Ceramics Processing

GSE is leading the ceramic processing technology development efforts on the Century 3+, LLC Ring Extruder. The Ring Extruder presents a novel method to mix ceramic materials in a continuous, repeatable, and automated process. GSE’s role is broad, from raw material selection, to extruder operation, to developing the material forming process, to the thermal process, to machining the ceramic sponge in its final form.

GSE offers the following ceramics processing services:
Metal Matrix Composites
Aluminum MMC
Magnesium MMC

The products in development have been focused on selectively reinforced metal matrix composite (MMC) applications. Using the Ring Extruder, GSE is developing ceramic sponge material, called a preform. The preform is extruded, shaped, dried, baked, fired, and machined to its final shape. The preform is then placed into a mold, and infiltrated with molten metal to produce a component with ceramic reinforcement in a region where it will perform to a particular specification. With lightweight brake drums and rotors, the ceramic provides superior wear resistance. With lightweight pistons, the ceramic prevents ring wear, and provides temperature resistance in the combustion bowl. With lightweight connecting rods, the ceramic significantly improves the stiffness of the rod.

The Ring Extruder provides a homogeneous mix of materials which is critical to the predictability and reliability of the end product. The extruder is versatile as preforms can be made with particulate, with fiber, or together as a hybrid of particulate and fiber.

This work provides the foundation to developing cost effective, high performance components that will help the vehicle market reach its weight savings goals. See the aluminum MMC brake drum that is 45% lighter than the standard iron drum.

GSE studied magnesium MMC under direction of Oak Ridge National Laboratory.

Contact us to learn more about our ceramics processing experience and how we can assist you.