FRIALIT®-DEGUSSIT® HIGH-PERFORMANCE CERAMICS SLIDE & ROLLING BEARINGS Full ceramic or hybrid bearings

www.aliaxis-ui.se

INDEX

02 2

Introduction

04–05

Bearings in general

06–07

Characteristics of high performance ceramics

08–1 1

Markets and applications



12–13

Bearing types, sizes and informations

14–17

Material data

18–19

Contacts

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FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

3 03

You can always count on our vast experience

A few words about ALIAXIS UTILITIES & INDUSTRY and Friatec: Aliaxis Utilities & Industry is a part of the Aliaxis-conglomerate along with FRIATEC. FRIATEC is one of the oldest and most reknowned companies in the Mannheim area in Germany. Founded in 1860, the company has since been working with ceramics and the improvement of the material and processing technologies.

Aliaxis Utilities & Industry has a wide range of ceramic products and solutions together with a wealth of knowhow and experience to support the oil and gas industry. At your disposal is our vast experience of customer specific manufacturing for the industry including choice of materials and product design.

This makes us an excellent partner already in the development and design phase of a new product or application. If you have the idea, we will find the right ceramic solution for your purpose. Get in touch with us to assure highest quality and function of your products and applications.

FRIALIT ®-DEGUSSIT ® High-Performance Ceramics Our know-how and experienced team can be the solution to your demands. Regardless of whether you are looking for durability, a more economically viable solution or striving for an universal application, you can count

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on our vast experience. Kindly get in touch with us for your special application. Aliaxis is one of the leading manufacturers of high performance

FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

technical ceramic components for the industry. The products are manufactured from high purity ceramic materials: alumina, zirconia, silicon carbide and silicon nitride.

5 05

DURABLE MATERIALS GUARANTEE EXTENDED LIFE

corrosion resistance and especially the capability of running dry or at least with a minimum demand for lubrication are contemplated exemplarily.

Critical applications are often limited by machine parts made of conventional materials. Bearings, slide bearings and rolling bearings must be made from materials that are durable, operate with minimum friction and show minimum wear in contact areas to guarantee extended life.

High performances ceramics are designated materials for slide bearings and rolling bearings in critical applications:

In critical applications several additional requirements are strongly claimed for these machine elements; resistance to elevated temperatures,

• Silicon Nitride (Si3N4) • Silicon Carbide (SiC) • Zirconia (ZrO2) • Alumina (Al2O3)

High-Performance Ceramics can be your solution

Ceramic slide bearings can run against another ceramic partner or against components like hardened or hard coated steel. Ball and roller bearings, generically called rolling bearings, can be designed as ceramic bearings as well as hybrid bearings. In ceramic rolling bearings rings and rolling elements

The bearings can be designed as full ceramic or hybrid bearings are made of ceramics. In hybrid bearings only the rolling elements consist of ceramic materials while the rings are made of sophisticated bearing steels.

To utilize the total gain of advantages of these bearing designs, the derivative components in rolling bearings like ball retainers, seals or shields come into focus. High performance plastics and composites like PEEK or PTFE with low

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friction and outstanding properties in corrosion, temperature and wear resistance are chosen for maximum performance. Due to special mechanical properties in particular zirconia (ZrO2) and silicon nitride (Si3N4) are used

FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

for ceramic rolling bearings. These ceramics have outstanding material properties compared with conventional bearing steels.

07

CHARACTERISTICS OF HIGHPERFORMANCE CERAMICS

have excellent emergency running properties and do not fail spontaneously.

Outstanding physical characteristics of high performance ceramic materials enable extraordinary solutions with ceramic or hybrid bearings. Low chemical affinity against other materials is one of the key characteristics and results in very limited adhesive wear. This allows completely new solutions for bearings operating under poor lubrication conditions or even without any lubricant. Ceramic bearings therefore

Extremely good high temperature properties

Excellent corrosion resistance makes it possible to run ceramic bearings in aggressive environments and

FRIALIT®-DEGUSSIT® High-Performance Ceramics have outstanding material properties Low friction coefficient in combination with state of the art lubrication leads to highly efficient bearing systems. Bearings operate with massively reduced friction which results in lower temperatures and increased maximum rotational speeds.

in areas where the use of standard steel bearings is out of question. New design solutions can be realized with the help of ceramics and new bearing technology.

