Silica ceramic composites

SILICATE COMPOSITES

Types RSLE-57 panels, RSLE-501 cylinders in RSLE-56 plastic

 

Silica ceramic compositeZIRCAR Refractory Composites, Inc. manufactures a wide variety of modern highly effective ceramic-ceramic composites and similar products. Our materials are used around the world in demanding heat, structural and electrical insulation applications at temperatures ranging from 600°C to 1650°C. For more than 25 years we are in cooperation with several industries with the goal to minimize their issues with heat insulation. We have developed materials, which have become standard in the industries of induction melting, forging and application of heat treatment, casting with lost wax core, glass processing, hot pressing and many other high-temperature electrical applications.

 

ZIRCAR heat-resistant panels type RSLE-57 is a reinforced composite based on silicon dioxide with low ductility and great strength. It is designed to be used as a strong insulator during induction hot pressing, is ideal for any king of application, where the material needs to be extremely strong even at high temperatures, which can go over 1200°C. Above 1200°C it begins to transform into a crystalline structure. RSLE-57 maintains its characteristics up to 1650°C, under the condition that there is no great temperature drop. At such great temperatures the material’s surfaces glazes over, but maintains its strength and integrity.

 

RSLE57 has a very low thermal expansion coefficient (0,3 x 10-6 °C), which enables extreme resistance to heat strokes up to 1200°C in a oxidizing atmosphere and enables its use in fast temperature shifts in this range.

The combination of a very low thermal expansion coefficient and a high density ensures resistance to heat strokes, which can be found in other ceramic composite materials. These characteristics give it a longer lifespan in most applications of hot pressing and induction heating.

 

RSLE-57 also has amazing non-absorbing qualities when in contact with melted aluminum, zinc, lead, tin and other undesired metals, which is why it is used during processes like casting, feeding, retention and forming. RSLE-57 is an ideal material for instances of use like bulkheads, nozzles, rafts, sinks, collecting troughs, deflecting plates, end plates, tips, rings, distribution cabinets, shutters, troughs, mouthpieces, transitional plates and lining for ingot hop-top casting and ingot molds.

RSLE-57 is 100% inorganic and doesn’t contain resistant ceramic fibers (aka. RCF).

 

RSLE-57 is a part of our hot press diamond segment production. RSLE-57 is used as a separator for electrical and thermal insulation between metal parts and graphite packages. At 1000°C it bears pressure of a few 100 bars without any superficial damage.

 

INFORMATION ABOUT USE

 

GUIDELINES FOR MECHANICAL TREATMENT

The material ZIRCAR fire-proof plates type RSLE has a uniformly bound structure with small pores. It enables precise dimension machine treatment with a normal carbide tool if the following guidelines are taken into consideration:

Cutting tool        Rotation speed Movement speed

Circular saw blade, with carbide tip, 25,4 cm diameter, 24 teeth              3450      4,5-6m/min

Carbide rectangular cutter          1000-2000           4,5-6m/min

This information, which can be changes, are merely of an informative nature and do not serve as a legally-binding warranty. In addition no part of these documents are allowed to be used as a permit or recommendation for the use of this patented invention without a license, the user is obligated to find out whether a proper patent exists.

 

MATERIALS MADE FROM SILICON COMPOSITE

 

ZIRCAR fire-proof panel type RSLE-501 is a high-capacity reinforced based on silicon dioxide with low ductility in cylinder form. This remarkable material is designed for the use as a very strong, resistant insulator during induction temperature treatment. The combination of a very low temperature coefficient and high density RSLE-57 enables resistance to heat strokes, which can be found in other structural ceramic composite materials.

 

RSLE57 has a very low thermal expansion coefficient (0,3 x 10-6 °C), which enables extreme resistance to heat strokes up to 1200°C in a oxidizing atmosphere and enables its use in fast temperature shifts in this range. Above 1200°C it begins to transform into a crystalline structure. RSLE-57 maintains its characteristics up to 1650°C, under the condition that there is no great temperature drop. At such great temperatures the material’s surfaces glazes over, but maintains its strength and integrity.

 

ZIRCAR fire-resistant plate type RSLE-56 moldable is a ceramic composite material reinforced with fibers with high quartz glass content, which can easily be cut and molded into different forms. When it dries the RSLE-56 moldable becomes a strong rigid structure. Additional thermal treatment or exposure to process temperatures greatly increase the physical strength of this material.

 

Type RSLE-56 has a very low thermal expansion coefficient (0,5 x 10-6 °C), which enables extreme resistance to heat strokes up to 1200°C in a oxidizing atmosphere and enables its use in fast temperature shifts in this range. Above 1200°C it begins to transform into a crystalline structure. RSLE-57 maintains its characteristics up to 1650°C, under the condition that there is no great temperature drop. At such great temperatures the material’s surfaces glazes over, but maintains its strength and integrity.

 

Because it is designed and made with components with a low thermal expansion type RSLE-56 shows higher resistance to heat strokes than composited on the basis of aluminum oxide. Its binding agent is securely mounted and won’t separate from its support fiber reinforcement. The result is a homogenous structure of the entire material. Type RSLE-56 is 100% inorganic and when it dries very little to no gas is released.

 

Types RSLE-56 and RSLE-501’s hallmarks are extreme non-absorption, when used in combination with melted non-steel alloys, which is why they are used in many processes in contact with melted metal.

RSLE-501 cylinders have the following dimensions: from 1,27cm inner diameter to 122cm outer diameter and a length of up to 183cm.

