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Hydraulic Pressing of Advanced Ceramics: Process Engineering
Hydraulic Pressing of Advanced Ceramics: Process Engineering
Hydraulic Pressing
Alfred Kaiser
LAEIS GmbH
kaiser@laeis-
gmbh.com
of Advanced Ceramics
Abstract • possibility of „dry“ pressing Advanced Hydraulics and
• low binder content
Uniaxial hydraulic pressing is the Electric Control Systems
• high throughput capacities
most common shaping technology • moderate investment costs. Naturally one of the most important
for ceramic products. However, On the other hand, there have been elements of hydraulic presses is the
when production technologies for also some limitation factors for uni- hydraulic system. High pressing
new advanced ceramic products axial hydraulic pressing of advanced forces have to be combined with fast
with high quality requirements are ceramics reported in the past, action, but also with high precision.
discussed, in most cases this tech- namely: Energy consumption has to be kept
nology is considered to be only sec- • only simple geometries possible at a minimum, service and mainte-
ond choice. Other technologies like • limited dimensions of the speci- nance intervals extended to a maxi-
isostatic pressing, injection mould- mens to be pressed mum. Increasing importance is also
ing, pressure casting, tape casting • comparably high variations in the given to reduction of environmental
etc. seem to provide better quality green density; especially from top or working place impact, especially
products, even if they are more to bottom (3...10 % variation are the reduction of the noise level.
expensive, have much lower pro- reported) The new generation of hydraulic sys-
duction capacities or are limited in • limited dimensional accuracy, e.g. tems for the HPF presses offers the
other factors. thickness variations in the range of following features (among others):
The paper describes new possibilities ± 10 %. • scalable hydraulic units having the
for shaping of advanced ceramic When it comes to set up a produc- same design pattern
products with a wide variety of tion technology for high quality • regulated axial piston pumps for
dimensions and aspect ratios and technical ceramic products, thus an effective energy utilization
high quality requirements. Recent very often uniaxial hydraulic press- • proportional valves for an opti-
developments in pressing technolo- ing is not at all discussed as a real mum regulation of all cylinders
gies are shown and results of press- alternative for shaping in competi- • separate filtering and cooling cir-
ing tests for advanced ceramics are tion to isostatic pressing (cold and cuit for a constant good oil quality
presented which demonstrate that hot), injection moulding, slip cast- and cleanliness
highest quality can be achieved ing, pressure casting, extrusion, • valve blocks in special design,
using uniaxial hydraulic presses. injection moulding, tape casting etc. arranged close to the energy con-
Finally, a selection of application [5 - 10]. sumers; resulting in short reaction
examples is given, indicating However, in the last decade many times
advanced ceramic products already advances have been made in • auxiliary cylinders, moving the
hydraulically pressed in industrial hydraulic pressing technology which press plunger quickly and precise-
scale. allow to overcome the above men- ly thus reducing dead times
tioned limitations and open up com- • sealed and pressurized hydraulic
pletely new fields for advanced system for utmost oil cleanliness
ceramics production [11 - 14]. In the and improved service life
Introduction • encapsulated power unit with
following some aspects of improve-
Hydraulic pressing is a well known ments made in hydraulic pressing noise insulation, reducing the
and widespread technology for technology are reported, some char- noise level to < 80 dBA (Fig. 1)
shaping of ceramics [1 - 4]. Especial- acteristic data of samples obtained • flexible positioning of the power
ly for the production of "classic" using this advanced technology are unit, possible on both sides of the
ceramics like silicate ceramics (floor press and at different height levels. Fig. 1
given and examples of new applica- Hydraulic power
and wall tiles, facing elements etc.), tions resulting thereof are shown. Besides the performance of the unit in modular
for all types of refractories (even if hydraulic system and the precision design
many of them nowadays have to be
regarded as "advanced ceramics") Recent Improvements in
and for many types of kiln furniture Hydraulic Pressing
the uniaxial hydraulic pressing ist the
mostly used shaping technology. Technology
Also technical ceramic products (in Quality requirements are increasing
this paper "technical ceramic" will be constantly for practically all types of
referred to as ceramic produced shaped ceramic products. Thus it
mainly from synthetic powders, has become necessary to improve
either oxide or non-oxide) are made also the performance of presses per-
already using hydraulic pressing. But manently. Laeis GmbH, being one of
up to now this has been limited to the leading supplier of high duty
smaller sizes with additional restric- hydraulic presses especially for
tions regarding the complexity of refractories, but also for many other
the specimen and their aspect ratio. industries, made numerous contri-
Main advantages of uniaxial butions to define a new level of
hydraulic pressing technology are: state-of-the-art pressing technology.
