USE OF CERAMICS IN

MANUFACTURING BEARINGS

By: Naunihal
 SCOPE OF WORK
• Brief introduction about hybrid and ceramic bearings
• Their uses and advantages over normal steel bearings

• Comparison of different ceramic materials based on different properties

• Sort them according to the cost and which can be most easily manufactured
• Select an appropriate material that can be made keeping all the necessary factors in mind

• See in the market for suppliers of raw material or if possible final product can directly be
taken so that production of rolling parts can be started

• Now describe how the material can be made; right from material required to the final
product
• State all the processes and their necessity in the process

• Now the rolling part (balls) is made for hybrid bearings

• State the material suitable for other parts of bearings

• Specific application of this hybrid bearings in EV and aerospace industry

 KOYO
TITLE ABSTRACT (INTRODUCTION) RESULT & CONCLUSION REFERENCE
Basic This focuses on silicon nitride, which shows • Although all-ceramic bearings and hybrid bearings have
Performance characteristics of being the most superior bearing a comparatively higher maximum contact stress than KOYO 158e
of Ceramic material amongst various ceramic materials, and will steel bearing under the same load, they have a rolling
contact fatigue life equal to or longer than that of steel
(Silicon presents its basic performance for application to
bearings.
Nitride) bearings. Specifically, such subjects as static load
• It has become clear that if rolling life tests are
Bearings carrying capacity, rolling contact fatigue life, influences conducted on a silicon nitride flat plate in which a linear
affecting the life of surface scratches and flaking, and scratch is present, severe damage originating from this
fitting is discussed. scratch does not occur in a short period of time, and
also that, wear occurs and advances on both sides of
the linear scratch and on the surface of the silicon
nitride balls.
• In other words, in the case of all-ceramic bearings, it can
be speculated that even if flaking occurs on a silicon
nitride ball, this does not result in a serious damage of
the bearing in a short period of time.
• The physical as well as mechanical characteristics of
ceramics are very different from those of steels.
Consequently, to expand the applications of ceramic
bearings, it is very important to grasp their
characteristics thoroughly and to understand their
merits and demerits as a bearing material.

Bearings for The paper gives a comparison of characteristics for • A comparison of power loss between the hybrid
Extreme ceramics (silicon nitride) and bearing steel, ceramic bearing and steel bearing shows that at a KOYO
rotational speed of 80000 rpm or more, there was less
Special
Environment
configuration and applications of ceramic bearings,
basic performance concerning applications of ceramic power loss for the hybrid ceramic bearing. 160e_12
• in high speed rotation applications, reducing lubricating
bearings, and recent practical examples of ceramic
oil amount using a hybrid ceramic bearing enables
bearings. dramatic reduction of power loss of the bearing section.
• If hybrid ceramic bearings are used in water, therefore,
it is necessary to get a good understanding of the
relationship between bearing load and amount of wear.
• Applications of ceramic bearings in turbochargers,. HDD
spindle, fuel injection system etc.
• it is important to proceed with research and
development of retainer materials, lubrication methods
and materials for inner/outer rings in the case of hybrid
ceramic bearings corresponding to ambient
temperature, load, rotational speeds, degree of
corrosive atmosphere and with or without lubricants.
 TITLE ABSTRACT (INTRODUCTION)
Evaluation of Extra-small hybrid ceramic ball bearings are used to
Extra-Small improve the vibration, and low temperature rise during
Ceramic Ball
Bearings
high rotational speed and enhance life and long term
reliability related to vibration and noise9), 10). At this
point the authors have compared ceramic bearings
with steel bearings and shown that there is no problem
with ceramic bearings in regard to general data
(physical properties, load rating, life, and strength). In
the second half of the report are given the results of
life testing (rolling fatigue life and life by increase of
vibration) conducted on extra-small balls bearings.
RESULT & CONCLUSION REFERENCE
• The following items were clarified in regard to the
use of ceramic balls in order to expand the KOYO
application of extra-small hybrid ceramic ball
bearings.
156e_05
a) There is no problem with the basic
characteristics, such as load rating and strength.
Concerning rolling fatigue life, the life is at least
five times longer than the predicted life.
b) Vibration life
i. The life of hybrid ceramic ball bearings was at
least three times longer than that of all-steel
bearings when oil lubrication is insufficient.
ii. The vibration increase of hybrid ceramic ball
bearings was maximum 1/30 for that of steel
ball bearings under grease lubrication condition.
As described above, extra small hybrid ceramic
ball bearings exhibit superior characteristics and
are suitable for practical use. Their application is
expected to increase significantly in the future.
 SKF
TITLE INTRODUCTION REFERENCE
Development of basic This is the Final Report on the Development of Basic Processing Technology for http://www.dtic.mil/dtic/tr/fulltext/u2
processing technology for Bearing Quality Silicon Nitride Balls. Substantial rolling contact fatigue life data /a053330.pdf
bearing quality Silicon generated on balls has demonstrated the potential of this material for reliable long
Nitride balls life. To provide a cost-effective manufacturing technology, fabrication of rough
spheres directly from silicon nitride powder was undertaken. These were finished
into 17.5mm size balls to generate rolling contact fatigue life data comparable to
that available in the literature.

