With the support of companies like Ceradyne, the Hero Miles program has provided more than 25,000 tickets to service members and their families, worth nearly $35 million (average savings per ticket is currently about $1,400).

In August, 2011, the Ceradyne donation coordinator received the following thank you from the Hero Miles Program Director:

“I cannot begin to thank you for your generous donation.  Just so you know, I am sitting here booking tickets for family members of the Navy Seals and Flight Crew of the Chinook Helicopter that crashed in Afghanistan last week.  We have had an overwhelming cry for help to get families to the funerals and memorials of these men.  Having said, my phone just rang and it was the Department of the Army Casualty office.  (In addition to our fallen soldiers, they handle the transfer of all the injured troops overseas.)  I just booked three tickets to fly the father, mother and a sibling of a soldier who stepped on an IED and as a result has lost both his legs.  This all may be more than you want or really need to know, but I want you to realize the impact your donation makes to the men and women fighting for our freedom.  On behalf of those who are fighting for their lives and some of those who have made the ultimate sacrifice for this country, thank you.”

Hot pressed boron carbide (typically B₄C) is used for personnel protection in the form of plate inserts, for aircraft protection as panels and seats, in ships, and in armored land vehicles as seats. For protection against more lethal threats, such as heavy machine gun and medium cannon threats, hot-pressed silicon carbide (SiC) is typically the material of choice. Hot pressed silicon carbide is also used in armored vehicles as an applique, along with hot-pressed silicon nitride (Si3N4). (Titanium diboride [TiB2], while as effective ballistically, is not as widely used for ceramic armor, primarily for the lack of alternative market applications.)

Regardless of the ceramic material used, ceramic armor is damaged on impact, and this damage propagation affects the subsequent ceramic performance. Extensive research has shown that this damage is caused by the activation of preexisting defects by the shear and tensile forces that are generated on impact. The resulting behavior of the ceramic is a complicated combination of the integrated responses of the damaged and undamaged regions. Since a ceramic is rarely, if ever, used as a stand-alone armor, the mechanical response of the entire system determines the degree to which the damage is generated and how well the damage is confined so that the armor continues to be effective against subsequent impacts.

While obvious system design improvements have been achieved over the last decade, extensive work on improving the properties of the ceramic materials continues. One of the most desired variables to eliminate is porosity, so that full theoretical densities are achieved. Hot pressing creates fully dense ceramics, so the focus on ceramics processed using this technique is on the other property improvements.

The best way to increase ceramic efficiencies is to extend the time that the ceramic works on a bullet to cause shattering; increase the dwell duration or dwell penetration transition velocity (the velocity above which penetration occurs, and below which the bullet is defeated on the ceramic surface); and/or achieve a greater pressure on the penetrator during penetration to increase the erosion efficiency of the highly damaged, comminuted ceramic. Additionally, and of particular interest in personnel armor protection, is a requirement to predictably defeat multiple impacts within a single plate or array.

Finally, cost, manufacturability and integration with the backing materials of the armor system must also be taken into consideration.

Our materials are produced using state-of-the-art processing methods and diamond grinding techniques for custom components with exacting tolerances according to ISO9000:2000 quality standards.

A Wide Range of Applications

“Lossy” ceramics are designed to absorb microwave energy in specific frequency ranges based on specific electrical properties (dielectric constant and loss tangent). Ceradyne offers a complete line of “lossy” ceramics with repeatable electric properties and the capability to operate under high vacuum vacuum with no outgassing. Applications include:

Buttons

Buttons are components designed to “tune” the frequency of a coupled cavity microwave tube by absorbing energy in very specific frequency ranges. Ceradyne’s Ceralloy® 6703 and 6705 are particulate composites of magnesium oxide and silicon carbide where the absorbed frequency is a function of the composition.

Severs/Terminations

Severs/terminations absorb microwave energy over a very broad frequency range while exposed to high energy, requiring high thermal conductivity to dissipate heat and withstand thermal shock during operation. Ceralloy® 13740, 13740Y and 137 CD1 compositions are proven to meet these requirements through the use of aluminum nitride based materials.

