Non-Conductive Zirconia Ceramic Screws & Bolts for Equipment Insulation

Solving Fastening Challenges in Harsh Environments with ADCERAX® Zirconia Ceramic Screws & Bolts

ADCERAX® Zirconia Ceramic Screws & Bolts are engineered to address critical fastening problems in corrosive, high-temperature, and non-conductive environments. Their material properties enable stable performance where metal fasteners degrade, loosen, or introduce risk due to conductivity or corrosion.

• Zirconia Ceramic Screws & Bolts in Chlorine-Based Chemical Processing Lines

  ✅Key Advantages

  1. Superior Chlorine Stability – Zirconia Ceramic Screws & Bolts retain full mechanical strength after 96-hour exposure to 60°C chlorine-rich vapor, eliminating the surface pitting and metal ion release seen in alloy fasteners.
  2. Acidic Media Durability – Mechanical properties remain unchanged after immersion in 10% H₂SO₄ at 80°C for 72 hours, ensuring consistent clamping force in acid-transfer pipelines.
  3. Dimensional Integrity Under Vapor Pressure – With an elastic modulus of ~200 GPa, zirconia threads maintain alignment under cyclic loading and thermal expansion stresses in flanged joints.

  ✅ ️Problem Solved

  Preventing Corrosion-Induced Leakage in Acid Reactors

  A chemical processing plant in Yokohama replaced Inconel bolts every six months due to corrosion in HCl gas manifolds, causing recurring shutdowns and $40,000 annual maintenance costs. After installing ADCERAX® Zirconia Ceramic Screws & Bolts, the system maintained seal pressure for over 18 months without torque loss or corrosion marks. Field inspection confirmed zero pitting on thread surfaces, allowing extended maintenance intervals and consistent production uptime in chlorine-heavy environments.

• Zirconia Ceramic Screws & Bolts in Coastal Electrical Enclosures for Power Transmission

  ✅Key Advantages

  1. High Dielectric Protection – With a volume resistivity exceeding 10¹² Ω·cm and dielectric strength >15 kV/mm, the fasteners prevent leakage current even under high-humidity operation.
  2. Salt-Fog Resistance – No corrosion or discoloration observed after 1000-hour ASTM B117 salt spray testing, enabling long-term deployment in offshore switchgear.
  3. Non-Magnetic Conduct Interference Control – Magnetic susceptibility <10⁻⁵ minimizes electromagnetic distortion, maintaining stable sensor readings in coastal substations.

  ✅ ️Problem Solved

  Eliminating Short Circuits in Coastal Power Housings

  A Korean coastal substation experienced frequent insulation failures in 33 kV enclosures due to saline moisture causing stainless fasteners to corrode and short electrical joints. After integrating ADCERAX® Zirconia Ceramic Screws & Bolts, insulation resistance remained above 100 MΩ after 12 months of continuous salt exposure, and no galvanic corrosion occurred at contact interfaces. The plant reported zero maintenance calls during the period, validating long-term dielectric reliability and structural retention in marine humidity.

• Zirconia Ceramic Screws & Bolts in Furnace Bracket Assemblies of Battery Electrode Coating Lines

  ✅Key Advantages

  1. High-Temperature Strength Retention – Maintains ≥90% flexural strength at 1000°C continuous exposure, preventing creep deformation in oven brackets.
  2. Thermal Expansion Compatibility – With a CTE of 10×10⁻⁶/K, zirconia bolts remain dimensionally synchronized with ceramic and glass-lined frames, avoiding joint stress fractures.
  3. Oxidation-Free Operation – No surface oxidation detected after 50 furnace heat cycles, ensuring smooth disassembly and zero thread seizure in electrode coating fixtures.

  ✅ ️Problem Solved

  Maintaining Bracket Alignment in Battery Coating Furnaces

  In a Suzhou lithium battery plant, stainless fasteners in electrode drying ovens warped within four months, causing misalignment and coating uniformity deviation of ±5 μm. After replacement with ADCERAX® Zirconia Ceramic Screws & Bolts, bracket displacement was reduced to <0.5 μm over 1,000 continuous thermal cycles. The production line achieved consistent coating thickness and zero mechanical readjustments for one full operational year, proving the material’s ability to preserve alignment and minimize downtime in extreme thermal cycling environments.

Zirconia Ceramic Screws & Bolts offer exceptional performance across corrosive and high-temperature environments, but specific handling and assembly practices are essential to maximize their service life and maintain structural integrity. The following guide provides practical instructions tailored for industrial users managing high-demand fastening systems.

• Handling and Pre-Installation Considerations

  1. Inspect for Surface Micro-Cracks
  Each screw and bolt should be visually examined under good lighting for any visible cracks or edge chipping. Damaged components must be excluded to prevent propagation under load. Non-destructive testing is recommended for critical assemblies.
  2. Avoid Impact or Bending Forces
  Do not drop or flex the components before installation. Although zirconia offers excellent compressive strength, it remains vulnerable to tensile or impact shock. Use padded trays or foam-lined bins during transport to workstations.
  3. Clean Surfaces Before Use
  Both the ceramic fastener and the contact surfaces must be free from dust, oil, and metal filings. Contaminants may affect clamping integrity and accelerate wear in high-cycle applications. Use ethanol or compressed air for cleaning.

