Stc overview (pre brd)

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

Two Manufacturing FacilitiesTwo Manufacturing Facilities

STC 2

STC 1

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


• 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



• Inspection• Spray Drying• Mixing

Raw MaterialsRaw Materials

Forming Methods: OverviewForming Methods: Overview

STC manufactures from prototype to large volume orders.

Which forming method is chosen depends upon cost effectiveness.


Extrusion

Cold Isostatic Pressing

Dry Pressing

Blank Forming: ExtrusionBlank Forming: Extrusion


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


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.



• Milling• Turning• OD Grinding.

Green Machining: Green Machining:

FiringFiring


• 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


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


Bell-Jar Elevator KilnsBell-Jar Elevator Kilns


Applying glaze to parts creates a glossy smooth Applying glaze to parts creates a glossy smooth surface.surface.

Diamond GrindingDiamond Grinding


• 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


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

www.ceramics.net

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

www.intatech.com

Superior Technical CeramicsSuperior Technical Ceramics Thank you for your time This concludes the presentation


Date post:	19-Jun-2015
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Stc overview (pre brd)

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