Slot Mode Absorbers

Slot mode absorbers (SMA) are designed to absorb microwave energy over a broad frequency range; the composition is key to obtaining microwave absorption. Ceradyne produces the SMA geometry with Ceralloy® 7712, a particulate composite of aluminum oxide and silicon carbide.

Aluminum Nitride Components

Ceralloy® 1370DP is a sintered aluminum nitride material developed for thermal management applications. It is an electrical insulator having high thermal conductivity at room temperature (180-190 W/mK). Aluminum nitride thermal conductivity is similar to beryllium oxide at microwave operation temperature (150ºC).  This makes the material an ideal replacement to toxic beryllium oxide.  Ceralloy® 1370DP is capable of being formed into complex, three dimensional components for windows, collector rods and collectors in microwave applications.

To learn more, see our Microwave Ceramic Products brochure.

With this in mind, Ceradyne Boron Products has provided the global commercial nuclear power industry with high purity stable isotopes for more than 30 years. Our ¹⁰Boron isotope is a strong neutron absorber used for both nuclear waste containment and nuclear power plant neutron radiation control. Our enriched ¹⁰Boron materials include products for:

• Criticality control
• Emergency shutdown
• Reaction moderation
• Fuel manufacturing

Our nuclear power products include:

• 7-Lithium Hydroxide Monohydrate
  • Pressurized water reactors use lithium hydroxide to neutralize the acidity created by the addition of boric acid to primary coolant solutions. Enriched lithium is offered by Boron Products in lithium hydroxide monohydrate form and the enrichment level is greater than 99.9 wt% 7Li.
  • Enriched Boric Acid
    • Enriched boric acid is a precursor for most of the other boron containing chemicals used in nuclear power plant water chemistry control. Enriched in either the 10B or 11B isotope to very high levels, Ceradyne’s boric acid exceeds accepted standards of the nuclear industry throughout the world.
    • Enriched Sodium Pentaborate
      • Ceradyne Boron Products developed enriched sodium pentaborate to meet the changing needs of boiling water reactors. Sodium pentaborate is used in standby liquid control systems, which are designed to flood the reactor core with a 10B solution in case of an emergency.

History & Capacity

Our facility in Quapaw, Oklahoma, in operation since 1977, is the world’s largest boron isotope separation facility. These products serve the nuclear power and fuel, radiation waste containment, scientific, medical, and semiconductor industries, as well as the Federal government and Department of Defense.

With superior products and the largest boron isotope enrichment facility in the world, Ceradyne continues to be the leading manufacturer of nuclear chemistries.

To learn more, see our Nuclear Power Plan Chemistry page.

Ceradyne produces its Ceralloy® Silicon Nitride components in fully dedicated facilities using patented compositions and processing techniques. This yields cost effective, precision-engineered components that consistently receive high performance ratings. Moreover, our rigid process controls allow components to be produced to net or near net shape, thereby eliminating or reducing the need for diamond grinding. Our Silicon Nitride can be joined to metal components to form assemblies using a wide range of attachment methods.

Ceralloy® Silicon Nitride exhibits a combination of mechanical, thermal, and electrical properties not found in any other material. Features include:

• Lightweight (60% lighter than steel)
• High fracture toughness
• Exceptional wear resistance
• High dielectric strength
• Microwave transparency – non magnetic
• Corrosion resistance
• Chemical inertness
• Low coefficient of thermal expansion
• Thermal shock resistance
• Low coefficient of friction against steel
• Excellent high temperature oxidation resistance
• High strength fatigue resistance

With such a broad range of properties, Silicon Nitride has replaced stainless steel, super alloys, tungsten carbides, and first generation ceramics such as AI2O3 and ZrO2 in a multitude of demanding oil exploration applications.

From aerospace and industrial applications to automotive engines, Ceradyne’s Ceralloy® Silicon Nitride is the most versatile, advanced technical ceramic solution worldwide.

