Silicon Carbide products

Transcription

1 Siicon Carbide products

2 Section 14 Siicon Carbide products Metric information Page Siicon Carbide products Nitride bonded pressed Nitride bonded cast Ramming cements Castabe cements Laying cements SB 020 SB 019 CBF CBC The base of a Siicon Carbide (SiC) refractories is refractory grade apha siicon carbide, produced in arge eectrica resistance furnaces at approximatey 2400 C (4352 F) from a mixture of siicon, carbide, sat and sawdust. These refractory crystas are then cassified, crushed and graded for use as grog or aggregate in bricks or shapes. The apha siicon carbide crystas impart high therma conductivity and refractoriness, ow therma expansion and outstanding abrasion/erosion resistance. The bonds in sef bonded refractors have been carefuy formuated to give specific properties and subsequent performance criteria in any specific appication. Sef bonded Many bonding systems are avaiabe that interconnect the apha siicon carbide grains and in the case of sef bonded refractories, it is mainy in a matrix of siicon and auminiumsiicon gass. The bonds in sef bonded refractories have been carefuy formuated to give specific properties and subsequent performance criteria in any specific appication. Nitride bonded The siicon nitride bond phase in these refractories is the key to their superior performance in demanding appications. The Morsi nitride bonding system aows nitride bonded refractories to outperform other siicon carbide based refractories using siicate, aumina siica, and siicon oxynitride and beta siicon carbide bond systems. The apha siicon carbide crystas impart high therma conductivity and refractoriness, ow therma expansion and outstanding abrasion/erosion resistance. To manufacture Morsi nitride bonded, graded apha or eectric furnace siicon carbide crystas and fine siicon are formed into shape, and fired in a pure nitrogen atmosphere at approximatey 1420ºC (2588 F). The resut is a refractory consisting of a mixture of apha siicon carbide grain in a matrix of apha and beta siicon nitride, with minor amounts of residua siicon and siicon oxynitride. Due to the fact that the bond phase grows within existing porosity, there is itte to no dimensiona change upon firing and a net weight gain occurs. This bond is mainy responsibe for the extremey high moduus of rupture and outstanding oxidation and corrosion resistance of Morsi nitride bonded siicon carbide. 141

3 Typica appications for Siicon Carbide products: Auminium reduction ces Copper remet furnaces Thermocoupe sheaths Hearth ties Refining and assaying muffes Radient tubes Boier brick Burner bocks Combustion chambers Incinerators Siicon Carbide: Cay Bonded Our cay bonded siicon carbide enabe thick waed components to be manufactured as it features high mechanica strength and exceent therma conductivity. These properties make this materia exceent for outer protection tubes for temperature measurement up to 1200 C (2192 F) in ight and heavy meta smets. HaSiC Our HaSiC range is generay used for kin furniture due to its properties which incude: Withstanding temperatures up to 1600 C (2912 F) Compact SiC matrix Corrosion resistance The properties above make this materia an exceent choice for manufacturing arge components. Our engineers have the skis, knowedge and capacity to work with you to seect the right materia for your product in your appication. MORSIL Siicon Carbide Ramming cements MORSIL Nitride Bonded Siicon Carbide Pressed and cast Benefits: High strength and wear resistance, even at high temperatures High decomposition temperature Oxidation resistance even at very high temperatures Corrosion resistance Therma shock resistance due to the strength of the Siicon Nitride bond and the ow therma expansion coefficient Very ow therma expansion High therma conductivity Good triboogica properties Thermocoupe sheaths high therma conductivity, resistance to therma spaing, high hot strength and erosion resistance of Morsi gives accurate, reiabe temperature measurement sometimes under extreme and corrosive furnace operating conditions. Foundry: Hearth ties can resist abuse from heavy oads in heat treatment furnaces. Oxidation resistance and abrasion resistance grades are avaiabe depending on furnace operations. Precious metas: Refining and assaying muffes readiy transmit heat to the charge and are often used to contain corrosive fues that wi reduce the ife of furnace refractories and eectric heating eements. Radiant tubes ensures fues efficiency whie the high density and corrosion resistance proongs service ife. Steam generation: Boier brick exceent spa resistance and high conductivity couped with high density which protects the sidewa and grate from sag and cinker. Petrochemica: Burner bocks / combustion chambers can withstand very high temperature, resist corrosive gases and endure the severe heat shock experienced by burner bocks and combustion chambers. Incinerators successfuy used in door inings and arches to baance the overa ife in industria incinerators that have spa probems in these areas. Typica appications: Auminium reduction ces: Converting aumina to auminium by the eectroytic reduction process for carbon and graphite was in auminium reduction ces. Nonferrous: Copper remet furnaces high purity, high density Morsi gives ong troube free service in remet and hoding furnaces producing copper wire bar. 142