This report is written in four parts.

Part I discusses the techniques of forming rough spheres , and the subsequent machining operations to obtain finished balls .
Part II presents the results of physical property and microstructural evaluations of the selected materials.
Part III presents the results of the non – destructive techniques evaluated for detection of material processing and fabrication related defects
in silicon nitride balls .
Part IV discusses the rolling four-ball fatigue life data obtained.

CONCLUSIONS
1. Hot-pressed silicon nitride can be pressed into rough bearing shapes such as balls having just as good bearing life properties as bearing
parts cut from large billets.
2 . Material quality inspection technique s such as ultrasonic , acoustic microscopy and Krypton exposure correlate well with strength and
micro hardness properties and have inherent capabilities of detecting material defects in silicon nitride such as inclusions and porosity that
are detrimental to bearing performance .
3. Norton ’s MgO-bonded hot-pressed NORALIDE NC132 gives consistently superior wear and fatigue life performance in rolling contact ,
when properly finished . Ceradyne ’s Y2O3-bonded hot-pressed CERALLOY 1471 wore excessively at high element test stress conditions , but
still had an inherent fatigue spalling life superior to M-50 bearing steel in this test . GTE Sylvania ’s pressure less sintered silicon nitride wore
excessively and spalled at very early life, due to its relatively high porosity content (2% by volume).
 SKF (currently studying)
TITLE INTRODUCTION REFERENCE
Dry lubrication of Successful solid lubrication of silicon nitride has been demonstrated at high temperature. Rolling https://patents.google.com/paten
high temperature contact four ball tests were used to simulated bearing operation. Solid lubrication films were t/US5639531A/en?oq=United+Stat
Silicon nitride rolling transferred to the silicon nitride balls from graphite cages. Long term tests at a 1000 F (538 C) es+Patent+(19)+11+Patent+Numb
contacts produced very low silicon nitride wear rates. Favourable four ball test results indicate feasibility of er:+5%2c639%2c531+Chen+et+al.
silicon nitride bearings for high temperature turbine applications +45+Date+of+Patent:+Jun.+17%2c
+1997

Effect of surface and The report discusses the importance of understanding the extent of surface damage caused https://patents.google.com/paten
mechanical during the manufacture of bearing surfaces on ceramics. The likely impact of the damaged t/US5639531A/en?oq=United+Stat
Properties on silicon surface on the usefulness of ceramics as rolling bearing materials is presented. The results of flat- es+Patent+(19)+11+Patent+Numb
nitride bearing in washer rolling- contact fatigue tests signify the role of surface interactions in a steel- silicon er:+5%2c639%2c531+Chen+et+al.
element nitride contact on the life of the contact. The analysis shows that silicon nitride rolling elements +45+Date+of+Patent:+Jun.+17%2c
performance can improve the fatigue life of very high speed bearings. +1997

Establishment of A lot of hybrid ceramic/steel angular contact ball bearings was fabricated to a design optimized https://patents.google.com/paten
engineering design for operation at 2.5 x 10 to the 6th power dN. Life tests were conducted on these were t/US5639531A/en?oq=United+Stat
data for conducted on these bearings at low speed, 0.4 x 10 to the 6th power dN, using two load levels es+Patent+(19)+11+Patent+Numb
Hybrid steel/ceramic which produced maximum Hertz stress levels of 2.0 GPa and 2.4 GPa respectively. A detailed er:+5%2c639%2c531+Chen+et+al.
ball bearings failure analysis was completed to define the causes of the relatively early ball failures experienced +45+Date+of+Patent:+Jun.+17%2c
at the high load and verify the good performance achieved at the low load. +1997

Severe environment Wear rates for dry film lubricated rolling-spinning contacts of silicon nitride surfaces were studied https://patents.google.com/paten
testing of silicon to 540 C wear rate was essentially constant to 315 C. Surface stress modifications in hot pressed t/US5639531A/en?oq=United+Stat
nitride rolling silicon nitride have been shown to improve tensile stress behavior under high magnitude Hertzian es+Patent+(19)+11+Patent+Numb
elements stress fields. er:+5%2c639%2c531+Chen+et+al.
+45+Date+of+Patent:+Jun.+17%2c
+1997

