erosion and surface fusion, eliminating manual part separation damage.
4. Q4: Can the Zirconia Ceramic Refractory Plate withstand repeated high loads?
   A4: Yes. With a flexural strength > 25 MPa and recommended loading < 65 g/cm², the plate supports dense component layouts. This enhances batch productivity in multilayer capacitor or ceramic substrate sintering.
5. Q5: How does the plate perform under extremely high sintering temperatures?
   A5: It tolerates sustained exposure up to 1650 ℃ (yttria-stabilized grade). This makes it ideal for sintering of high-performance ceramics and specialty powder metallurgy parts without mechanical degradation or creep.

What Global Users Say About Zirconia Ceramic Refractory Plate

• ⭐️⭐️⭐️⭐️⭐️
  “The Zirconia Ceramic Refractory Plate has significantly reduced product sticking and contamination during MLCC sintering. The chemically inert surface makes a big difference in maintaining dielectric performance. After 25 cycles, the plates still show no surface deformation.”
  — Samuel D., Process Engineer, KELTRONIX Advanced Materials GmbH
• ⭐️⭐️⭐️⭐️⭐️
  “In our ferrite core manufacturing line, these plates have eliminated most edge chipping issues. The high thermal shock resistance lets us run at 1480 ℃ without failure. Our yield improved by over 12% within two months.”
  — Julia M., Production Manager, CoreWave Magnetic Components Inc.
• ⭐️⭐️⭐️⭐️⭐️
  “We've tested multiple setter materials, and this one is the most reliable for cobalt-based alloy sintering. The non-reactive interface prevents alloy discoloration and residue bonding. Post-sintering parts require minimal cleaning.”
  — Alex R., Metallurgical Lead, AeroForm Precision Metals LLC
• ⭐️⭐️⭐️⭐️⭐️
  “What impressed us most is the mechanical strength under full load. We managed to reduce setter thickness while increasing furnace capacity by 15%, without introducing warpage or cracks.”
  — Laura B., Operations Director, FerroCeramics North America