4 Siicon Carbide products Nitride Bonded Pressed Nitride Bonded Cast Ramming Cements Castabe Cements CFR 0100 (1) CFR 0110 (2) CFR 0120 (3) CFR 0130 (4) CFC 0100 (1) Bond type Siicon Nitride Siicon Nitride Maximum hot face temperature, C Moduus of rupture, ASTM C C 40 Buk density, ASTM 134, gm/cm Apparent porosity, % Hot oad contractions, % of engths Therma expansion coefficient, Cm/cm/ Cx Therma conductivity, ASTM C 202, W/m 1477 C Reative therma shock exceent exceent Specific heat, 1400 C, ca/gm/ C Reative abrasion resistance, 1400 C exceent exceptiona Spa resistance, % Compressive strength, kg/cm 2, MPa >137 >160 Permeabiity, ccof air/min/in/m 2 /in WG press 3.0 ni Eectrica characteristics semiconductor semiconductor Appication range, C Set heat heat ow temp heat air hydrauic Partice size, mm Required quantity, kg/m Water to be added before use itre/25kg dry or 1.5 dry or How shipped dry dry ready mix dry dry Pack size, kg Chemica composition SiC Si 3 N SiO A 2 O Fe 2 O CaO 0.2 Trace Eements Safety Data Sheet (SDS): are avaiabe for a our products. Data sheets, in other anguages, can aso be found by visiting our website. Pease visit our website and cick on the Safety Data Sheets Quick Link on our home page. Whist the vaues and appication information in these datasheets are typica, they are given for guidance ony. The vaues and the information given are subject to norma manufacturing variation and may be subject to change without notice. Morgan Advanced Materias Therma Ceramics makes no guarantees and gives no warranties about the suitabiity of a product and you shoud seek advice to confirm the product s suitabiity for use with Morgan Advanced Materias Therma Ceramics. Metric information 143

5 Siicon Carbide products Laying Cements CFL 0130 (1) CFL 0140 (2) CFL 0150 (3) CFL 0160 (4) SB 020 SB 019 CBF CBC Bond type Direct Siicate Bonded SiC Siicate Bonded SiC Maximum hot face temperature, C Moduus of rupture, ASTM C C Buk density, ASTM 134, gm/cm Apparent porosity, % Hot oad contractions, % of engths Therma expansion coefficient, Cm/cm/ Cx Therma conductivity, ASTM C 202, W/m 1477 C Reative therma shock very good good Specific heat, 1400 C, ca/gm/ C Reative abrasion resistance, 1400 C exceent exceent Spa resistance, % Compressive strength, kg/cm 2, MPa >140 >140 Permeabiity, ccof air/min/in/m 2 /in WG press Eectrica characteristics semiconductor V Appication range, C Set heat heat air air Partice size, mm Required quantity, kg/m Water to be added before use itre/25kg How shipped dry dry dry dry Pack size, kg Chemica composition SiC Si 3 N 4 SiO A 2 O Fe 2 O CaO Trace Eements Safety Data Sheet (SDS): are avaiabe for a our products. Data sheets, in other anguages, can aso be found by visiting our website. Pease visit our website and cick on the Safety Data Sheets Quick Link on our home page. Whist the vaues and appication information in these datasheets are typica, they are given for guidance ony. The vaues and the information given are subject to norma manufacturing variation and may be subject to change without notice. Morgan Advanced Materias Therma Ceramics makes no guarantees and gives no warranties about the suitabiity of a product and you shoud seek advice to confirm the product s suitabiity for use with Morgan Advanced Materias Therma Ceramics. 144 Metric information