COMPARISON MATERIAL PROPERTIES 100%

75%

bearing steel

50%

zirconia silicon nitride

25%

0% density

088

Young’s thermal exp. hardness operating modulus coeff. HV10 temperature

Thermal expansion needs to be considered very carefully. By choosing the right material combination, solid operational conditions of ceramic and hybrid bearings are maintained over a wider temperature range.

Both silicon nitride and zirconia have a wide operating temperature range. Theoretical operating temperatures up to 1 000 °C are possible.

FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

Alumina has a maximum working temperature of 1 950 °C.

9 09

OPERATES EVEN IN STRONG MAGNETIC FIELDS Non-magnetic properties are important in many applications. Silicon nitride and in particular zirconia fulfill the requirements and allow operation even in strong magnetic fields. Electric insulation is an advantage for many tasks. We also have ceramics on request that have even conductive properties. The combination of state of the art bearing steels and the excellent properties of ceramics can be transferred into hybrid bearings. The combination of corrosion resis-

tant and heat resistant (up to 450 °C) high performance bearing steel races with superior resistance against overall-fatigue allow bearing designs with properties much closer to ceramic bearings than to common steel bearings.

Ceramic materials are compatible with extreme environments

the load ratings and the service life will be lower than those for steel bearings. However, experience shows that the actual service life is significantly longer. Due to this, we use the same maximum dynamic load ratings* as for conventional bearings.  

The life time for hybrid or full ceramic bearings are significantly longer DIN/ISO standards do not specify any calculation methods for the determination of load ratings of ceramic or hybrid bearings. If the classical fatigue theory is used,

STATIC AND DYNAMIC LOAD CAPACITY FOR DIFFERENT BEARING MATERIALS

150% 125% 100%

static load cap.

75%

dynamic load cap.*

50%

dynamic load cap.

25% 0% steel brg.

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hybrid brg. ceramic brg. ceramic brg. ceramic brg. (Si3N4) (ZrO2/Si3N4) (ZrO2)

Summarizing, these sophisticated ceramic materials offer reduced friction and are compatible with extreme environments, stable at high temperatures, electrical insulating

and extraordinary durable in advanced bearing applications.

an incomparable level of wear and corrosion resistance.

Compared to common bearing steels, ceramics are much harder and have

This allows, in many cases, media lubrication or even complete dry running conditions.

FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

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Markets and applications

FROM SUBSEA TO SPACE Hybrid Bearings have been in use in high speed machine tool spindles for decades. In innumerable applications hybrid bearings are indispensable for reliable operation of spindles with excellent performance parameters. In aviation and aerospace, ceramic bearings are nowadays used widely. The flagship project is the U.S. Space Shuttle with tailor-made hybrid bearings in the three main engines finally allowed a reliable,

Due to these very special material characteristics, ceramic and hybrid bearings are dedicated for applications and markets where the focus is on:

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Extreme performance: Machine tools Aviation and aerospace Motor sports Harsh environment: Offshore and Subsea industry Chemical industry

efficient and cost effective operation under extreme conditions. Today, hybrid and ceramic bearings are used in jet engines, gears and motion drives in aviation and also in

formance enhancement in mechanical transmission and suspension systems. Formula 1, racing and rally cars are all equipped with hybrid bearings in their wheels, gearboxes

In aviation and aerospace ceramic bearings are on the advance actuation systems for satellites and similar applications. In motor sport, all challenges faced by racing teams, within many different racing disciplines, lead to per-

and engines. Weight saving, reduced friction and an extraordinary durability pushed the designs to new limits.

