Manufacture of prototype nanostructured ceramic components
Lead Research Organisation:
Loughborough University
Department Name: Materials
Abstract
Zirconia-based ceramics are used in many engineering applications but they fail when exposed to moisture at 100 300oC. Overcome this and major new markets open up in the medical and petrochemical industries amongst many others. Results obtained by Loughborough University indicate this can be achieved by producing nanostructured zirconia.The science is now largely understood so the task is to scale up the manufacture of these materials to prototype level and transfer the technology into industry. Three industrial partners, including a nanopowder producer, a ceramic manufacturer and a control valve manufacturer, will work with Loughborough to achieve this.
Publications
Ghanizadeh S
(2014)
Synthesis of nano a-alumina powders using hydrothermal and precipitation routes: a comparative study
in Ceramics International
Ghanizadeh S
(2017)
Improved transparency and hardness in a-alumina ceramics fabricated by high-pressure SPS of nanopowders
in Ceramics International
Ghanizadeh S.
(2016)
Spray Freeze Granulation of Submicrometre alpha-Alumina Using Ultrasonication
in JOURNAL OF CERAMIC SCIENCE AND TECHNOLOGY
Min Nah Tong
(2011)
Characterisation of Submicron-Grain Sized Yttria-Stabilised Zirconia Electrolyte for SOFCs
in Journal of Materials Science and Engineering A
Paul A
(2011)
Hydrothermal Aging Behavior of Nanocrystalline Y-TZP Ceramics
in Journal of the American Ceramic Society
Paul A
(2013)
Micro-Raman spectroscopy of indentation induced phase transformation in nanozirconia ceramics
in Advances in Applied Ceramics
Ramanujam P
(2016)
Solvothermal nanoYAG synthesis: Mechanism and particle growth kinetics
in The Journal of Supercritical Fluids
Ramanujam P
(2014)
A comparative study of the synthesis of nanocrystalline Yttrium Aluminium Garnet using sol-gel and co-precipitation methods
in Ceramics International
Saremi-Yarahmadi S
(2018)
Erosion and mechanical properties of hydrothermally-resistant nanostructured zirconia components
in Ceramics International
Sun J
(2020)
3D printing of zirconia via digital light processing: optimization of slurry and debinding process
in Journal of the European Ceramic Society
| Description | The inability to produce nanostructured ceramics via industrially viable manufacturing routes has been the key barrier to market penetration. Work undertaken at Loughborough University has resulted in overcoming this barrier as large, complex shapes are now being fabricated through optimising the pilot scale manufacturing conditions for nanostructured zirconia components. Scale up quantities of granulated powders suitable for industrial pressing trials have been prepared and successfully used in factory-floor automated presses, which was a milestone in fabrication of valve components. In order to evaluate the suitability of nanostructured zirconia for valve component applications the parts were subjected to slurry erosion and ultrasound cavitation tests at Southampton University. Zirconia showed 6 fold improvement compared to the commonly-used stellite-coated commercial stainless steel specimens under slurry erosion conditions, although it was less good for cavitation situations. In parallel, a market survey was performed to investigate the size of the market. It was found that the global sales for advanced ceramics was around US$ 44 billion in 2011 and was projected to reach >US$ 56 billion by 2015. Japan and the US formed half of the market in 2011 but it is projected that by 2015 Japan will gain a majority share of >40% in the annual sales of advanced ceramics. Over 50 zirconia manufacturing companies were identified, mainly in the US and Europe and contacted. All the companies who participated in the survey confirmed that the granulated powder was relevant to their existing technologies and were happy to adopt the powder for initial trials. Following the successes obtained, additional funding has been obtained, from both Loughborough University until Aug 2012 and MEL Chemicals from Aug 2012, to transfer the technology to MEL and to seek to exploit the properties of nanostructured zirconia further and improve the environmental sustainability of the production processes. Furthermore, a licence agreement has been signed with MEL Chemicals Ltd. The achievements of this project along with other activities of ceramic research group in the field of nanoceramics have been recognised by the Enterprise Office at Loughborough University and it has been nominated for Loughborough University 2012 Enterprise Award (outcome known 25/04/12). |
| Exploitation Route | The technology has been licensed to MEL Chemicals. With a license now signed between MEL Chemicals and Loughborough University a clear exploitation route exists. The focus is now on scaling up two key steps in the process route. |
| Sectors | Aerospace, Defence and Marine,Electronics,Energy,Manufacturing, including Industrial Biotechology |
| Description | This research led to a series of subsequent research grants and the processes developed have been licensed by MEL Chemicals. |
| First Year Of Impact | 2010 |
| Sector | Aerospace, Defence and Marine,Chemicals,Electronics,Manufacturing, including Industrial Biotechology |
| Impact Types | Economic |
| Description | EPSRC |
| Amount | £358,390 (GBP) |
| Funding ID | EP/L024780/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2014 |
| End | 05/2017 |
| Description | Loughborough Univ Enterprise Office - Bridging funds for postdoc |
| Amount | £8,487 (GBP) |
| Organisation | Loughborough University |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 12/2011 |
| End | 03/2012 |
| Description | Loughborough Univ research studentship - Transparent nanocrystalline YAG |
| Amount | £51,570 (GBP) |
| Organisation | Loughborough University |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 10/2010 |
| End | 09/2013 |
| Description | Manufacturing nanostructured ceramics: new process for concentrating nanosuspensions via an industrially viable route |
| Amount | £12,983 (GBP) |
| Organisation | Loughborough University |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | |
| Description | Morganite Electrical Carbon Ltd - Transparent nanocrystalline YAG |
| Amount | £45,000 (GBP) |
| Organisation | Morgan Advanced Materials |
| Department | Morganite Electrical Carbon Ltd |
| Sector | Private |
| Country | United Kingdom |
| Start | 10/2010 |
| End | 09/2013 |
| Description | Nano transparent alumina |
| Amount | £50,000 (GBP) |
| Organisation | Defence Science & Technology Laboratory (DSTL) |
| Sector | Public |
| Country | United Kingdom |
| Start | 10/2012 |
| End | 03/2015 |
| Description | Nano transparent alumina |
| Amount | $66,000 (USD) |
| Organisation | ONRG Office of Naval Research Global |
| Sector | Public |
| Country | United States |
| Start | 10/2012 |
| End | 03/2015 |
| Description | Nanoplant |
| Amount | £358,390 (GBP) |
| Funding ID | EP/L024780/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 05/2014 |
| End | 04/2017 |
| Description | TSB - Nanozirconia for ceramic implants |
| Amount | £206,020 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 10/2011 |
| End | 09/2013 |
| Description | Manufacturing nanostructured ceramics |
| Organisation | MEL Chemicals Inc |
| Country | United States |
| Sector | Private |
| PI Contribution | MEL Chemicals licensed our nanozirconia technology in Feb 2012; we are now working very closely with them to see the products through to market. We are now taking the technology to market. |
| Start Year | 2011 |
| Description | Plenary lecture |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Talk given at the International Conference on Advanced Materials 2011, Coimbatore, India, December 2011. |
| Year(s) Of Engagement Activity | 2011 |