UltraTemp ^TM Composite

The perfect replacement for silicon carbide, cordierite, zirconia & alumina/mullite

Tests are underway at a number of application sites to assess the overall mechanical and thermal properties of the material.  The initial tests show an extreme toughness and chemical inertness, a thermal conductivity similar to high alumina ceramics, and excellent thermal shock resistance.  Surface characteristics of the new composite are readily amenable to coatings of both metallic and inorganic compositions. See Figure.

UltraTemp Composite by SenCer Inc.

SenCer Inc. has recently developed a fiber/matrix composite which has been designed for use as a thermal package for an electronic component but which has exhibited excellent properties as a high temperature structural material. As seen from the micrograph below, the final structure is fairly dense and exhibits an excellent bond between fiber and matrix.  The chemistry of the material is essentially a pure high alumina (Al2O3) composition in both matrix and fiber with a small amount of mullite formation.

The new material dubbed "Ultratemp" shows an extreme resistance to chemical attack as well as an overall chemical inertness to vapor transport from other materials, Ultratemp has been has been tested to temperatures as high as 1460°C without signs of mechanical, thermal, or high temperature creep degradation. New Compositions are currently available to extend the range to 1650°C

        Advantages of UltraTemp

• Max Use Temperature 1650°C                                    
• Ends chemical attack                                                    
• No mechanical, thermal creep @ high temp      
• Ends labor & kiln costs of painting cordierite   
• Extremely Long Cycle Life                                           
• Decreases land fill contamination & costs              
• Abrasive and corrosive resistant                               
• Any 3 Dimensional shape with finest tolerance
• No redesign fees – change now for increased yield
• Maintains strength @ high temperature
• Saves energy – significantly lighter than zirconia, silicon carbide, & cordierite
• Thinner walls mean more yield with less energy
• Surface Engineering Coatings Available – extremely strong bonds
• High electrical stand off resistance
• Excellent Thermal Shock characteristics
• Metal embedding capable
• Zero Reaction with Molten Alumina
• Extremely Low Free Silica
  

The composite is formed utilizing a near net shape forming technique and can be easily developed in large sheets, and complex shapes. UltraTemp can also include micro and macro hole generation. Applications in production or under investigation include:

• A mid-temperature (<1460°C) Setter or Kiln Furniture replacing cordierite and Al2O3/Mullite materials.
• A High-Temperature (<1600°C) Setter or Kiln Furniture rivaling silicon carbide in strength but without generation of chemical silica.
• A Pre-Fabricated Radiation Liner in high temperature furnaces which can prolong the life of existing kiln systems and can lead to minimizing expensive rebuild of fiber lined systems.
•   An Electronic Setter System for high purity electronic ceramics including MLC,PTC, thick and thin film as well as semiconductor boats.
•   An Aluminum Holding and Smelting Refractory Liner for process, life and energy savings.
•   Use in Other High Temperature Systems such as glass systems, incinerator systems and emissions filtering are also being considered.  Applications where caustic and chemical attack is a problem is another potential use area.  Platinum and metal coatings of the composite could lead to it's use as a high temperature glass melt crucible.