TITLE
Ball bearing and balls of
ceramic
High precision hot press
silicon nitride ceramic ball
bearing and its
manufacturing method
Conductive ceramic bearing
ball, ball bearing, motor
having bearing, hard disk
drive, and polygon scanner
Sintered body of silicon
nitride used in roller
bearings - nitride particles
are elongated with specific
width and length dimensions
to improve fracture strength
PATENTS
INTRODUCTION REFERENCE
This invention relates to a new and novel arrangement of a high frequency https://patents.google.com/patent/U
rotatable device employing ball bearings and balls of ceramic material. S5639531A/en?oq=United+States+Pa
tent+(19)+11+Patent+Number:+5%2c
639%2c531+Chen+et+al.+45+Date+o
f+Patent:+Jun.+17%2c+1997
The invention relates to a high-precision angular contact ball bearings, more https://patents.google.com/patent/U
particularly to a hot-pressed silicon nitride ceramic with high precision ball S5639531A/en?oq=United+States+Pa
bearings and a manufacturing method thereof, belonging bearing production tent+(19)+11+Patent+Number:+5%2c
technology, adapted to be mounted on high precision, high speed, high-end CNC 639%2c531+Chen+et+al.+45+Date+o
machine tools and the machining centre spindle. f+Patent:+Jun.+17%2c+1997
A conductive ceramic bearing ball made of composite ceramic and having a mixed https://patents.google.com/patent/U
microstructure of a silicon nitride phase and a titanium nitride phase. The content S5639531A/en?oq=United+States+Pa
ratio of the silicon nitride phase to the titanium nitride phase is such that the tent+(19)+11+Patent+Number:+5%2c
conductive ceramic bearing ball has an average coefficient of linear expansion 639%2c531+Chen+et+al.+45+Date+o
within a temperature range of 20° C.-100° C. of from 2×10−6/K to 5×10−6/K. f+Patent:+Jun.+17%2c+1997
Sintered body used for roller bearings contains 70 wt.% Si3N4 with 30 wt.% https://patents.google.com/patent/U
additives. It has a relative density of above 95% in the sintered state, more than S5639531A/en?oq=United+States+Pa
90% of the longitudinally elongated Si3N4 particles have a cross sectional width of tent+(19)+11+Patent+Number:+5%2c
less than 1 micron and more than 90% of the elongated Si3N4 particles have a 639%2c531+Chen+et+al.+45+Date+o
length of less than 5 microns. USE/ADVANTAGE - As ball bearings. Used in place of f+Patent:+Jun.+17%2c+1997
steel ball bearings to reduce heat generation and so plastic deformation whilst
maintaining a fracture stress above 29.4 KN.
 PATENTS
TITLE INTRODUCTION REFERENCE
Ceramic bearings A bearing comprising two coengaging members movable relative to one another, the https://patents.google.com/patent/US5
bearing surfaces of said members being provided by a body of ceramic material and a film of 639531A/en?oq=United+States+Patent+
solid lubricant interposed and in engagement with both said bearing surfaces. (19)+11+Patent+Number:+5%2c639%2c
531+Chen+et+al.+45+Date+of+Patent:+J
un.+17%2c+1997

Self lubricating A self-lubricated bearing assembly made of two bearing members having coengaging https://patents.google.com/patent/US5
material surfaces which are movable relative to each other. One of the bearing members is a ceramic 639531A/en?oq=United+States+Patent+
material of a composition consisting essentially of at least 99% by weight polycrystalline (19)+11+Patent+Number:+5%2c639%2c
aluminumoxide having an average grain size of 45 microns or finer and a density of at least 531+Chen+et+al.+45+Date+of+Patent:+J
3.80 grams per cubic centimetre. The other bearing member is carbon which preferably is un.+17%2c+1997
impregnated with silver.

