During the preparation process of lithium battery materials, the sand mill bears the critical task of grinding coarse particles down to the micron or even nanometer scale; however, this grinding process concurrently faces the risk of metal contamination. The base plate and end cap of the sand mill are in long-term contact with the high-speed slurry, making wear inevitable. Once metal components are exposed and generate micro-debris through friction, these particles will mix into the slurry, compromising the purity and electrochemical performance of the final product.
Consequently, an increasing number of lithium battery material enterprises are opting to replace metal with ceramics in the critical internal parts of sand mills, utilizing ceramics to isolate metals and physically sever the source of contamination.
A client from Hunan approached Kingcera to manufacture specialized ceramic base plates and end caps for their sand mills. These two types of components share several characteristics: a sectorial structure, large dimensions, irregular shapes, and requirements for high precision.
Large dimensions entail significant difficulty; in this project, the radius of the largest sectorial ceramic component reached 517 mm. For ceramic products, this is an exceptionally formidable dimension.
The forming and sintering processes of ceramics inherently involve shrinkage, which is influenced by multiple factors including green body density, sintering temperature, and holding time. The larger the dimensions, the greater the absolute deviation of the shrinkage. For a sectorial
structural ceramic with a radius exceeding 500 mm, a post-sintering radial deviation of a few millimeters might not be visually apparent, but it will cause significant issues during assembly. The client was evidently well aware of this. Their requirements for precision were explicit and stringent, yet the products delivered by Kingcera achieved a flawless, “seamless fit.”
In addition to the sectorial contour, the product features various distributed holes and notches. These structural features serve the positioning, fixation, and flow channel design of the sand mill. The positional accuracy of the holes, the tolerance of the hole diameters, and the shape and size of the notches must each be precisely controlled during the machining phase. For hard and brittle materials like ARZ ceramics, drilling an extra hole or grinding an additional notch multiplies the difficulty exponentially, imposing extremely high demands on machining equipment and processing techniques. However, Kingcera not only undertook this project but also delivered a perfect outcome.
During the forming stage, Kingcera employed large-scale isostatic pressing to ensure uniform density throughout the sectorial green body. Uniform density is the fundamental prerequisite for minimizing post-sintering deformation. If the density distribution of the green body is uneven, the shrinkage rates in different regions will be inconsistent during sintering, potentially resulting in warping or distortion of the final product—deformations that are virtually impossible to fully correct through subsequent machining.
For the sintering phase, Kingcera is equipped with high-temperature kilns spacious enough to accommodate large-sized workpieces. The sintering curve has been iteratively optimized, with heating and cooling rates precisely controlled to minimize thermal stress to the greatest extent possible.
What truly demonstrates their machining capability is the subsequent processing procedure. Kingcera is outfitted with large-scale CNC machining centers specifically dedicated to processing high-precision
structural ceramic components.
Advanced and comprehensive equipment, mature processes, abundant experience, and highly skilled technicians provide Kingcera with the prerequisites to accept such high-precision, cutting-edge orders; meanwhile, their proactive attitude of confronting challenges and pursuing excellence gives them the confidence to successfully fulfill these requests. Kingcera—A trustworthy expert in wear protection!
(Original link:
锂电研磨砂磨机陶瓷端盖：大尺寸高精度，防金属污染)
Samuel Wu / Translated
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