Zirconia Toughened Alumina (ZTA) Plate for Wear & High-Temp Fixtures

Applications of ZTA Plates

• Bulk Handling (mining/cement/steel) — ZTA Wear Plate

  ✅Key Advantages

  1. Impact-edge resistance: crack initiation delayed by zirconia toughening; edge-chip rate reduced by ~65% vs. Al₂O₃ liners.
  2. Abrasive wear endurance: 12–13 GPa hardness slows wall thinning under slurry abrasion by ~40%.
  3. Hybrid mounting: steel- or rubber-backed ZTA plates absorb 25–30% impact energy while preserving surface hardness.

  ✅ Problem Solved

  In a cement transfer chute retrofit, standard alumina liners fractured along bolt edges after 6 months of operation. After switching to ZTA wear plates, chip-outs were nearly eliminated, with measured service life exceeding 18 months under identical feed rate (≈1200 t/h). Maintenance downtime dropped by 40%, and liner replacement cycles synchronized with scheduled mill shutdowns.

• Thermal Processing & Kiln Fixtures — ZTA Setter Plate

  ✅Key Advantages

  1. Flatness stability: <0.3 mm deviation after 50 thermal cycles at 1450 °C, outperforming alumina setters by 2×.
  2. Thermal-shock tolerance: fracture toughness 6–10 MPa·m¹ᐟ² suppresses crack growth during rapid heating/cooling.
  3. Surface integrity: polished ZTA faces maintain Ra ≤ 0.4 µm, minimizing part print-through in sintering.

  ✅ Problem Solved

  A heat-treatment tray line previously used 99.5% alumina setters that warped after 40 cycles, causing uneven part heating and scrap. After adopting ZTA setter plates, flatness retention stayed within spec across 80 cycles. Scrap rate fell from 9% to under 3%, saving both fixture replacement and rework costs.

• Powder Classification & Cyclone Systems — ZTA Liner Plate

  ✅Key Advantages

  1. Directional wear resistance: micro-crack deflection in ZTA reduces erosion depth by ~45% on outer-radius zones.
  2. Precision fit: contoured ZTA panels cut via water-jet minimize installation gaps to <0.2 mm, preventing leak paths.
  3. Dimensional reliability: controlled thickness ±0.2 mm maintains uniform airflow and consistent classification efficiency.

  ✅ Problem Solved

  In a mineral powder classifier, SiC liners eroded unevenly, distorting airflow and lowering efficiency by 8%. The replacement with ZTA liner plates restored geometry stability; after 10 months of service, wear depth averaged <0.3 mm versus >0.6 mm previously. Throughput improved by 7%, and maintenance inspection intervals doubled.

ZTA Ceramic Plate Usage Instructions

• Install

  1. Dry-fit and verify alignment before fixing; ensure hole positioning, edge relief, and clearance at tight corners.
  2. Adhesive installations: clean and roughen matte or sandblasted faces; maintain uniform bond-line (0.15–0.30 mm) and follow recommended cure temperature/time.
  3. Bolted assemblies: torque bolts in a diagonal/cross sequence to equalize stress; re-check after initial operation.
  4. Backed panels: confirm full rubber or steel contact without gaps; avoid excessive compression that induces bending stress.
  5. Inspection tip: use a feeler gauge or laser alignment to verify even contact between plate and base before final tightening.

• Use

  1. Zone selection: place high-toughness ZTA plates in impact or transfer areas; use standard ZTA for sliding wear sections.
  2. Shock absorption: pair with rubber or steel backing where impact energy exceeds 20 J/cm²; check seam clearance after thermal expansion.
  3. Thermal applications: distribute load evenly across fixtures; avoid single-point contact to maintain plate flatness (<0.3 mm deviation).
  4. Replacement cycle: inspect after first 100–200 hours to confirm wear pattern; use this data to predict stable maintenance intervals.
  5. Avoid using unbacked ZTA plates under hammer impact or unbuffered chute corners; localized stress may initiate cracks.

• Store

  1. Store horizontally on soft separators or foam sheets; keep polished faces upward to prevent abrasion.
  2. Do not stack unprotected plates; use interleaving spacers between each piece.
  3. Maintain a dry, temperature-stable environment (20–25 °C; RH < 60%) to prevent adhesive surface contamination and condensation.
  4. Label each plate with orientation and serial code for traceability.

• Clean

  1. Wipe using non-abrasive cloths or neutral solvents; avoid acid or alkali cleaners.
  2. Do not use metal scrapers or sharp blades on ground or polished faces.
  3. For adhesive-mounted plates, inspect bond lines for dust or oil; clean with isopropyl alcohol before re-bonding.
  4. Periodically verify the Ra surface condition to ensure consistent friction and bonding performance.

Zirconia Toughened Alumina (ZTA) Plate FAQ

1. Q: How is a ZTA plate different from a pure alumina plate?
   A: A ZTA plate has embedded zirconia particles that increase fracture toughness by 2–3×, giving it superior resistance to edge chipping and thermal cracking compared to alumina.
2. Q: Can ZTA plates be drilled or machined with holes and slots?
   A: Yes. Through holes, countersinks, and slots are machined with diamond tools or ultrasonic drilling for crack-free precision and tight positional tolerance (±0.05 mm).

3. Q: What flatness can be achieved on a precision ZTA setter plate?
   A: After double-side grinding, flatness ≤ 0.3 mm per 300 mm is typical; tighter bands are available for thermal fixture applications requiring consistent load support.

4. Q: How should ZTA plates be installed and fixed?
   A: They can be bolted, bonded, or assembled onto backing substrates. Use cross-pattern torque tightening and proper adhesive preparation (Ra ≈ 2–4 µm, solvent-cleaned).

5. Q: What is the typical service life of a ZTA wear plate?
   A: In bulk handling systems, ZTA plates last 2–3 times longer than standard alumina liners, depending on material hardness, particle size, and flow speed.

6. Q: Can ADCERAX manufacture custom-shaped ZTA plates?
   A: Yes. ADCERAX supports fully custom ZTA plate fabrication from drawings or CAD files, including non-rectangular profiles, step joints, and contoured liners.
7. Q: What information is required for a ZTA plate quotation?
   A: Please specify L×W×T dimensions, hole or slot layout, surface finish, backing type, quantity, and operating temperature or medium. Drawings (PDF/DXF/STEP) are preferred for precise evaluation.

Zirconia Toughened Alumina (ZTA) Plate Reviews

• ⭐️⭐️⭐️⭐️⭐️
  The performance remains stable under high-temperature conditions, with no deformation or cracking issues, thanks to the ceramic robotic arm we purchased from Adcerax.
  -- Alex Morton Maintenance Manager, RidgeRock Aggregates (USA)
• ⭐️⭐️⭐️⭐️⭐️
  Working with ADCERAX on custom ZTA plate drawings was straightforward. Pricing tiers were clear and the hole arrays matched our legacy jigs.
  -- Jinwoo Park Production Engineer, Hanmin Kiln Systems (KR)
• ⭐️⭐️⭐️⭐️⭐️
  The ZTA ceramic plates came ground and labeled by tray position. Flatness held through cycles, which cut rework on heat-treated parts.
  -- Maria Conti Sourcing Lead, FerroFlow OEM (IT)
• ⭐️⭐️⭐️⭐️⭐️
  The zirconia toughened alumina plates we ordered achieved excellent dimensional accuracy and stable performance under high thermal stress. These ZTA plates have become our standard for new kiln fixture designs.
  -- Ethan Clarke Reliability Supervisor, Northern Metals (CA)