KA-EDM: A DISRUPTIVE MATERIAL SOLUTION IN METAL FORMING

KA-EDM Applications in the Metal Forming Industry. Nanoker.

 

KA-EDM is an already tested and proven innovative and disruptive High Performance EDM machinable alumina composite. It has huge applications for non ferrous metal extrusion and calibration. Also in other metal forming activities, such as cutting tools.

Nanoker Research S.L. is a Spanish manufacturer and supplier of advanced nanocomposite ceramic products and solutions for a variety of top-end applications. The in-depth knowledge of material science and industrial ceramics processes enables NANOKER to implement relevant competitive advantage such as precisely defining the design and machining of green bodies and prediction of the dimensional processing behavior and grain phasing of the material even in complex shapes and geometries. With agile logistics, dedicated post-sales monitoring, and a long trajectory in the industry, we are versatile, always focusing on quality and satisfaction by being our customers’ best partners.

 

 

We put expertise and passion into production of advanced and revolutionary ceramic solutions; from atomization to colloidal routes and nano ceramic powder synthesis. From cold isostatic press to spark plasma sintering techniques, providing a perfect solution to any complex needs for our clients.

 

We supply extrusion and calibration dies, advanced ceramic centering and locator pins for welding and stamping applications,  high-performance heat sinks (break rings for steel billet horizontal continuous casting amongst other applications that include power electronics), and we are also active in many other custom-made ceramic parts. From laboratory ware, to high pressure intensifiers, waterjet nozzles, canning rollers, etc. We have a medical device division that is growing rapidly as well.

 

Extrusion and Calibration Dies

 

For the nonferrous metal forming industry (copper, brass, nickel), NANOKER produces ceramic extrusion and cold calibration dies. They can be used for bars, tubes, or extrusion of profiles with an objective to meet final dimensions within the required tolerance.

 

Extrusion and calibration dies available in the market are mainly manufactured in one of two materials: A pure ceramic solution, Zirconia Magnesia, or alternatively Zirconia Yttria Tetragonal Polycrystal, and a metal compound one, Molybdenum-Hafnium.

 

NANOKER regularly supplies solutions in both ceramic types, featuring tailor made die shapes, with or without incorporated Shrink-Fitting which we carry out in-house.

 

 

 

 

 

 

 

 

 

 

Extrusion die in ZrMg                                                                                                              Calibration die in Y-ZTP

 

However, NANOKER is now bringing a totally novel, deep tech disruptive material solution to the market, putting together the best of both worlds (Technical Ceramics and Complex Metal Compounds), in a most effective and economical manner. We call it KA-EDM.

 

KA-EDM

 

This new material consists of an electro conductive material, an alumina composite. The KA-EDMclick to open TDS(Electro conductive Alumina Composite) is manufactured using a pressure-assisted sintering method (SPS). It is a compound based on high-strength electro conductive alumina and suitable for EDM machining (one of the main advantages of the Molybdenum-Hafnium solution).

 

Spark Plasma Sintering (SPS) is the most advanced sintering technique in the market, that has been developed as a key technology in the processing of many materials, such as Nano structuring materials, composite, and gradient materials.

 

The SPS method is based on a modified hot press configuration, in which an electric current flows directly through the pressing mold and element. The pulsed electrical current and the ‘spark plasma effect’ enable very quick heating times and short process cycles. The process suppresses the growth of granular material, and achieves equilibrium states, allowing the production of materials in sub-micron or nano-scales, therefore enabling the design and development of totally new composite materials with compositions and properties which have not previously been achieved.

 

Microstructure of KA-EDM

 

KA-EDM Calibration Dies

Samples of KA-EDM ( EDM machinable alumina composite) calibration dies

 

Properties and applications of KA-EDM

KA-EDM’s main properties are its;

 

  1. High hardness (22.5GPa)
  2. High thermal conductivity (35W/m k)
  3. The maximum working temperature of 1000℃
  4. Manageable by EDM (electro-discharge machine)
  5. Excellent dimensional stability
  6. Strong chemical tolerance in challenging conditions

 

Being a CERMET: combination of Ceramic and Metal Composite, our solution KA-EDM possesses the best qualities of both the materials. It is tough and easily machinable like a metal composite but also hard and chemical and heat resistant like a ceramic. It is the material of the future for extrusion and calibration, made from highly durable and stable alumina composite.

 

KA-EDM has other applications such as metal cutting tools. Due to its high hardness and thermal conductivity, it can be used for processing high strength aerospace material like Inconel. In addition, their anti-corrosion and anti-rusting properties also makes it suitable to be used for marine applications. Therefore, KA-EDM is considered to be the best choice for extreme environment metalworking.

 

Other products for Metal Forming applications

 

Ceramic Pins

 

NANOKER also produces a variety of ceramic and nanoceramic composite welding centering and location pins. These are widely used in the automotive industry, both for stamping and resistance welding processes. NANOKER delivers custom design pins including regular metric, threaded shapes and combined metal-base & ceramic-body ensembles.

 

Nanocomposite NC2 threaded welding pins with laser markingNanocomposite NC2 pins sintering

 

 

 

 

 

 

 

 

 

Nanoker colored technical ceramic and composite pins for welding and stamping

 

Nanoker Advanced Composite Ceramic Pins

 

With our patented NC2® Nanocomposite, we have achieved significant success, clearly outperforming other alternative materials such as steel, KCF, coated steel, Zirconia or other Alumina composites, and is now present as a first line supplier of Tier-1 and OEM automotive groups worldwide setting a new standard in terms of mechanical, wear & corrosion resistance, dimensional stability and heat conductivity, which reflects in the number of cycles and lifespan of the pins.

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