6 Fires refractory shapes products

7 Section 15 Fired refractory shapes products Imperia information Page Fired refractory shapes products Cerox Vacor Therma Ceramics fired refractory shapes are used in a wide range of critica, heat intensive appications. High aumina, siicon carbide, fused siica and auminazirconiasiica (AZS) compositions are thixotropicay cast to precise customer specifications. These products feature superior hot strengths, therma shock Therma Ceramics refractory fired shapes are used in a wide range of critica, heat intensive appications. Fired refractory shape product range incudes: Cerox Cerox fired refractory shapes are thixotropicay cast using a dispersion agent, which aows the Cerox mix to fow when vibrated without requiring a high water content. These manufacturing techniques, combined with precisey controed firing and 100% product inspection, produce highquaity components suited to the most arduous of high temperature environments. Variety of avaiabe compositions using highaumina, fused zirconia muite, and siicon carbide Exceent chemica attack resistance Exceent therma shock resistance Low gas permeabiity Tight toerance capabiity The Cerox cast fired shapes are used in a variety of super aoy metpour systems. The cast manufacture process meets the tight toerance specifications required by end users. Precise tooing and detaied product inspection provide the user with a high quaity, dimensionay accurate refractory shape. Variety of avaiabe compositions in high aumina, muite and fused siica Tight toerance capabiities Good nonwetting characteristics Exceent mechanica strength Proven performance in super aoy, and investment casting Therma Ceramics refractory fired shapes are used in a wide range of critica, heat intensive appications 145

8 Typica appications for fired refractory shapes products: Vacuum induction meting industry Furnace spouts Distribution boxes (often referred to as hot tops) Sampers and Metamic (metaceramic composite) thermocoupe sheaths for the VIM market Muffes, ade iners, saggars, seaed quench furnace muffe assembies and other specia shapes Gass contact refractories, particuary gass feeder ware consumabes Vacor Vacor fired refractory shapes, avaiabe in two compositions: G high aumina mix GAZ AZS premium grade and has a proven track record inmoten gass contact appications. The shapes are engineered to meet precise customer specifications and are individuay inspected. Years of proven performance in moten gass contact appications Very smooth surface finish Individua part inspection 146