To learn more, see our Oil & Gas Severe Environments brochure.

Our engineered shell systems reduce costs, shorten cycle times, improve process capability, and reduce reliance on zircon. Characteristics of our fused silica products include:

• Greater than 99.7 percent pure.
• Cristobalite content below detectable levels.
• Extensive ferromagnetic separation facilities to reduce ferromagnetics to PPM levels.
• Expanded production to ensure sufficient supply.

We also have state-of-the-art particle size analysis systems, along with enhanced grinding and blending processes, to further improve our market-leading products.

WDS III & Gray Matter II

WDS III and Gray Matter II are patented high performance flour blends for investment casting back up slurries. The products build on the strengths of original Nalco Gray Matter and Minco WDS investment casting shell systems. The increased shell build and improved permeability help remove dips and minimize autoclave shell cracking.

WDS III and Gray Matter II:

• Improve permeability to help reduce non-fill and autoclave cracking.
• Provide a non-fiber based shell system optimized for parts with difficult geometries and detail.
• Improve knock out for easier shell removal.
• Optimize slurry rheology to substantially shorten drain times and increase foundry output.
• Optimize shell build for uniform coverage of corners and edges without neglecting the flow required to fill slots and holes in difficult castings.
• Reduce handling damage and cracking with a strong laminar shell.

To learn more, visit our fused silica page.

To meet this demand, Ceradyne provides the advanced material of choice: silicon nitride. Silicon nitride delivers:

• High strength and reliability
• Contact fatigue resistance
• High elastic modulus
• Light weight (40% of metal)
• Tribological compatibility (low coefficient of friction and wear resistance) with metals.

As a result, silicon nitride enhances the maximum stress levels for steel rollers in diesel fuel pumps and is ideal for a wide range of other applications.

Properties

Fuel pump rollers can take full advantage of the light weight, high stiffness, and high Hertzian contact strength of silicon nitride. These rollers can operate at higher speeds and stress levels with reduced lubrication when compared to metal rollers. Ceradyne’s silicon nitride rollers excel in these applications because of superior mechanical reliability and contact fatigue resistance, along with machined OD crown profiles on roller bearing elements.

Additionally, silicon nitride rollers are preferred because metal and coated metal rollers fail due to wear and “scuffing”. Silicon nitride components eliminate this problem, while allowing pumps to operate at higher pressures. Silicon nitride also exhibits reduced friction when in contact with cast iron or steel.

Processing

Ceradyne’s silicon nitride is processed by gas pressure sintering. The outstanding contact fatigue capability and mechanical reliability is attained from its microstructure that is fully dense and free of porosity. Also, Ceradyne’s silicon nitride has a high fracture toughness of 6 MPam^1/2, which produces high strength and reliability.

Applications

Ceradyne’s silicon nitride components have been successful in providing solutions to specific problems involving high volume Heavy Duty Diesel applications. Ceradyne’s materials also are a cost effective alternative to metal components over full life cycles. As a result, Ceradyne’s silicon nitride components can solve warranty problems while providing increased system capabilities and performance.

Visit our Fuel Pump Rollers page to learn more.

Our solutions are based on a broad material portfolio that offers superior properties, advanced forming technologies, and high quality products. Moreover, we use specific formulations and processing methods to produce components that outperform other materials. Ceradyne high performance materials enable the production of components that deliver excellent results.

Two examples of our advanced technical ceramics are boron carbide and silicon nitride.

Boron Carbide

Ceralloy® 546 Boron Carbide is the lightest technical ceramic material (2.5 g/cm³) as well as the hardest (second only to diamond). Our fully dense boron carbide is produced by hot pressing and delivers many in-demand characteristics:

• Light weight
• High hardness
• Erosion resistance
• High modulus
• Neutron absorption

Ceralloy® 546 Boron Carbide is used for vehicle armor systems, sputtering targets, industrial manufacturing, semiconductors, and much more.

