Machinable insulating materials for high T

Macor

Macor Machinable Glass Ceramic was developed and manufactured by

Corning Incorporated for use in the NASA space shuttle space program.
After an extensive testing program by NASA and UCLA it became clear
that Macor was more suitable than Silica Glass, Boron Nitride (BN) and
Silicon Nitride in certain components and applications.

Over 200 parts of Macor MGC could and can be found on the now
retired Space Shuttle Orbiter. Macor is still being used in the Aerospace
Industry and in several ongoing space programs around the world today.
Machinable insulating materials for high T

Macor

For instance Ceramic to Metal bonding for pressure transducers. A few

other examples are retaining rings at all hinge points, windows and
doors. Larger pieces of Macor were used for NASA spaceborne gamma
radiation deflector.
Machinable insulating materials for high T

Macor

Glass-ceramics are polycrystalline materials produced through

controlled crystallization of base glass. Glass-ceramic materials share
many properties with both glasses and ceramics. Glass-ceramics have
an amorphous phase and one or more crystalline phases and are
produced by a so-called "controlled crystallization" in contrast to a
spontaneous crystallization, which is usually not wanted in glass
manufacturing. Glass-ceramics have the fabrication advantage of glass
as well as special properties of ceramics.
Machinable insulating materials for high T

Macor

Glass-ceramics usually have between 30% [m/m] to 90% [m/m]

crystallinity and yield an array of materials with interesting properties like
zero porosity, high strength, toughness, translucency or opacity,
pigmentation, opalescence, low or even negative thermal expansion,
high temperature stability, fluorescence, machinability, ferromagnetism,
or high chemical durability, biocompatibility, bio-activity, ion conductivity,
superconductivity, isolation capabilities, low dielectric constant and loss,
high resistivity and break down voltage. These properties can be tailored
by controlling the base glass composition and by controlled heat
treatment/crystallization of base glass.
Machinable insulating materials for high T

Macor
Glass-ceramics are mostly produced in two steps: First, a glass
is formed by a glass manufacturing process. The glass is cooled
down and is then reheated in a second step. In this heat
treatment the glass partly crystallizes. In most cases nucleation
agents are added to the base composition of the glass-ceramic.
These nucleation agents aid and control the crystallization
process. Because there is usually no pressing and sintering,
glass-ceramics have, unlike sintered ceramics, no pores.
Machinable insulating materials for high T

Macor

Machinable with ordinary metalworking tools

Macor allows fast turnaround, no post firing required

Holds tight tolerances, up to 0.01 mm

Withstands high temperature, up to 1000C (no load)

Macor is clean, no outgassing and zero porosity.

Rapid prototype services available

Machinable insulating materials for high T

Macor

Macor (machinable glass ceramic) has a continuous use

temperature of 800C and a peak temperature of 1000C. Its
coefficient of thermal expansion readily matches most metals
and sealing glasses. It is non-wetting, exhibits zero porosity,
and unlike ductile materials, wont deform. It is an excellent
insulator at high voltages, various frequencies and high
temperatures. And, when properly baked out, it wont outgas in
vacuum environments.
Machinable insulating materials for high T

Macor

Macor can be machined to a surface finish of less than 0.5m

and polished to a smoothness of 0.01 m. Configurations are
limited only by available equipment and the experience of the
machinist.
Machinable insulating materials for high T

Macor

Macor can also be joined or sealed-both to itself and to other

materials-in a number of ways; metalised parts can be soldered
together and brazing has proved to be effective method of
joining the material to various metals: epoxy produces a strong
joint, and sealing glass create a vacuum tight seal. Even a
straight forward mechanical joint is possible. It can be thick film
metalised using metal inks, or thin film metalised by sputtering.
Possible metal coatings are Gold, Silver, Copper, Nickel,
Platinum, Chrome and Tungsten.
Machinable insulating materials for high T

