1. Keramisches Pulver – Verunreinigung Problem & Lösungen
Todd Byrnes
29 März 10

2. Verfahren…… End Product : Ceramic Paste (50% H2O content) Operation :
Mixing (EIRICH Mixer)
Problem :
Contamination of Product due to abrasive action of product on mixer parts, at high mixing rate
e-SYSTEMS

3. Optionen 1 Si Compatible Very Hard Wearing Mechanical Ceramic (Si2N3)
Cladding / Sleeving (PU). No coating required
Si Compatible
Si-based (SiO2, SiC, Si). No contamination
Very Hard Wearing
(CrC3, WC)
e-SYSTEMS
Organic (C-based). Burns of during firing. May be ceramic reinforced
Product 99,9999%

4. Optionen 2 Solution Si-compatible Si-incompatible Organic
Very Hard Coating
Coating
Ceramic Parts
SiO2 / SiC PU
Si2N3
WC-Co / CrC3
Non-coating*
Polymer / Rubber
UHMWPE / PU
Ceramic
*Cladding / Lining or bulk parts (tiles, blades etc)
Multi-sensor Traversing System

5. Optionen 3 Table 1. Protective Coatings - Options
e-SYSTEMS
Multi-sensor Traversing System

6. Specifische Lösungen Table 2. Protective Coatings - Detail System
Applied?
pro
con
CrC3 WC
HVOF
Easy to apply
Wear rate ~0
Suitable at all scales
Thick layers possible
Slight contamination
PU /
Polyurea
Wet spray
Easy to apply & repair
Organics burn out
Wear rate higher
Burn out may cause graphitisation
Glass Flake or mineral reinforced Epoxy
Wet spray/trowel
Very tough
Fillers may contribute to contamination
DLC
PVD
Hardest coating known
Pure carbon
Requires vacuum chamber
Very thin layer
SiC,
Si, SiO2
Does not introduce contamination
Difficult to find firms that do it.
High MP materials - requires vacuum PVD process
Thin coating
Difficult to repair
Polymer / ceramic
Cladding
Easy to apply to large areas
Pure polymer / ceramic possible
Only for large scales and simple shapes
e-SYSTEMS

7. Beschichtungen (Auftragung)
Table 3. Thermal Spray Types & Conditions
Type
Conditions
Powder
Wire
Evap
Suitable for…
Cold
air 
all
Plasma
chamber / air
HVOF
Flame
Electric Arc
PVD / CVD
chamber
small
Wet Application (Spray / Trowel application of organics) of course is the most flexible. Cladding is only good for simple geometries. What is also important is….

8. Auskleidung / Verkleidung…..
Steel Shaft
Angular Velocity – very low
Ceramic Tiles
Ceramic Stirrer blades
Highest Angular velocity
Rubber Cladding
All-Ceramic Stirrer

9. Upscaling…..
Two solutions can of course, exist side by side, but having the same solution would save development time……

10. Angebote…….. Table 4. Quotations based on R02 EIRICH Mixer Firm Method
Coating
Thick. mm
System Type
Cost (€)
Ease of application & repair
Poly-Tec
Wet Spray
Polyurethane 4
Pure PU
400
Very good
Plascoatech
Plasma
DLC carbon
0,01
PVD Diamond
835
Poor (vacuum)
ICV
HVOF
Cr3C2/Ni20Cr
0,2
Very hard
995
good
Fiehl & Kremer
WC-Ni/Co
0,15
5825
ENECON
Wet Coat
Ceramalloy Epoxy
thick
Ceramic filled epoxy
182/kg