9 Fired refractory shapes : Cerox Product Name Cerox 100 Cerox 120 Cerox 200 Cerox FC 200 Cerox 700 Cerox 720 Cerox 730 Cerox 1000 Cerox 1200 Cerox 1300 Cerox 1400 Chemica anaysis, % weight basis after firing Aumina, A 2 O > Siica, SiO Zirconia, ZrO 2 23 Siicon carbide, SiC 59 Ferric oxide, Fe 2 O Titanium oxide, TiO trace Magnesium oxide, MgO 0.1 trace Akaies, as Na 2 O trace Buk density, pcf (kg/m 3 ) ASTM C (2468) 136 (2179) 161 (2580) 157 (515) 173 (2772) 176 (2820) 172 (2456) 179 (2869) 183 (2933) 190 (3045) 161 (2580) Apparent porosity, % ASTM C Permeabiity, ft /hr ft 2 in., psi (MPa) 4 (0.03) 3 (0.02) 4 (0.03) 6 4 (0.03) Moduus of rupture, psi (MPa), ASTM C 75 F ( F (1260 C) 1200 (8.28) 2400 (16.55) 1600 (11.03) 2000 (13.79) 1500 (10.34) 1800 (12.41) 1600 (11.03) 2400 (16.55) 2400 (16.55) 4800 (33.10) 1300 (8.97) 1600 (11.03) 5000 (34.48) 2600 (17.93) 3000 (20.69) 1800 (12.41) F (1426 C) 1000 (6.89) 1100 (7.59) 1000 (6.89) 1900 (13.10) 3700 (25.52) 900 (6.21) 1400 (9.65) 2300 (15.86) F (1538 C) 600 (4.14) 800 (5.51) 700 (4.83) 1000 (6.89) 1600 (11.03) 700 (4.83) 1400 (9.66) 500 (3.44) Cod crushing strength, psi (MPa), ASTM C 2800 F (1538 C) (48 69) (34 55) (55 69) (62 76) (55 76) Permanent inear change, % ASTM C F (1648 C) F (1760 C) Deformation under hot oad, 25 psi (0.17 MPa), ASTM C 16 11/ F (1448 C) / F (1538 C) / F (1566 C) / F (1760 C) Abrasion oss, cm 2, ASTM C Coefficient of reversibe therma expansion, in./in. F Spa resistance, reative good very good good very good fair ow exceent very good Safety Data Sheet (SDS): are avaiabe for a our products. Data sheets, in other anguages, can aso be found by visiting our website. Pease visit our website and cick on the Safety Data Sheets Quick Link on our home page. Whist the vaues and appication information in these datasheets are typica, they are given for guidance ony. The vaues and the information given are subject to norma manufacturing variation and may be subject to change without notice. Morgan Advanced Materias Therma Ceramics makes no guarantees and gives no warranties about the suitabiity of a product and you shoud seek advice to confirm the product s suitabiity for use with Morgan Advanced Materias Therma Ceramics. Imperia information 147

10 Fired refractory shapes : Cerox prefired refractory shapes Product Name Cerox 90V Cerox FS99V Cerox 90P Cerox 95P Cerox FS85P Method of forming thixitropic cast pressed pressed pressed Chemica anaysis, % weight basis after firing Aumina, A 2 O Siica, SiO Ferric oxide, Fe 2 O Titanium oxide, TiO trace Cacium + Magnesium oxide, CaO + MgO 0.1 Akaies, Na 2 O + K 2 O Buk density, pcf (kg/m 3 ) ASTM C (2820) 113 (1811) 178 (2853) 188 (3013) 109 (1510) Apparent porosity, % ASTM C Cassification temperature rating, F ( C) 3090 (1699) 2800 (1538) 3090 (1699) 3100 (1704) 2750 (1510) Moduus of rupture, psi (MPa), ASTM C (17.2) 1150 (7.9) 4000 (27.6) 4100 (28.3) 510 (3.5) Coefficient of therma expansion, in./in. F Therma conductivity, BTU in./hr ft 2 F (W/m K), ASTM C 417 mean 2000 F (1093 C) 16.0 (2.3) 22.0 (3.2) 10.6 (1.5) 9.5 (1.37) Fired refractory shapes : Vacor Product Name Vacor G VacorGAZ Chemica anaysis, % weight basis after firing Aumina, A 2 O Siica, SiO Zirconia, ZrO 2 23 Ferric oxide, Fe 2 O Titanium oxide, TiO Magnesium oxide, MgO trace Akaies, as Na 2 O 0.2 Buk density, pcf (kg/m 3 ), ASTM C (2868) 190 (3045) Apparent porosity, % ASTM C Permeabiity, ft /hr ft 2 in., psi (MPa) 4 Meting point, F ( C) 3560 (1960) 3200 (1760) Hot moduus of rupture, psi, ASTM C 75 F (24 C) 1600 (11) F ( F (1426 C) 900 (6.2) F (1538 C) 700 (4.8) 1400 (9.7) Permanent inear change, %, ASTM C F (1648 C) F (1760 C) 1.9 Deformation under hot oad, 25 psi, ASTM C / F (1448 C) Coefficient of reversibe therma expansion, in./in. F Safety Data Sheet (SDS): are avaiabe for a our products. Data sheets, in other anguages, can aso be found by visiting our website. Pease visit our website and cick on the Safety Data Sheets Quick Link on our home page. Whist the vaues and appication information in these datasheets are typica, they are given for guidance ony. The vaues and the information given are subject to norma manufacturing variation and may be subject to change without notice. Morgan Advanced Materias Therma Ceramics makes no guarantees and gives no warranties about the suitabiity of a product and you shoud seek advice to confirm the product s suitabiity for use with Morgan Advanced Materias Therma Ceramics. 148 Imperia information

