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Applications will grow for ceramic wear-resistant parts Wear has plagued equipment designers and plant operators since the beginning of industrial development. Wear affects equipment and plant efficiency, maintenance frequency, product quality, and profitability, to name but a few variables. As industry becomes more time and cost conscious, the wear of critical components and the components' intrinsic relationship to output and efficiency are warranting increased attention. Following a long period of extensive research and development efforts, advanced wearresistant structural ceramics have become a reality in a wide range of applications. The US market for wearresistant ceramics has been consistently expanding and is expected to grow rapidly through the end of the decade (see Table). Wear-resistant ceramic applications include: bearings, mechanical seals, liners for mineral and processing industries, grinding media, ball mill liners, metal processing dies, thread and wire guides, pulleys, sandblast nozzles, etc. The components are produced using monolithic ceramics, ceramic matrix composites or ceramic coatings. One important feature of the ceramic wear parts market is that many of the components last a great deal longer than those of the past. Therefore, when a replacement market eventually arises for ceramic wear parts, the overall market itself may be quite different in both form and composition. Closely related to concerns of reliability are concerns of cost. Ceramic wear parts are relatively expensive and many of their uses so far have been limited to low quantity specialized high performance applications except for areas such as ceramic liners used in mining and mineral industries and ceramic seals for pumps used in automobiles and appliances. In these two cases, inexpensive alumina ceramics have been mass produced and are competitively priced. However, in other wear-resistant applications, because of the low volume of production, the costs are synthetically high. However, if ceramic wear components are used massively, the costs will come down, which in turn will open up a wide range of new applications. Ceramic wear-resistant parts accounted for sales of $115 million by 1991 and are expected to grow 9.9% annually to reach $184 million by 1996. Ceramic bearings, an important ceramic wear part, are finding many applications as replacements for steel and carbide rolling elements. Advantages associated with ceramic bearings include high 186
speed and acceleration capability, extended life and wear, minimal lubrication requirements, and corrosion resistance. The market for ceramic bearings is expected to increase at an average annual rate of 22.5% from 1991 to 1996. By the turn of the century, the ceramic bearing market is expected to reach a dollar value of hundreds of millions. Ceramic coating has become an economical method of increasing the life of machine parts and other wear components whether they are new or worn. The wear-resistant ceramic coating service market is expected to increase from $29 million in 1991 to $50 million by 1996 with a growth rate of 11.5% annually. The overall market for ceramic liners, grinding media and components for the pulp and paper-making industry will grow at 7.2% annually from 1991 to 1996. The ceramic liner business is presently stagnant because there are few new mining, iron and steel, coal preparation and mineral processing plants. Also, the prices of these liners have remained the same for the past decade. There is always demand for replacements markets. However, over
the past few years, some of the plants have been stretching the life span of existing liners. This is also a reflection of the economic downturn in the mining, mineral and processing industries. Still, specialty liners for the chemical processing industry will experience 15% annual growth. US market for advanced ceramic wear parts and coating services 1991-1996
Millions of Dollars 1991 Ceramic wear parts Ceramic coating services Total
AAGR (%) 1996 1991-1996
115.0 184.0 29,0
9.9
50.0
11.5
144.0 234.0
10.2
This data and analysis is extracted from a study by BCC Inc. RGB-152, Wear-Resistant Ceramic Parts, published March 1992 and available for $2550.00. Further information from Business Communications Company Inc., 25 Van Zant Street, Norwalk, CT 06855, USA. Tel: + 1 203 853 4266.
Principles of Failure Analysis preview tape ASM International has made available a preview tape of the 'Principles of Failure Analysis' videocourse claimed to be the most comprehensive, applications-oriented video training series available to the metalworking industry on the subject of failure analysis. The preview package is offered to help users evaluate the complete 15-tape 'Principles of Failure Analysis' videocourse series, which will be available in mid-1992. A fullocolour preview tape plus an inspection copy of the accompanying reading modules offers an overview of the actual series, not only providing an indication of the scope and quality of the course, but also demonstrating to potential users what they can expect to learn from the series. The entire 'Principles of Failure Analysis' videocourse series will be of interest to those who are new to the field, need a state-of-the-art update, or provide technical support in purchasing, sales, and administrative roles. The first seven videotapes of the 15-tape series focus on failure analysis procedures and specific types of failures. The tapes cover: General Procedures for Failure Analysis: Types of Failure and Stress; Ductile and Brittle Fractures; Fatigue Fractures; Wear
Failures; Corrosion Failures; and Elevated Temperature Failures. Tapes 8 through 15 concentrate on failures of specific materials, parts and parts configurations. The tapes address: Failures of Cast and Wrought Ferrous Metals; Failures of Welded, Brazed and Soldered Joints; Failures of Tools and Dies; Failures of Shafts and Bearings; Failure of Gears, Failures of Mechanical Fasteners; Fasteners of Boilers and Heat Exchangers; and Failures of Pressure Vessels. The videocourse series provides detailed coverage of general failure analysis; procedures; and types of failure and stress, including ductile and brittle, fatigue, wear, corrosion and elevated temperature. Also covered are failures of: cast and wrought ferrous metals, joining, tools and dies, shafts and bearings, gears, mechanical fasteners, boiler and heat exchangers, and pressure vessels. To order the 'Principles of Failure Analysis' preview package for $95, or for further information on this or any other ASM videocourse, please contact the ASM International Education Department, Materials Park, Ohio 44073-0002, USA. Fax: + 1 216 338 4634. MATERIALS & DESIGN Vol. 13 No. 3 1992
