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Ceramic Waffers

12/27/2007 11:27 AM

I recently saw a segment on "How's it made." The segment was on making ceramic knives, which appear to be unbreakable. Can waffer thin ceramics that are about 0.004" thick (4" W X 6" L) be made from a similar material? I realize that a 0.004' thick waffer is very thin and will snap. However, these waffers would be tightly stacked together (about 12" long) by a housing. Will such a stack hold together without internal cracking of waffers?

ASF

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#1

Re: Ceramic Waffers

12/28/2007 11:34 AM

Ceramic knives certainly are not unbreakable. In fact, the edge is easily chipped if the blade is moved sideways across hard material such as bone. The great feature of ceramic knives is their abrasion resistance, which allows them to remain sharp many times longer than any steel blade- as long as one is careful how the ceramic blade is used.

Bill Morrow

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#2
In reply to #1

Re: Ceramic Waffers

12/28/2007 11:56 AM

Thanks Bill,

Thanks for your reply. I've learned something new. It's what I've suspected. I'm still curious if 0.004" dense, waffers can be made?

Have a good day and Happy New Year

ASF

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#3
In reply to #2

Re: Ceramic Waffers

12/28/2007 12:33 PM

I don't see why 0.004 " wafers can not be fabricated successfully, but they would not be robust if subjected to vibration. I am guessing you are considering their use as substrates for microcircuits. The circuits I have seen on ceramic substrates used wafers about 10 times thicker. But if protected from vibration I would think it is possible, albeit difficult, to fabricate circuits on 0.004 " wafers.

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#4

Re: Ceramic Waffers

12/28/2007 1:15 PM

A thickness of 0.004" (Not 0.048" or .004', right?) is possible through chemical-mechanical planarization, commonly called lapping. Excess material is gradually removed from the planar surfaces until the desired thickness is reached. My company has successfully used this approach to make piezo-ceramic elements 0.003" thick, which then had to be cut to size by laser.

Alternately, you could try using an abrasive-waterjet cutter or liquid-cooled abrasive cutting wheel saw to dice these wafers off of a block of your material. Some cutters can achieve a tolerance of +/- 0.001", so it's almost as reliable for thickness dimensioning as most lappers. However, there may be some surface effects and breakage at the edges of these wafers; and a higher risk of the wafer shattering during cutting. I've never tried this approach (or heard of it being done) but it should be possible.

Your biggest problem will be the size of your wafer; 4" by 6" is a huge surface area to keep a tolerance across and will definitely increase the chances that handling or assembly stresses would cause fracture. Keep in mind though that some ceramics have better elastic moduli than others and will tolerate higher stresses. Your success in attempting this will be most affected by the material you choose. Likewise, your housing material should be rigid enough to limit the stress transferred to the wafer layers. Any intra-layer adhesive should be a compromise of flexibility and rigidity as needed to dampen internal forces. Good luck.

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#5
In reply to #4

Re: Ceramic Waffers

12/28/2007 2:35 PM

Thanks for that info. I think I'm "up the creek" with this one. Sounds extremely expensive to make, even if feasible. I was hoping that they could be pressed and fired and hold tolerance (0.004" thick +/- 0.0005"). I'll have to stick with steel, since the number thin plates are in the 100,000's. The other "nut" is that I would not be able to stack and press them together without, "snap, pop and crack."

Thanks again. Happy New Year

ASF

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