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Superior Technical CeramicsSuperior Technical CeramicsSt. Albans, VermontSt. Albans, Vermont
A WORLD LEADER IN ADVANCED A WORLD LEADER IN ADVANCED MATERIALS SOLUTIONSMATERIALS SOLUTIONS
Vital StatisticsBUSINESS: Ceramic material technology with complex forming and
machining capabilities to manufacture technical ceramic components and assemblies.
EMPLOYEES: Approximately 130
AGE: 113 years old
SIZE: 135,000 ft2 in St. Albans location – two buildings
OWNERSHIP: Privately held – American owned and operated
Location: St. Albans, VT – headquarters and primary manufacturingPartners: INTA Technologies - Santa Clara, CA –– plating / metalizing,
brazed assemblies Anderman Ceramics Ltd.- Supplier of Industrial Ceramics
STC at a Glance…STC at a Glance…
• Superior Technical Ceramics has been Superior Technical Ceramics has been producing ceramics for 113 yearsproducing ceramics for 113 years
• In 1975, the business moved from New York / In 1975, the business moved from New York / New Jersey to its current location in the Saint New Jersey to its current location in the Saint Albans Industrial ParkAlbans Industrial Park
• The two facilities in St. Albans have The two facilities in St. Albans have approximately 135,000 square feet of approximately 135,000 square feet of manufacturing, warehouse, and office spacemanufacturing, warehouse, and office space
• STC expands its capabilities by continually re-STC expands its capabilities by continually re-investing in new machinery, lab equipment, investing in new machinery, lab equipment, and technologyand technology
Company DirectionCompany Direction• To maintain a high level of customer To maintain a high level of customer
satisfaction through the continued satisfaction through the continued excellence of quality, on time delivery, and excellence of quality, on time delivery, and exceptional Customer Service. exceptional Customer Service.
• To insure that Superior’s Technical Sales To insure that Superior’s Technical Sales Force and in house Engineering Force is Force and in house Engineering Force is interfacing with current and perspective interfacing with current and perspective customers tocustomers to• Resolve design and costing issuesResolve design and costing issues•Consider form, fit and functional criteria Consider form, fit and functional criteria are utilized with an eye on manufacturingare utilized with an eye on manufacturing•Minimize cost of ownershipMinimize cost of ownership
Diverse Engineering StaffDiverse Engineering Staff• Designing and processing
ceramics are different than metals or plastics.
• Our team of engineers consists of:
• Ceramic Engineers• Mechanical Engineers• Materials Scientists
• Material property analysis• Product development• Failure analysis
• Aviation & Military• Semiconductor• Telecommunications• Pumps and Valves• Medical• Lamps/Lighting• Electro-Optics• Plasma Cutting• Industrial Ignition• Textile/ Wire Feed
• Laser Systems• Refractories• Nuclear• Appliance Insulators• Electrical Feed thru• Scientific Instruments• Water Treatment • X-Ray Systems• Mass Spectroscopy• Conveyor Systems
Markets ServedMarkets Served
www.superiortechceramics.com
Material SelectionMaterial Selection• Standard materials:
• Aluminum Oxide • (85% to 99.9% purity)
• Zirconium Oxide (Y-TZP and Mg Stabilized)
• Zirconia Toughened Alumina (ZTA)
• Steatite• Cordierite• Mullite • Bisque Alumina (machineable
ceramic)• Porous Alumina
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• Machined materials:
• Macor
• Boron Nitride
• Grade “A” Lava (hydrous alumina silicate)
Manufacturing ProcessManufacturing Process
Isostatic Pressing
Diam ond G rinding
Inspect & Ship
Coatings Assem bly
Firing
G reen M achining
Extrusion Dry Pressing
Raw M aterials M ixed & Batched
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Forming Methods: OverviewForming Methods: Overview
STC manufactures from prototype to large volume orders.
Which forming method is chosen depends upon cost effectiveness.
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Extrusion
Cold Isostatic Pressing
Dry Pressing
Blank Forming: ExtrusionBlank Forming: Extrusion
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Pan mixed material is loaded then extruded or “squeezed” out of a metal die to form rods.
Pressures in excess of 200 tons are often required for this process.
Blank Forming: IsopressingBlank Forming: Isopressing
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Dry bag isopressing is used for high volume production
Wet bag isopressing is done in a chamber press
Part Forming: Dry PressingPart Forming: Dry Pressing
Uniaxial dry pressing involves applying pressure from top and bottom punches.
Often only large volume orders are dry pressed because of tooling requirements.
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FiringFiring
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• Firing, also known as sintering, is the process used to densify the ceramic to achieve optimal properties .
• Depending on the ceramic composition – also known as a “body” – temperatures for densification can be as high as 3100oF (1700oC)!
Shrinkage During FiringShrinkage During Firing• Ceramic components can
shrink from 15-25% during the firing process!
• Shrinkage is accounted for in green forming and machining to yield a near net shape after firing.
• Typical “as fired” tolerances are +/- 1% or +/-0.005” whichever is bigger
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Designing for Ceramic MfgDesigning for Ceramic Mfg
Typical “as fired” tolerances:
• +/- 1% or +/-0.005” whichever is bigger• 0.006”/inch max camber allowance• Wall thicknesses of 1/16”min – (geometry dependant)• Fillets and edgebreaks - .025”max R or ch• 63 microinch surface finish
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Applying glaze to parts creates a glossy smooth Applying glaze to parts creates a glossy smooth surface.surface.
Diamond GrindingDiamond Grinding
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• Ceramic components requiring tolerances tighter than +/-1% require diamond grinding.
• By using the latest in automated CNC machines, STC reduces time and costs.
Diamond GrindingDiamond Grinding• ID and OD grinding• Cutting, reaming & honing • Lapping and finishing
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Equipment & QualityEquipment & Quality• Quality Management System:
• ISO 9001:2008 and AS9100 Certified
• Calibration: Traceable to NIST• Sampling: ANSI/ASQ Z1.4-
2003• Manual & Programmable
CMM• Touch Probe• Video• Laser
• Non-destructive testing• Ultrasonic• Dye penetrant• Radiography
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Materials SolutionsMaterials Solutions
SuperiorTechnicalCeramics
Form
ing
Al2O3, ZrO2
Gla
zin
g
Firing
Machining
INTATechnologies
Plating
Hea
t T
reat
ing
Metallizing
INTA TechnologiesINTA TechnologiesSanta Clara, CASanta Clara, CA
Plating & Metallizing Plating & Metallizing SolutionsSolutions
Specialty Plating ServicesSpecialty Plating Services
Substrate Materials: Kovar Copper-Tungsten Molybdenum Copper Brass Stainless Steel Titanium Plastic Ceramic
www.intatech.com
Electrolytic & Electroless PlatingElectrolytic & Electroless Plating
Plating Materials:
Gold Nickel Silver Copper Rhodium Tin Platinum
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