Proven manufacturing expertise
CeramTec has perfected a broad range of processes and methods over many decades. Systems managed in compliance with TS 16949 standard specifications form the basis of a production system that meets even the most exacting quality requirements, e.g., of the automotive and safety systems industries. A product mix of over 90% customerspecific components testifies to the flexibility of CeramTec’s manufacturing systems, which produces single specimens with the same precision as standardized volume parts.
Notwithstanding the diversity of material compositions formulated to meet the requirements, the piezoceramic manufacturing process follows a basic scheme:
Precision sophisticated technology
Production normally involves a powder preparation process in which oxide raw materials are mixed to obtain the defined chemical product composition. Further steps include the compaction of the conditioned powder and a forming stage such as dry-pressing. The ceramic blank is then sintered at temperatures between 1000 °C and 1300 °C in a continuous tunnel style electric furnace. In the course of this sintering step the product develops its polycrystalline ceramic structure. The sintered piezoceramic component is mechanically finished by grinding, lapping, polishing, and sawing to assure its geometrical dimensions and surface finish remain within the specified narrow tolerances. The geometrical dimensions of the product, apart from material coefficients, determine its functional characteristics such as capacitance or resonant frequency. Electrical connections are usually made by applying silver electrodes in a screen printing process with subsequent sintering at approx. 600 °C. This is followed by the polarization step in which the product is exposed to an electric DC field (2 to 3 kV/mm) at temperatures between 80 °C and 140 °C to achieve the appropriate dipole orientation within the ceramic.
Material testing
In the final outgoing product inspection, the component is tested for a wide range of parameters (e.g., geometrical dimensions, adhesion strength of the silver metallization layer). Its piezoelectric data are recorded prior to shipping.
The parameters to be inspected and the severity of the test conditions are agreed with the customer on an individual basis. In-process inspections and an TS 16949 compliant manufacturing process assure a high quality level even in volume production.
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