Machining Ceramic Insulation Materials

Ceramic Materials

• Stating that ceramic insulation materials are made from clay is oversimplifying. Factories use a variety of recipes based on the properties of the insulation materials. Alumina silicate is a primary ingredient, but it often is backed up by synthetic binding compounds, glass materials and mica-based additives. With the right additives, ceramic materials can be made slightly harder or slightly softer. The softer versions are much easier to machine.

Machining

• Machining refers to drilling, sanding or cutting the insulation material after it has been extruded and the production process is finished. Some machining is accomplished by the factory itself after production to finish the product. This helps smooth rough ceramic surfaces, and ceramic shapes can be punched out of molds into pre-determined shapes to make many smaller shapes. However, some work also is possible on workbenches and in mechanic shops after the material has been purchased.

Tools

• Even the softer ceramic insulation designed to be machined still is very hard and resistant to damage - it needs to be to withstand high heat. The only tools that can cut effectively through ceramic insulation are carbide drills, clippers and saws. These are tipped with diamond-like grit and edges that have enough strength to make clean cuts. Wet saws, which add water to reduce friction, also are common additions to a machining set-up. Polishers and buffers can help created very precise ceramic surfaces.

Uses

• All this machining is used to create ceramic parts for detailed production and repair work. Some ceramic parts are used in electronics, and require customized shapes and settings. Other ceramic insulation products are used in engines, heating elements and heat exchangers. Some are used to create furnaces or furnace components for melting metals.