Clean room technology: Food industry Medical industry Pharmaceutical industry Vacuum technology Semiconductor industry

FRIALIT ®-DEGUSSIT ®  High-Performance Ceramics

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Ceramic bearings can be used in the most critical production processes

CERAMIC BEARINGS CAN OPERATE IN CLOSE CONTACT WITH PROCESS MEDIA Clean room technology uses all different types of processing where clean processes are crucial for high quality products, such as ceramic bearings. Food and drug processing requires clean machinery equipment. More and more equipment for aseptic food, drug and beverage processing is installed worldwide. With respect to the productivity

Offshore and subsea industries are highly interested in employing ceramic bearings due to their excellent mechanical and tribological properties in their applications. Extreme environmental operating conditions can not be overcome without additional effort spent to protect conventional bearing solutions against external corrosive impact. With ceramic bearing, design rules for drive technologies can be defined in a new way. Corrosion resistant ceramic and hybrid bearings are

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used in offshore applications for example in equipment for sea water desalination on oil rigs worldwide. Ceramic bearings successfully proved their outstanding performance under extreme maritime conditions on America’s Cup yachts, as well as in wavepower equipments in renewable energy areas. In chemical processing, ceramic bearings can operate in close contact with process media without sealing or directly in aggressive environment

and the large inline production lines, all motion drives are directly integrated in the process room. The need of lubrication free, corrosion

tor technology. With superior wear rates and negligible particle emissions, ceramic bearings can be used in special areas of processing.

Ceramic bearings show excellent properties under dry running conditions resistant motion drives is increasing permanently. Ceramic bearings close the gap perfectly to fulfill these requirements.

Particularly in areas close to the critical production processes where lubricants are prohibited.

Similar needs can be found in pharmaceutical and medical industry as well as in vacuum and semiconduc-

under corrosive attack, in high temperatures and in many cases without any additional lubrication. Applications could be found in thin film evaporators, polyethylene reactors, gas induction reactors and control leakage shaft seals. Ceramic bearings have shown particularly excellent running properties over conventional slide bearings under dry running conditions.

FRIALIT ®-DEGUSSIT ®  High-Performance Ceramics

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Types, materials, dimensions and specifications

SLIDE BEARINGS: MATERIALS AND DIMENSIONS Ceramic slide bearings are always custom made and are mainly used in zones exposed to abrasion, corrosion and high temperature

together with electrical and/or magnetic fields. Slide bearings can be manufactured from Ø 2 to max 400 mm. The inner and outer bushing can be fit together with very small gaps of some microns. Surfaces with Ravalues of < _ 0.8 micron are possible.



Bearing types:

Dimensions and specifications:



Radial and thrust rolling bearings

Ceramic rolling bearings:

Hybrid rolling bearings:



Deep groove ball bearings

ISO standard dimensions

ISO standard dimensions



Angular contact ball bearings

From 4 mm bore to 200 mm

From 1 mm bore to 1 600 mm

outer diameter

outer diameter

Customized, radial and/or axial



Standard types: ball bearings

Standard types: ball and roller

Design

With or without grooves for lubrication



from 6–100 mm

bearings from 4–400 mm

Design

Full ceramic or shrinked into metal housing



Rings and balls/rollers ZrO2

Rings conv. bearing steel,

From Ø 2–400 mm



Design



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ROLLING BEARINGS: TYPES, DIMENSIONS AND SPECIFICATIONS



Sizes



The construction can be designed as a ceramic-to-metal solution, where the ceramic bushing will be shrinked into a housing of stainless steel or other special steels. The ceramic-to-metal shrink fit will remove any fear of thrust and fracture sensibility of the ceramic.  

Possible gaps

2–10 micron, depending on size

Possible surface values

< _ 0.8 micron

Lubrication required

Product media or water

Materials

Al2O3, ZrO2, SiC, Si3N4

Spherical ball bearings

Cylindrical roller bearings



balls/rollers Si3N4



Rings corrosion and heat resistant

Custom designed bearings

Rings and balls/rollers Si3N4



HNS steels, balls/rollers Si3N4



Customized specialty steel rings,

Precision grades

Rings ZrO2, balls/rollers Si3N4



FRIALIT ®-DEGUSSIT ®  High-Performance Ceramics

balls/rollers Si3N4 or ZrO2

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FRIALIT ®- DEGUSSIT ® High-Performance Ceramics

F99.7

AL 23

DD 57

Silicon Carbide SiC

Zirconia ZrO2

Alumina AI2O3

Material

AL 24

FZT

AL 25

FZM/K

FZY

FZM

SiC 198D

SiC 198

Comparision to conventional steel

Silicon Nitride Si3N4

HP 79

GP 79 Structural properties:

Structural properties: (g/cm3)



Open porosity

(%)



Grain size

(µm)