11 Heat Shied products

12 Section 16 Heat shied products Heat shied products She Tech Integrated Tech Fexibe Tech Rigid Box Tech By empoying a range of materias the Therma Ceramics business of Morgan Advanced Materias can provide heat shieds and microporous insuation in a wide variety of demanding environments across different industries and sectors. Our heat shieds and microporous insuation are used frequenty within mobie appications and are often incorporated into shipping, aeronautica and automotive design. Depending on the specific appication, our materia engineers can deveop and impement a high performance soution that meets your requirements. This is done by taking the unique properties of ceramics to produce heat shieds and microporous insuation that is highy adept in extreme environments, whist retaining characteristics such as ight weight and robustness. Having worked extensivey with shipping, aerospace and automotive industries in both commercia and defence spheres, we are ideay paced to provide you with heat shieds and microporous insuation that is on budget, without sacrificing performance. Common insuation materias used in our heat shieds: Gass Fibre Siica Fibre Microporous insuation Common materias used for encapsuation: Austenitic and ferritic stainess stee Incone Titanium 149

13 She Tech (picture 1) Designed to foow the shape of your equipment, our ightweight She Technoogy provides an eegant fitted soution to your therma protection needs. Our She Technoogy is made using Superwoo Pus insuating fibre, FireMaster fibre, siica, gass fibre or microporous insuation materia competey encapsuated in stainess stee and customshaped to fit your appication requirements. This ensures the possibiity for the customer to manage the fina assemby on site. She Technoogy is made of corrugated SS in a thickness from 0.05 to 0.3mm. Idea where space is at a premium, She Technoogy is easy to fit, and easy to remove for maintenance or other reasons for appications incuding: Aerospace: thrust reverser Automotive: exhaust catayst Passenger vehices: exhaust manifod OffRoad vehices: turbocharged Marine & power generation: exhaust manifod Our heat shieds made from our she technoogy offer the foowing benefits to our customers: Eegant, fitted, ightweight soution Effective ifetime insuation Easy to fit and to remove Integrated Tech (picture 2) For the insuation of arge or compex equipment, our integrated technoogy soutions are custom designed. Our integrated technoogy is made using Superwoo Pus insuating fibre, FireMaster fibre, siica, gass fibre or microporous materia, competey encapsuated in stainess stee and customshaped to fit your appication requirements. This ensures that the assemby is made in Morgan Therma Ceramics, Ecrans Thermiques with the part provided by the customer. Our fexibe technoogy soutions are suitabe for a wide range of appications incuding: Automotive: exhaust manifod Passenger vehices: exhaust manifod Marine & power generation: exhaust manifod Oi & gas: vaves & actuators Rigid Box Tech (picture 4) Our rigid box technoogy offers effective therma and fire protection for a types of equipment, in an easytouse, SOLASapproved and jet and hydrocarbon fire approved system. Rigid box encosures are custombuit to suit each appication using FireMaster Marine Pus banket or siica or gass fibre insuation materia which is competey encapsuated in austenitic or ferritic stainess stee at our advanced manufacturing faciity. Rigid box technoogy is made of SS in a thickness from 1 to 5 mm. Our rigid box technoogy provides customers with the foowing benefits: SOLAS approved, ifetime insuation Jet and hydrocarbon fire approved Easy to fit and to remove No contact with insuation materia No tooing required Integrated technoogy is made of corrugated SS in a thickness from 0.05 to 0.3mm and provides exceent ifetime insuation for appications incuding: Aerospace: heicopter turbine Automotive: exhaust catayst Passenger vehices: exhaust manifod Marine & power generation: exhaust manifod 150 Fexibe Tech (picture 3) Our fexibe technoogy provides an effective and versatie soution for therma protection in a wide range of industria and other appications. Made from siica or gass fibre encased in siicone and stainess stee fabric, our fexibe technoogy offers heat shieding in continuous operating temperatures up to 600 C. A fuy fexibe jacket, it is ightweight and easy to fit, and to remove if necessary even in a restricted space.