Green Strength
The plates could be removed from
the mould after pressing without any
problems. Even thin plates with 1
mm thickness could be handled
without destruction (Fig. 8), even
though the binder system was not
optimized. If no vacuum was
Tab. 1 Linear
springback effect
depending on fill- Tab. 2 Thickness and density variation of green alumina plates
ing height and
applied pressure applied, however, the plates were and accordant average thickness,
destroyed immediately after releas- but also the standard deviation
ing the pressure (Fig. 9). decreases with increasing pressure.
The green density values are also
shown in Tab. 2, calculated from the
Dimensional Accuracy, Densi- weight and dimensions of each indi-
viual plate and given as average val-
ty and Density Distribution ue with the corresponding standard
After pressing and ejection from the deviation for each test pressing
mould cavity, the plates underwent a series. The absolute density values
springback in diameter (re-expan- should not be discussed here,
sion of the material), depending on because the aim of these tests was
the plate thickness and on the not to obtain maximum density, but
applied pressure (Tab. 1). A spring- to demonstrate reliability and repro-
back in vertical direction was pre- ducibility of the hydraulic pressing
vented by ejection under load. The process. Again, the 3 test series with
green plates showed a very high 16 mm filling height can be com-
dimensional accuracy. Variations in pared to each other, showing a
green plate thicknesses are shown in steady increase in density with
Tab. 2. increasing pressure. More important,
The average values and standard however, is the reproducibility of the
deviations given for each set of filling green density within each test series,
height and densification pressure having standard deviations of typi-
represent a collective of 4-10 plates cally < 0,4 %.
pressed under the same conditions In an earlier test series, also thickness
and 4 thickness measurements of and density variations were investi-
each plate at different spots. Though gated on similar samples after firing.
the thickness variations are already The results are shown in Tab 3. In this
quite low, they can be reduced fur- table, only one plate of each type
ther in an optimized automatic was investigated. Each line of the
Fig. 8 process, because the data given in table represents values of one plate,
Manual handling of thin plates immediately after pressing Tab. 2 are obtained with manual fill- where the thickness and density
ing of the mould with small quanti- were measured at up to 30 spots
ties of powder and without a special each, distributed over the whole area
adjustment of the pressing die paral- of the plate. Again the results are
lelism. Both factors contribute to very good, with fluctuations only in
deviations in thickness, the first one the range of typically < 2 % (it has to
mainly between the plates, the sec- be noted that the values in Tab. 3 are
ond one within a single plate. Natu- absolute values, not standard devia-
rally, the percentage of deviation is tion values!). Naturally, the thinnest
increasing with decreasing thickness. plate with a fired thickness of < 1 mm
The densification factors, also given again has a bigger percentage of
in Tab. 2, can not be discussed in thickness fluctuation, but the
detail, because the different test absolute value is in the same range as
pressings were performed with dif- the other plates.
ferent pressing parameter combina-
tions. However, the data of the 3
series with 16 mm filling height (with Surface Quality
specific pressures of 5, 10 and 15 The plates show a very smooth sur-
kN/cm2) were obtained under con- face already in the green state. After
Fig. 9 stant conditions. They show a good firing a similar surface quality is
Destroyed plate (pressed without vacuum) consistency of densification factor obtained as with tape casted sheets,
Application Examples
A big variety of applications was
investigated in detail during the last
years and many of them have been
brought to industrial application.
The following section describes some
of these applications.
Fig. 11 PEM fuel cell bipolar plate Fig. 12 Carbon filter elements References
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