Density

≥ 3.9 0 10



≥ 3.9 0 10

3.70–3.95 0 10

> 3.4 ≤5 40

> 2.8 20–30 70



≥ 4.05 0 5



≥ 5.7 0 50



≥ 5.5 0 30



≥ 6.0 0 0.5



3.1





3.23 0 –





3.21





0





1–5

(MPa)



23 000



23 000



23 000

–

–



20 000



16 000



17 000



18 000



21 000



Compressive strength

(N/mm2)

(MPa)



3 500



3 000



3 500

1 000

300



3 000



2 000



2 000



2 200



1 200



Bending strength

(N/mm2)

(MPa)



350



300



300–350

150

70



460



500



400



800



350







–





–



9







200



200



0.22



0.22



–

–



0.24





–



0.30



> 10 330 0.20



–

> 15 185 0.30



–

> 15 360



> 10 380 0.22

–



> 10 380





> 10 380

(Knoop)

7.8

Open porosity

0

Grain Size

–

Mechanical properties:

Mechanical properties: Hardness

Density (g/cm3)

(N/mm ) 2

Weibull modulus E-modulus E

(GPa)

Poisson ratio v







26 000 > 3 000 450



17 000



17 000



3 000





3 000



900





760

≥ 12 400 0.16



15





15



310





320

E-modulus E (GPa)



0.26





0.28

Poisson ratio v

Hardness (HRC)

61

Yield strength (N/mm2) (MPa)

1 700

Tensile strength (N/mm2) (MPa)

2 300

Fatique life L10 (mill. Circles)

3 210 0.30

Thermal properties:

Thermal properties: (°C)



1 950



1 950



1 950

1 950

1 950



1 700



900



1 700



1 200



1 400



1 650

1 200





1 200

(J/kg•K)



900



900



900

–

–



850



400



400



400



900



800





700

Spec. heat (50-100°C) (J/kg•K)

480

(W/m•K)



30



35 ***



30

–

–



25



2.5



2.5



2.5



90



1 000 125

28***



25*** Thermal conductivity (W/m•K)

45

Coefficient of expansion 20–1000°C (10-6/K)



8.2



8.5



8.2

8.2

8.2



8.3



10.6*



10.9



10.8



4.4



4.5

3.2





Max. operating temperature in air Specific heat 20°C



Thermal conductivity 100°C

3.2

20°C



1015

Ω•cm Ω•cm

Ω•cm

500°C 1000°C





1014

–

–

10



–

107



10 107

–

red





1014



11

10



10



107



Coefficient of expansion 20-300°C (10-6 /K) 12



10



1010

–





–





white





–

–



– white



1010



10-1



4 • 10 15



2

10



–



–



white



white





1010

10 84**



yellow



4



2

1010 –





107 –

–



–

107



black



black







1011

Specific resistance 20°C (Ω•cm)

10-6

– 107





Colour:

120–280

Electrical properties:

Electrical properties: Specific resistance

Max. operating temperature (°C)

ivory



ivory

ivory



black



black

* at 20–900°C ** at 900°C *** at 20°C The data shown in the table above is valid according to German industrial standard DIN 40685, where the given values only pertain to the measured test specimen. The given values must be taken as a guideline value and may not be applicable to other shapes of the same material.

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FRIALIT ®-DEGUSSIT ® High-Performance Ceramics

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Denmark

Production site

Aliaxis Utilities & Industry AB Ceramics Division Stormbyvägen 6 - SE-163 55 Spånga - Sweden Tel: +46 8 44 66 910 - Fax: +46 8 44 66 911 E-mail: [email protected]

Aliaxis Utilities & Industry A/S Ceramics Division Sandvadsvej 1 - DK-4600 Køge - Denmark Tel: +45 46 77 25 75 - Fax: +45 46 75 54 30 E-mail: [email protected]

www.aliaxis-ui.se

www.aliaxis-ui.dk

FRIATEC AG Ceramics Division Postfach 710261 - D-68222 Mannheim Steinzeugstraße 50 - D-68229 Mannheim - Germany Tel: +49 6 21/4 86-0 - Fax: +49 6 21/4 77-9 99 E-mail: [email protected]

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www.friatec.de

Slide & Rolling Bearings • 1 • 04. 2015 • KM

Norway, Sweden and Finland