• Installation Techniques and Torque Application

  1. Use Manual Torque Control
  Apply torque using calibrated manual tools—not pneumatic drivers. Excessive torque can cause fracture, especially with threaded holes in metal mating parts. Follow torque charts provided by the supplier.
  2. Support Uniform Clamping Load
  Distribute forces evenly across contact areas using flat washers made of compatible ceramic or plastic. Avoid sharp metal contact edges that can concentrate stress on ceramic surfaces.
  3. Avoid Cross-Threading During Alignment
  Begin threading by hand to prevent misalignment. Do not force ceramic bolts into undersized or damaged holes. Lubrication should only be applied if explicitly allowed for the operating environment.

• Operational Environment and Maintenance Alerts

  1. Monitor Thermal Gradient Zones
  If used across joints experiencing large thermal differentials, ensure materials on both sides have compatible expansion profiles. Sudden thermal shocks can lead to fastener loosening or fracture.
  2. Watch for High-Vibration Scenarios
  In systems prone to vibration or pulsed stress (e.g., compressors or rotating machines), pair the screws with ceramic-based lock nuts or vibration dampers. Regular rechecking is advised after initial cycles.
  3. Track Exposure to Reactive Chemicals
  Zirconia performs well in acids and alkalis but should still be isolated from fluorine-based agents or molten salts where possible. Co-located metal elements may suffer corrosion and compromise structural balance.

• Replacement Planning and Disposal Notes

  1. Follow Predictive Replacement Schedules
  For high-cycle installations, establish inspection intervals based on usage hours or load cycles. Replace screws showing wear, thread rounding, or surface dullness even without visible cracks.
  2. Document Usage Histories by Batch
  Keep detailed logs of installation date, torque applied, and environment type for each fastener batch. This supports failure analysis and helps improve future selections.
  3. Dispose Responsibly as Inert Waste
  Zirconia ceramics are non-toxic and chemically stable, but fragments should be collected and disposed of via industrial ceramic recycling where available. Do not mix with metal scrap streams.

FAQs – Technical Insights on Zirconia Ceramic Screws & Bolts

1. Q1: How do Zirconia Ceramic Screws & Bolts perform in corrosive chemical environments?
   Zirconia Ceramic Screws & Bolts exhibit exceptional chemical inertness, resisting acids, alkalis, and saline solutions where metal fasteners typically corrode. Even under continuous chlorine or sulfur vapor exposure, no pitting or oxidation occurs. This ensures extended service life and reliable sealing performance in chemical process lines.

2. Q2: Can Zirconia Ceramic Screws & Bolts handle high operational temperatures?
   Yes, they retain over 90% of their mechanical strength at 1000°C, far exceeding the thermal limits of stainless or titanium fasteners. Their low thermal expansion coefficient (~10×10⁻⁶/K) allows stable clamping under cyclic heating, preventing loosening or misalignment in furnace and oven applications.
3. Q3: Are Zirconia Ceramic Screws & Bolts suitable for high-vibration machinery?
   They maintain consistent performance in moderate vibration environments due to high elastic modulus (~200 GPa) and dense microstructure. To manage extreme vibration, pairing with ceramic locknuts or damping washers is recommended. This ensures sustained preload and thread stability during prolonged operation.
4. Q4: How do Zirconia Ceramic Screws & Bolts prevent electrical interference?
   Their volume resistivity exceeds 10¹² Ω·cm, offering complete insulation against current leakage and electrochemical corrosion. The material is entirely non-conductive and non-magnetic, which is ideal for RF systems, sensors, and power distribution equipment requiring electromagnetic neutrality.
5. Q5: What advantages do Zirconia Ceramic Screws & Bolts provide in saline or marine conditions?
   They resist salt-fog corrosion for more than 1000 hours (ASTM B117), outperforming all metallic alternatives. The screws do not seize or rust under long-term humidity exposure. This makes them particularly effective in coastal and offshore electrical systems.

• ⭐️⭐️⭐️⭐️⭐️

  We switched to Zirconia Ceramic Screws & Bolts for our acid scrubber flanges after repeated stainless-steel failures. These fasteners have now lasted over 14 months with zero corrosion or thread deformation, even in high chloride exposure. Thermal cycle resistance has been flawless. Maintenance costs have dropped significantly.
  — Lucas M., Senior Maintenance Engineer, HCT Petrochem GmbH

• ⭐️⭐️⭐️⭐️⭐️
  Our coastal power cabinets experienced ongoing grounding issues due to galvanic corrosion. Since adopting Zirconia Ceramic Screws & Bolts, we’ve seen stable electrical insulation, no rust migration, and improved long-term enclosure integrity. This is a vital fix in our HV switchgear design.
  — Sarah J., Electrical Systems Manager, Pacific Gridworks Inc.
• ⭐️⭐️⭐️⭐️⭐️
  We implemented these screws for electrode oven frame brackets on our lithium battery line. After 2,000+ thermal cycles at 800°C, they retained dimensional stability and mechanical preload without loosening. This has reduced our line recalibration by over 60%.
  — Ken A., Process Development Lead, IonCell Technologies
• ⭐️⭐️⭐️⭐️⭐️
  Zirconia Ceramic Screws & Bolts solved our persistent failure issue in reactor valves handling hydrochloric acid. The components have shown superior chemical inertness and no pitting or material loss after prolonged exposure. Ideal for specialty chemical systems.
  — Elise R., Plant Reliability Engineer, Westshore Process Systems Ltd.