The ceramic fire process depends heavily on ceramic setters, sometimes referred to as kiln setters or setter plates. In order to avoid deformation, provide uniform heat distribution, and make it easier to remove binders and other contaminants during sintering, they are made to support and separate ceramic pieces inside the kiln. Our setters combine endurance, thermal stability, and accuracy to satisfy the strictest requirements of the ceramics sector.
Due to their overall performance of little contamination, high-temperature resistance, chemical inertness, low thermal expansion, and good mechanical stability, alumina ceramics are frequently utilized as setter plates. Alumina setter plates come in two forms: non-porous and porous.
Non-Porous Alumina Ceramic Setters
In the processes of ceramic injection molding (CIM), metal injection molding (MIM), and low temperature co-fired ceramics (LTCC), 99% high purity alumina plates are frequently used as setters.
High Thermal Resistance
Ceramic setters can be employed in vacuum at temperatures up to 1600°C. Furthermore, the excellent thermal stability results in reduced thickness of the setters, which increases energy efficiency due to less thermal ballast.
Avoid Contamination
Alumina ceramics can be used in place of releasing agents or protective layers because they won't react chemically with metals. They don't need to be reconditioned and can be used repeatedly without breaking or deforming. Alumina plates with high purity can be employed in both protective gas atmosphere and reduction atmosphere. Additionally, they are also stable in hydrogen and reactive atmospheres.
Excellent Thermal Conductivity
Because of its high thermal conductivity, alumina enables efficient heat transfer throughout the sintering and debinding processes. This aids in the removal of the binder and the uniform heating of the components.
Dimensional Stability
Under high temperatures, alumina retains its shape and size. In addition to having a poor thermal expansion capacity, it can lower weight through smaller setter plate thickness and retain very little residual heat when it cools. This is critical to make sure that the parts stay in the right positions throughout firing.
Smooth Surface
The surface of the setter plate is flat, smooth, and delicate after double-sided grinding, allowing it to shrink evenly during the firing process and not affect the forming of the sintered parts. The smooth, particle-free surface also safeguards the component from being contaminated from the setters.
Porous Alumina Ceramic Setters
Setters, saggers, and other high-temperature kiln furniture made of high-purity porous alumina possess excellent high-temperature resistance, good thermal shock resistance, low thermal expansion coefficient, and outstanding creep resistance, etc. In continuous furnaces, vacuum furnaces, batch furnaces, hydrogen furnaces, etc., our high alumina sintering plate (corundum mullite setter plate) exhibits exceptional sintering performance.
Excessive impurities of the kiln furniture, such as sintered plates, will cause chemical adhesion and prevent metal parts from going through thermal expansion and contraction smoothly, thereby causing metal parts to deform and seriously affecting the appearance gloss of them during the high-temperature sintering process of pressed powder metallurgy. The phenomena of siliconization and decarburization will cause rusty effects on stainless steel components.
UNIPRETEC provides ceramic setters with high-purity inert chemical composition to ensure that chemical reactions such as carburization, decarburization, and dechromation will not occur during the sintering of metal parts. Additionally, effective porosity guarantees that the sintered plate has a very low storage energy, and it won't crack even after repeated cold and heat cycles. The surface is delicate and smooth, and it will not deform during high-temperature sintering.
Principal Elements and Details
Materials: Our Ceramic Setters offer the ideal combination of mechanical strength and thermal shock resistance for a range of applications. They are constructed of Mullite, Alumina, and Alumina-Zirconia.
Precision Engineering: Our setters are made to exact specifications using cutting edge production techniques such as vacuum forming, casting, pressing, and CNC machining, guaranteeing a flawless fit and reliable performance each and every time.
Thermal Characteristics: Suitable for high-temperature sintering processes, our setters have low heat capacity and outstanding thermal shock resistance, allowing them to survive abrupt temperature fluctuations without warping or breaking.
Outstanding permeability is essential for the effective removal of binders during the sintering process, and our setters are made to be easily cleaned and maintained.
Customizable Solutions: We provide adaptable solutions in terms of size, shape, and material composition to satisfy particular needs because we are aware of the special demands of different applications.
Lightweight Design: Our lightweight, easily handled setters lessen operator physical strain and increase overall kiln loading and unloading process efficiency.
Chemical Stability: Our setters offer a chemically stable platform that does not react with the materials being sintered, guaranteeing the purity and quality of the final product, with very little contaminants such silica, iron oxide, and sodium oxide.
High Temperature Durability: Depending on the material composition, our setters may endure temperatures as high as 1650ºC, making them appropriate for a variety of sintering uses.
Safety and Reliability: Our setters are built to guarantee dependable operation in every firing cycle and are compliant with international safety requirements.
Application of non-porous and porous alumina ceramics
Industrial Ceramics
For burning lightweight ceramic goods where gas release is essential to preserving the integrity of the product.
Glass Industry
In glass product annealing and tempering procedures.
Hot Processing
For operations, including firing certain refractory goods, where gas permeability and thermal insulation are essential.
Compare and Choose
The particular needs of the application determine which of the two alumina kiln stands—non-porous or porous—to use.
Product Capacity
Stronger mechanically than porous alumina kiln supports, they are the best option for big loads.
Uniformity in Temperature
Processes where temperature consistency and gas release are crucial are made easier by porous alumina kiln supports, which also provide improved thermal insulation.
Installation and Handling
Because they weigh less, porous kiln stands are simpler to move and erect.
Cost Factors
Although porous alumina kiln stands are often less expensive, non-porous alumina may be worth the greater outlay for applications requiring greatest durability and least contamination.
Alumina kiln stands with porous and non-porous surfaces provide special benefits designed for certain industrial operations. It is easier to make wise choices to guarantee best performance and efficiency in high temperature conditions when one is aware of their features and applications.
More than simply instruments, our Ceramic Setters are the cornerstone of producing superior ceramic goods. Selecting our setters is like to working with a business that respects accuracy, dependability, and creativity. We are dedicated to provide you the best solutions available to assist your ceramic production processes.
Please contact us with any questions you may have, technical details, or to talk about how our Ceramic Setters might improve your production capacity. Working with you and helping your ceramic manufacturing projects succeed excites us.