Macor thermal properties

Machinable insulating materials for high T

Macor mechanical properties

Machinable insulating materials for high T

Macor electrical properties

Machinable insulating materials for high T

Macor electrical properties

Machinable insulating materials for high T

Macor electrical properties

Machinable insulating materials for high T

Macor machining
Key factors for successful machining are proper machining
speeds and coolant. Macor can be machined with high-speed
steel tools, but carbide tools are recommended for longer wear.
Achieve the best results by using a water-soluble coolant
especially formulated for cutting and grinding glass or ceramics.
No post firing is required after machining.
Machinable insulating materials for high T

Macor composition
Macor is a white, odourless, porcelain-like (in appearance)
material composed of approximately 55% fluorophlogopite mica
and 45% borosilicate glass. It has no known toxic effects:
however the dust created in machining can be an irritant. Good
housekeeping and appropriate machining techniques can avoid
this irritation. The material contains the following compounds:
Machinable insulating materials for high T

Macor microstructure
Machinable insulating materials for high T

Macor components
Machinable insulating materials for high T

Shapal
Machinable insulating materials for high T

Shapal

Shapal is a machinable ceramic which combines a high thermal

conductivity with a high mechanical strength with high strength.
In particular, it has an excellent sealing ability to vacuum. It also
has good heat resistance and an extremely low coefficient of
thermal expansion.
Machinable insulating materials for high T

Shapal

Typical applications: Electronic components, especially where

electrical insulation and heat dissipation are required. Also
components where low dielectric constant and dissipation factor
are required; fixturing parts where a low coefficient of thermal
expansion is required.
Machinable insulating materials for high T

Shapal

Vacuum components
Electronic components where electrical insulation and heat

dissipation are required

Components where a low coefficient of thermal expansion

required.
Electronic components where low dielectric constant and

dissipation factors are required.

Heat sinks

Crucibles for vacuum deposition

Special refractory parts such as protective tubes

A wide range of industrial and structural components

Machinable insulating materials for high T

Shapal

Vacuum components
Electronic components where electrical insulation and heat

dissipation are required

Components where a low coefficient of thermal expansion

required.
Electronic components where low dielectric constant and

dissipation factors are required.

Heat sinks

Crucibles for vacuum deposition

Special refractory parts such as protective tubes

A wide range of industrial and structural components

Machinable insulating materials for high T

Shapal
Machinable insulating materials for high T

Macor VS Shapal
Machinable insulating materials for high T

Macor VS Shapal
Machinable insulating materials for high T

PEEK
Polyether ether ketone (PEEK) is a colourless organic polymer
thermoplastic in the polyaryletherketone (PAEK) family, used in
engineering applications.
Machinable insulating materials for high T

PEEK
Polyaryletherketone (PAEK) is a family of semi-crystalline
thermoplastics with high-temperature stability and high
mechanical strength.

Generally speaking, PAEK can have continuous operating

temperature of 250 C (482 F) and under short-term loads can
function up to 350 C (662 F). When burned it has the least toxic
and corrosive fumes. It also has a low heat output when burned,
so it qualifies for use in interior aviation applications. It also has
good overall chemical resistance.
Machinable insulating materials for high T

PEEK
It has a tensile strength of 85 MPa (12,300 psi) and a Young's
modulus of 4,100 MPa (590,000 psi). Its yield strength is 104
MPa (15,100 psi) at 23 C (73 F) and 37 MPa (5,400 psi) at 160
C (320 F). It does not break in an un-notched Izod impact test.
Machinable insulating materials for high T

PEEK
PAEK plastics are characterized by phenylene rings that are
linked via oxygen bridges (ether and carbonyl groups (ketone)).
Machinable insulating materials for high T

PEEK
The ratio and sequence of ether to ketones mainly affects the
glass transition temperature and melting point of the polymer. It
also affects its heat resistance and processing temperature. The
higher the ratio of ketones the more rigid the polymer chain,
which results in a higher glass transition temperature and melting
point. The processing temperatures can range from 350 to 430
C.
Machinable insulating materials for high T

