High Performance Ceramic Insert Custom High-Quality Ceramic Tooling Insert

Ceramic inserts are an ingenious design in modern engineering. By embedding one or more ceramic components within a base material (usually metal or plastic), they combine the advantages of both materials, thereby enhancing the overall performance of the product.

A ceramic insert is a prefabricated, small, precision component made from advanced ceramic materials (such as zirconium oxide, aluminum oxide, silicon carbide, and silicon nitride). It is secured to a specific location within another component (the base) through press-fit, bonding, injection molding, or brazing. It fulfills a critical function, leveraging the superior properties of ceramic to compensate for the shortcomings of the base material while avoiding inherent drawbacks such as brittleness and difficult machining.

1. Extremely wear-resistant, extending service life.

Advantage: Ceramic's extremely high hardness (second only to diamond) provides excellent resistance to wear, scratching, and particle erosion.

Applications:

• Guide Rings/Wear Rings: In hydraulic cylinders and pistons, they replace metal or plastic wear rings, extending service life several times in harsh environments such as mud, sand, and dust.
• Nozzles: Sandblasting, spraying, and water jet cutting nozzles offer a service life far exceeding that of carbide.
• Mechanical Seal Rings: Paired with materials such as tungsten carbide, they create highly wear-resistant seals.

2. Ultra-low friction, reducing drag. 

Advantages: Certain ceramics (such as zirconia) are self-lubricating and have a low coefficient of friction, effectively reducing friction and energy consumption in moving parts.

Applications:

• Bearing balls/rollers: In high-speed, high-precision spindles, ceramic bearings can achieve lower thermal expansion and higher speeds.
• Pump and valve components: Reduce frictional resistance in fluid transportation.

3. Corrosion resistance and insulation.

Advantages: Ceramics are extremely resistant to most acids, alkalis, and salt solutions and are excellent electrical insulators.

Applications:

• Chemical equipment: Linings or key components of reactors, pump casings, and pipelines for conveying corrosive media.
• Electronic packaging: Used as insulators or substrates, embedded in metal casings to achieve hermetic packaging and electrical signal extraction.

4. Biocompatibility.

Advantages: Ceramics such as zirconia are non-toxic, inert, compatible with human tissue, and not corroded by body fluids.

Applications:

• Medical Implants: Embedded in the critical friction areas of dental implants or orthopedic implants, serving as joint heads, they are more wear-resistant than metal and less likely to cause allergies.