14 Structura bcok insuation products

15 Section 17 Structura bock insuation products Imperia information Page 152 Structura bock insuation products TR 19 Bock TR 19HS Bock TR 20 Bock TR 2000SL Bock Our TR 19 and TR 20 bock insuation products offer economica and efficient soutions to your insuation needs. These products feature significanty improved temperature and weight characteristics when compared with traditiona products. TR19 and TR19 HS are vermicuite based products and TR20 is a diatomaceous siica product. These materias offer exceent energy saving efficiencies, good strength and minima shrinkage. TR19 Bock and TR19HS Bock Manufactured from vermicuite granues and high temperature bonding materias TR19 features ower therma conductivity than competitive vermicuite boards TR19HS offers high compression strength Operates in temperatures up to 1038 C (1900 F) Exhibits good strength and minima shrinkage up to use imit temperature Provides exceent resistance to auminum cryoite attack TR20 Bock Very good resistance to breakage Long, maintenancefree service and maximum operating efficiency Low conductivity and high stabiity Superior hightemperature bock insuation Made from diatomaceous siica with a hydrauic binder Suitabe for use up to 1093 C (2000 F) TR2000SL Bock Minima shrinkage at top temperature imits Wi not decompose at their maximum service temperature Cacium siicate composition Very ow therma conductivity Lightweight Good high temperature strength TR bock products are traditionay found in many Auminium appications such as Carbon Bake Ovens, PotCes, Meting and Hoding Furnaces. TR bock insuation products can be used as both genera insuation or backup insuation in roofs, was and foors Genera backup insuation use with Morgan Therma Ceramics monoithics, firebricks, refractory pastics, and ceramic fibre products 151

16 Structura bock insuation products Product Name TR 19 TR 19 HS TR 20 TR2000 SL Coor beige off white white Density, pcf (kg/m 3 ) 25 (400) 35 (561) 29 (465) 17.5 (280) Continuous temperature use imit, F ( C) 1900 (1038) 2000 (1093) 1922 (1050) Moduus of rupture, psi (MPa), dried 110 (0.8) 175 (1.2) 110 (0.8) 155 (1.07), ambient fired F (1038 C) 100 (0.7) 105 (0.7) Cod crushing strength, psi (MPa) dried 175 (1.2) 250 (1.7) 180 (1.2) fired 24 use imit 65 (0.5) 215 (1.48) Linear shrinkage, % fired F (1038 C) fired F (1093 C) 4 Chemica anaysis, % weight basis after firing Aumina, A 2 O Siica, SiO Cacium oxide, CaO Magnesium oxide, MgO Ferric Oxide, Fe 2 O Other Therma conductivity, BTU in./hr ft 2 F (W/m K), ASTM C 201 mean 500 F (260 C) 0.72 (0.11) 1.10 (0.16) 0.68 (0.09) F (538 C) 0.83 (0.13) 1.16 (0.17) 0.79 (0.11) F (816 C) 0.99 (0.15) 1.20 (0.17) F (1038 C) 1.14 (0.17) F (1093 C) 1.16 (0.17) 1.12 (0.16), 1800 F (980 C) Safety Data Sheet (SDS): are avaiabe for a our products. Data sheets, in other anguages, can aso be found by visiting our website. Pease visit our website and cick on the Safety Data Sheets Quick Link on our home page. Whist the vaues and appication information in these datasheets are typica, they are given for guidance ony. The vaues and the information given are subject to norma manufacturing variation and may be subject to change without notice. Morgan Advanced Materias Therma Ceramics makes no guarantees and gives no warranties about the suitabiity of a product and you shoud seek advice to confirm the product s suitabiity for use with Morgan Advanced Materias Therma Ceramics. 152 Imperia information