Silicon Nitride

Ceradyne offers a complete family of silicon nitride materials, including:

• Ceralloy® 147 Gas Pressured Sintered Silicon Nitride (GP-SRBSN)
  • A family of fully dense materials with a range of compositions that are produced in cost effective, complex net shapes.
  • Used in automotive transportation, bearings and rolling elements, industrial applications, armor systems, and more.
  • Ceralloy® 147 GP-SRBSN or Needlelok® Silicon Nitride
    • Produced using patented compositions and processing techniques that result in an in-situ silicon nitride interlocking needle-like microstructure.
    • Provides exceptional hardness and superb fracture toughness that translates to superior mechanical reliability.
    • Ceralloy® 147-3 GP-SRBSN or Needlelok® Silicon Nitride
      • Produced using high pressure sintering that results in an essentially pore-free microstructure.
      • Delivers many key characteristics: light weight, strong, hard, tough, low coefficient of friction, thermal shock resistant, wear resistant, contact fatigue resistant.
      • Ceralloy® 147 Reaction Bonded Silicon Nitride (RBSN)
        • A high purity grade of silicon nitride having a density of approximately 70-80% theoretical.
        • Can be manufactured to close tolerance without the need for expensive diamond grinding.
        • Ceralloy® 147 Hot Pressed Silicon Nitride (HPSN)
          • Formulated into a variety of compositions having minimal densification aids.
          • Provides the highest strength of Ceradyne’s silicon nitrides.

To learn more, visit our Advanced Materials page.

With 2,500 people working across 20 locations worldwide, the Ceradyne team is global, diverse, and passionate about innovation in Energy, Defense, Commercial and Industrial markets.  Together, we are solving the world’s challenges every day.  Ceradyne offers vast opportunities to build a rewarding and valuable career.  We are currently hiring top notch talent in Orange County, CA; Lexington, KY; northeast Oklahoma; and Quebec, Canada.  Visit our Careers page to learn more about opportunities in engineering, procurement/planning, IT, product marketing, and management.  Now is a great time for you to join our diverse group of talented professionals!

BORAL®

Well suited to many neutron absorption applications and with the longest continuous service history of any neutron absorbing material, the BORAL® Composite is used for spent fuel storage pools, dry storage dual-purpose casks, and fresh fuel canisters in the United States, Europe, and Asia.

Since the late 1950’s, BORAL® has been used in research reactors, nuclear power plants, and spent fuel storage systems worldwide. It performs its intended function for very long periods in high gamma and neutron radiation fields, never failing to meet its neutron absorption function.

BORTEC® MMC

Ceradyne manufactures BORTEC® MMC in its Canadian ISO and NQA-1 facility. This is a dense and high thermal conductivity composite to absorb neutrons in both wet and dry nuclear storage applications. BORTEC is extruded and rolled into shapes with B4C contents up to 45% by volume using various aluminum alloys. The resulting composites have outstanding properties for structural or non-structural design applications. They also are lightweight and adaptable for neutron capture in both wet and dry environments.

Ceradyne Quality Program

The Ceradyne ISO 9001:2000 and NQA-1 Quality Program is fully qualified, audited, and approved by many worldwide customers. Ceradyne’s unique advantage is that the company controls the entire value stream in the manufacture of these specialized materials. Whether natural boron carbide from ESK Ceramics or enriched boron from Ceradyne Boron Products, Ceradyne specialists engineer and manufacture neutron absorber materials that meet or exceed stringent end user requirements. Under NQA-1 and ISO programs, Ceradyne Canada provides best-in-class service covering all steps of neutron absorber manufacturing and processing.

Boron Products

Ceradyne Boron Products supplies neutron absorbing and reflecting components in materials utilizing enriched 10Boron and 11Boron isotopes. Ceradyne has produced enriched boron products for more than 40 years. With the largest boron isotope enrichment facility in the world, Ceradyne Boron Products continues to be the leading manufacturer of enriched boron.

To learn more, visit our page on Neutron Absorbing Materials.