Applications will grow for ceramic wear-resistant parts Wear has plagued equipment designers and plant operators since the beginning of industrial development. Wear affects equipment and plant efficiency, maintenance frequency, product quality, and profitability, to name but a few variables. As industry becomes more time and cost conscious, the wear of critical components and the components' intrinsic relationship to output and efficiency are warranting increased attention. Following a long period of extensive research and development efforts, advanced wearresistant structural ceramics have become a reality in a wide range of applications. The US market for wearresistant ceramics has been consistently expanding and is expected to grow rapidly through the end of the decade (see Table). Wear-resistant ceramic applications include: bearings, mechanical seals, liners for mineral and processing industries, grinding media, ball mill liners, metal processing dies, thread and wire guides, pulleys, sandblast nozzles, etc. The components are produced using monolithic ceramics, ceramic matrix composites or ceramic coatings. One important feature of the ceramic wear parts market is that many of the components last a great deal longer than those of the past. Therefore, when a replacement market eventually arises for ceramic wear parts, the overall market itself may be quite different in both form and composition. Closely related to concerns of reliability are concerns of cost. Ceramic wear parts are relatively expensive and many of their uses so far have been limited to low quantity specialized high performance applications except for areas such as ceramic liners used in mining and mineral industries and ceramic seals for pumps used in automobiles and appliances. In these two cases, inexpensive alumina ceramics have been mass produced and are competitively priced. However, in other wear-resistant applications, because of the low volume of production, the costs are synthetically high. However, if ceramic wear components are used massively, the costs will come down, which in turn will open up a wide range of new applications. Ceramic wear-resistant parts accounted for sales of $115 million by 1991 and are expected to grow 9.9% annually to reach $184 million by 1996. Ceramic bearings, an important ceramic wear part, are finding many applications as replacements for steel and carbide rolling elements. Advantages associated with ceramic bearings include high 186
speed and acceleration capability, extended life and wear, minimal lubrication requirements, and corrosion resistance. The market for ceramic bearings is expected to increase at an average annual rate of 22.5% from 1991 to 1996. By the turn of the century, the ceramic bearing market is expected to reach a dollar value of hundreds of millions. Ceramic coating has become an economical method of increasing the life of machine parts and other wear components whether they are new or worn. The wear-resistant ceramic coating service market is expected to increase from $29 million in 1991 to $50 million by 1996 with a growth rate of 11.5% annually. The overall market for ceramic liners, grinding media and components for the pulp and paper-making industry will grow at 7.2% annually from 1991 to 1996. The ceramic liner business is presently stagnant because there are few new mining, iron and steel, coal preparation and mineral processing plants. Also, the prices of these liners have remained the same for the past decade. There is always demand for replacements markets. However, over
the past few years, some of the plants have been stretching the life span of existing liners. This is also a reflection of the economic downturn in the mining, mineral and processing industries. Still, specialty liners for the chemical processing industry will experience 15% annual growth. US market for advanced ceramic wear parts and coating services 1991-1996
Millions of Dollars 1991 Ceramic wear parts Ceramic coating services Total
AAGR (%) 1996 1991-1996
115.0 184.0 29,0
9.9
50.0
11.5
144.0 234.0
10.2
This data and analysis is extracted from a study by BCC Inc. RGB-152, Wear-Resistant Ceramic Parts, published March 1992 and available for $2550.00. Further information from Business Communications Company Inc., 25 Van Zant Street, Norwalk, CT 06855, USA. Tel: + 1 203 853 4266.
Principles of Failure Analysis preview tape ASM International has made available a preview tape of the 'Principles of Failure Analysis' videocourse claimed to be the most comprehensive, applications-oriented video training series available to the metalworking industry on the subject of failure analysis. The preview package is offered to help users evaluate the complete 15-tape 'Principles of Failure Analysis' videocourse series, which will be available in mid-1992. A fullocolour preview tape plus an inspection copy of the accompanying reading modules offers an overview of the actual series, not only providing an indication of the scope and quality of the course, but also demonstrating to potential users what they can expect to learn from the series. The entire 'Principles of Failure Analysis' videocourse series will be of interest to those who are new to the field, need a state-of-the-art update, or provide technical support in purchasing, sales, and administrative roles. The first seven videotapes of the 15-tape series focus on failure analysis procedures and specific types of failures. The tapes cover: General Procedures for Failure Analysis: Types of Failure and Stress; Ductile and Brittle Fractures; Fatigue Fractures; Wear
Failures; Corrosion Failures; and Elevated Temperature Failures. Tapes 8 through 15 concentrate on failures of specific materials, parts and parts configurations. The tapes address: Failures of Cast and Wrought Ferrous Metals; Failures of Welded, Brazed and Soldered Joints; Failures of Tools and Dies; Failures of Shafts and Bearings; Failure of Gears, Failures of Mechanical Fasteners; Fasteners of Boilers and Heat Exchangers; and Failures of Pressure Vessels. The videocourse series provides detailed coverage of general failure analysis; procedures; and types of failure and stress, including ductile and brittle, fatigue, wear, corrosion and elevated temperature. Also covered are failures of: cast and wrought ferrous metals, joining, tools and dies, shafts and bearings, gears, mechanical fasteners, boiler and heat exchangers, and pressure vessels. To order the 'Principles of Failure Analysis' preview package for $95, or for further information on this or any other ASM videocourse, please contact the ASM International Education Department, Materials Park, Ohio 44073-0002, USA. Fax: + 1 216 338 4634. MATERIALS & DESIGN Vol. 13 No. 3 1992