Composite material for https://patents.google.com/patent/US5

a sliding member 639531A/en?oq=United+States+Patent+
(19)+11+Patent+Number:+5%2c639%2c
531+Chen+et+al.+45+Date+of+Patent:+J
un.+17%2c+1997

Process for making A process for making a hybrid ceramic article is disclosed. The process involves embedding https://patents.google.com/patent/U
a hybrid ceramic an array of refractory ceramic tiles in a fiber reinforced glass-ceramic matrix composite S5639531A/en?oq=United+States+Pa
article substrate. The hybrid ceramic article so formed exhibits high thermal stability and elevated tent+(19)+11+Patent+Number:+5%2c
temperature load-bearing ability. 639%2c531+Chen+et+al.+45+Date+o
f+Patent:+Jun.+17%2c+1997
 SILICON NITRIDE
TITLE ABSTRACT (INTRODUCTION)
Ceramic The process of manufacturing of Silicon nitride involves
bearing powder homogenization, pre-nitriding, high-speed
specimen green machining, reaction bonding, pressure less
technology sintering and container less hot isostatic pressing.
Extensive experimental and analytical tasks are
performed in each process step to develop a low-cost,
reliable silicon nitride bearing material with a uniform
microstructure and a premium quality.
Hot pressing The densification behavior of Si3N4 containing MgO
behaviour of was studied in detail.
Si3N4
Structural The paper describes experiments to establish the
aspects of conditions under which cx- and ,B-silicon nitride may
silicon nitride be produced independently or in varying proportions.
It also suggests a method for varying the properties of
silicon nitride by incorporating a dispersion or
continuous network of other elements and
compounds.
RESULT & CONCLUSION REFERENCE
Low-cost silicon powder is used as a raw material. A http://dx.doi.org/10.
quality assurance procedure is developed to examine 1179/pom.1961.4.8.
the powder homogeneity in the blended powder. 012
Conditions for the pre-nitriding are defined to provide
powder compacts with sufficient strength for the
high-speed green machining. The reaction bonding
process converts silicon to silicon nitride completely.
It is demonstrated that silicon nitride can be sintered
in a non-reactive gas environment. Processing
parameters for the hot isostatic pressing are
optimized to control thermal decomposition and gas
dissolution-evolution reactions to fabricate the pore-
free bearing material without using a glass
encapsulant.
It was concluded that MgO forms a liquid phase (most G. R. TERWILLIGER
likely a magnesium silicate). This liquid wets and and F. F. LANGE
allows atomic transfer of SiIN,. Evidence of a second- Westinghouse
phase material between the Si.,N, grains was Research
obtained through etching studies. Transformation of Laboratories,
a- to ,6'-Si3N, during hot pressing is not necessary for Pittsburgh,
densification. Pennsylvania 15235
The basic concept of employing a combination of http://dx.doi.org/10.
powder metallurgy and the nitriding of particles in 1179/pom.1961.4.8.
situ has now been extended to produce a variety of 012
textures, and material in the alpha, beta, or mixed
alpha and beta form. A combination of denser green
compacting and longer solid-state nitriding promises
higher-strength material.
 SILICON NITRIDE
TITLE ABSTRACT (INTRODUCTION) RESULT & CONCLUSION REFERENCE

Silicon The present the recent developments in silicon nitride J Mater Sci (2012)
nitride: the (Si3N4) ceramics and to examine the achievements 47:535–552
engineering regarding our understanding of the relationship DOI 10.1007/s10853-
material of between processing conditions, chemical composition, 011-5942-5
the future microstructure and mechanical properties of Si3N4.

Synthesis of Carbothermal reduction and nitriding of silica has Reaction of high-purity silica and carbon in T. Li6ko, V. Figusch &
Si3N4 by been recognised as an effective method for the nitrogen flow begins at approximately 1250°C and J. Pfichyovfi
Carbothermal synthesis of reasonable quality and sinterable alpha practically pure a-silicon nitride is formed up to Institute of Inorganic
Reduction silicon nitride powders. 1550 _+ 10°C. Kinetics of the reaction is accelerated Chemistry, Slovak
and Nitriding by seeding with a fine silicon nitride powder and the Academy of Sciences,
of Silica intensity of the seeding effect increases with Dflbravsk~i cesta 9,
increasing surface area of the seeding powder. Silicon CS-842 36 Bratislava,
monoxide evolved in the early stages of the reaction Czechoslovakia
must be effectively consumed for silicon nitride
growth. It was concluded that silicon nitride is formed
in the sites where carbon activity is lower than unity.
Surfaces of alpha-cristobalite grains, formed during
the reaction, were found to serve for the nucleation
and growth of silicon nitride crystals.

Dense silicon A method is described for preparing silicon nitride Silicon nitride powder is hot pressed with a small By G. G. DEELEy,t J.
nitride bodies of almost theoretical density. proportion of catalyst, preferably magnesium oxide or M. HERBERT,t and N.
nitride, at 1850°C. The bodies have very high flexural C. MOOREt
strength up to high temperatures, and preliminary
measurements of creep rate and thermal shock-
resistance indicate that dense silicon nitride should
be a suitable material from which to make
components required to operate under high stress at
temperatures up to -- 1200°C.