 

PROPOSED APPLICATIONS

 

Coating of induction coils

Repair of glass furnaces

Coatings for hot installations

Isolation for hot pressing

Insulation of the inner walls, where the gas speed is important

Casting tables and wrap troughs

 

RSLE-56 moldable enables easy coating of troughs and casting tables. It can be underlain with a blanket with low mass, fiber plate or calcium silicate to lower the general density and raise the insulation value.

 

Type RSLE-56 and RSLE-501 are 100% inorganic and do not contain any resistant ceramic fibers (aka RFC). Both types are precisely dimensionally mechanically treated with normal tools.

 

Fireproof plate type RSLE-56 moldable is supplied as a wet plate-like mass, coiled onto a plastic tube, separated and wrapped into plastic. Type RSLE-56 moldable can be molded and cast before drying and scorching, which enables the molding of complicated forms as well as flat plates.

 

How to make a flat plate: Open the plastic lid and take the desired amount of RSLE-56 moldable. Cut into desired sized with a knife. Leave on a hard glass, wood or metal plate, separated with a layer of plastic, cloth or paper. Dry at 60°C until dry. The 1,27cm thick plate RSLE-56 moldable will be completely dry in 16 to 24 hours. Prevent curving by holding it in place or turn it around to enable drying from both sides. RSLE-56 moldable can be dried at higher temperatures without it negatively impacting the product.

 

How to make a cylinder: choose a smooth thorn of a desired size and shape. Wrap the thorn with a plastic plate. From the roll cut enough RSLE-56 moldable to reach desired shape. With a knife cut a diagonal of the leading edge of RSLE-56 moldable. Wrap the RSLE-56 moldable around the thorn to achieve desired wall thickness. Mount the joints with a tool like a knife, spatula or screwdriver, to make sure the fibers align perfectly. Wrap the wet cylinder in a porous cloth, to make it retain shape during drying. Dry at 60°C until dry.

 

How to make complex shapes: Make a mold (can be made from plaster), with enough diagonal to make it easily removable. Form the plate into or on the mold or form the material by hand to make the entire surface of the material touch the desired texture. Dry at 60°C until dry. Large complex shapes can be made by combining several RSLE-56 moldable plates. RSLE-56 moldable sticks to itself during drying.

 

Other information: When it dries, RSLE-56 moldable becomes permanently hard. Make sure to reseal the unused material. Be careful RSLE-56 moldable doesn’t freeze. Freezing with cause the silicon dioxide base to separate from its fiber reinforcement. RSLE-56 moldable has a lifespan of about 120 days. After 120 days RSLE-56 moldable becomes rigid and can break during wrapping. RSLE-56 moldable will have a higher physical strength after scorching. Dried and scorched RSLE-56 moldable can be sanded, drilled into and cut with usual tools.

 

AVAILABILITY

Product #            Description        Product #            Description

HS01      RSLE-57 plate, 24'' x 36'' x ¼''      IS01       RSLE-501 cylinder, 2'' ID x 2 ½'' OD x 30'' L

HS02      RSLE-57 plate, 24'' x 36'' x 3/8''   IS02       RSLE-501 cylinder, 3'' ID x 3 ½'' OD x 30'' L

HS03      RSLE-57 plate, 24'' x 36'' x 1/2 ''  IS03       RSLE-501 cylinder, 4'' ID x 5'' OD x 30'' L

HS04      RSLE-57 plate, 24'' x 36'' x 5/8''   IS04       RSLE-501 cylinder, 5'' ID x 6'' OD x 30'' L

HS05      RSLE-57 plate, 24'' x 36'' x 3/4''   IS05       RSLE-501 cylinder, 6'' ID x 7'' OD x 30'' L

HS06      RSLE-57 plate, 24'' x 36'' x 1''       IS06       RSLE-501 cylinder, 7'' ID x 8'' OD x 30'' L

HS07      RSLE-57 plate, 24'' x 36'' x 1 1/2''                               

HS08      RSLE-57 plate, 24'' x 36'' x 2''                       

HS12      RSLE-57 plate, 24'' x 36'' x 1/8''                 

 

Plates, shapes and products can be made to order. Our processes of shaping, large tool stock to order and excellent techniques of machine treatment enable the production of several different sizes and shapes. We can produce even special shapes, like discs, rings and other. We also offer machine treatment with little tolerance, compositional variance and the use of surface hardeners and hardening agents.

We are available to you for any special requests.

 

Number #           Description

HS30      RSLE-56 Moldable plate, 24'' x 36 '' x 1/8''

HS31      RSLE-56 Moldable plate, 24'' x 36 '' x 1/4''

HS32      RSLE-56 Moldable plate, 24'' x 36 '' x 1/2''

HS33      RSLE-56 Moldable plate, 24'' x 36 '' x 3/4''

HS34      RSLE-56 Moldable plate, 24'' x 36 '' x 1''

 

Our process of shaping enables a wide variety of cylinders, which we can manufacture. RS-501 cylinders can have an inner diameter from 1,9cm with lengths up to 183cm to an inner diameter of 91cm. RS-201 and RS-202 cylinders can have an inner diameter from 1,27sm with lengths up to 183cm to an inner diameter of 91cm with lengths up to 91cm.

 

ZIRCAR Refractory Composites, Inc.

P.O. BOX 489, FLORIDA, NY 10921-0489

Tel: (845) 651-2200, Fax: (845) 651-1515

 

Exclusive and authorized representative;

NATURA SEAL d.o.o.

Stegne 35

1000 Ljubljana

Slovenija

01 511 3770

01 511 3775

info@natura.si

Excellent SME certifikat