PEEK
Plastics that fall within this family include:

PEK
PEEK

PEKK

PEEKK

PEKEKK
Machinable insulating materials for high T

PEEK applications
One major engineering application is oil drilling components,
such as seals, compressor rings, valve parts, gears, bearings,
and wire coatings. It is also used in the chemical pump industry
because it can withstand the temperature, stress, and has the
corrosion resistance. In the automotive industry it is used to
make gears and thrust bearings in transmissions.
Machinable insulating materials for high T

PAEK applications
Due to its excellent resistance to hydrolysis it is used in medical
devices because it does not break down when sterilized.
PEKEKK is used to make surgical implants, such as artificial
hips.
Machinable insulating materials for high T

PEEK
PEEK is a semicrystalline thermoplastic with excellent
mechanical and chemical resistance properties that are retained
to high temperatures. The Young's modulus is 3.6 GPa and its
tensile strength 90 to 100 MPa. PEEK has a glass transition
temperature at around 143 C (289 F) and melts around 343 C
(662 F). The thermal conductivity increases nearly linearly
versus temperature between room temperature and solidus
temperature. It is highly resistant to thermal degradation as well
as attack by both organic and aqueous environments. It is
attacked by halogens and strong Bronsted and Lewis acids as
well as some halogenated compounds and aliphatic
hydrocarbons at high temperatures. It dissolves completely in
concentrated sulfuric acid at room temperature.
Machinable insulating materials for high T

PEEK applications
Because of its robustness, PEEK is used to fabricate items used
in demanding applications, including bearings, piston parts,
pumps, HPLC columns, compressor plate valves, and cable
insulation. It is one of the few plastics compatible with ultra-high
vacuum applications. PEEK is considered an advanced
biomaterial used in medical implants. It is extensively used in the
aerospace, automotive, and chemical process industries.
Machinable insulating materials for high T

PEEK applications
Machinable insulating materials for high T

PPS
Polyphenylene sulfide (PPS) is an organic polymer consisting
of aromatic rings linked with sulfides. Synthetic fiber and
textiles derived from this polymer are known to resist chemical
and thermal attack. PPS is used to make filter fabric for coal
boilers, papermaking felts, electrical insulation, specialty
membranes, gaskets, and packings.
Machinable insulating materials for high T

PPS
Polyphenylene sulfide is an engineering plastic, commonly
used today to make high performance components. PPS can
be molded, extruded, or machined to high tolerances. In its
pure solid form, it may be opaque white to light tan in color.
Maximum service temperature is 218 C. PPS has not been
found to dissolve in any solvent at temperatures below about
200 C.

An easy way to identify the plastic is by the metallic sound it

makes when struck.
Machinable insulating materials for high T

Thermoconductive PPS (Idemitsu)

Machinable insulating materials for high T

PPS applications
Machinable insulating materials for high T

PPS applications
Machinable insulating materials for high T

PPS
Polyphenylene Sulfide (PPS) - A crystalline polymer having a
symmetrical, rigid backbone chain consisting of recurring p-
substituted benzene rings and sulfur atoms. A variety of grades
suitable for slurry coating, fluidized-bed coating, electrostatic
spraying, as well as injection and compression molding are
offered. Polyphenylene sulfides exhibit outstanding chemical
resistance, thermal stability, dimensionally stability, and fire
resistance. PPS's extreme inertness toward organic solvents,
and inorganic salts and bases make for outstanding
performance as a corrosion-resistant coating suitable for
contact with foods.
Machinable insulating materials for high T

PPS
Tensile Strength 0.50 N/mm
Notched Impact Strength 1.50 Kj/m

Thermal Coefficient of expansion 70 x 10-6

Max Cont. Use Temp. 200 C

Density 1.34 g/cm3