Product

Alumina Disc | Al2O3 Round Plate

Cersol manufactures custom alumina ceramic discs using advanced gel-casting technology. Our process delivers four clear manufacturing advantages:

Low Mold Costs: We utilize inexpensive mold materials like aluminum or plastic, avoiding the expensive hard tooling required in dry pressing.
Low Production Costs: Complex shapes are CNC-machined in the green state, eliminating costly post-sintering diamond grinding.
High Density: The process ensures highly uniform powder compaction, resulting in dense, reliable components.
Fast Response Speed: Economical mold fabrication and efficient green machining enable rapid prototyping and short delivery times.

inquiry now

product details

High-Density Alumina Ceramic Discs | Custom Machined & Gel-Casted | Cersol

High-Density Alumina Ceramic Discs

Custom Machined, Cost-Effective & Fast Delivery

Why Choose Our Gel-Casted Alumina?

In industrial manufacturing, traditional ceramic forming methods like Dry Pressing or Cold Isostatic Pressing (CIP) often struggle with density gradients, warping, and high diamond-grinding costs.

Our Proprietary Gel-Casting Technology provides a highly effective alternative. By breaking the agglomeration of ceramic powders and achieving uniform 3D spatial dispersion, our gel-casting process lowers sintering temperatures and minimizes internal defects. The result is a high-density (99.5%+ purity) Alumina Ceramic Disc that supports complex geometries at a fraction of traditional hard-machining costs.

Forming Method	Density Variation	Mold Cost	Shape Complexity	Green Strength	Machining Cost
Dry Pressing	High (obvious density gradients)	High (hard steel / tungsten carbide)	Low (limited to simple 2D shapes)	~ 0.5 - 1.0 MPa	High (heavily relies on post-sintering hard machining)
Isostatic Pressing	Low (good uniformity)	High (expensive high-pressure equipment & flexible molds)	Medium (prone to "elephant foot" distortion)	~ 1.5 - 2.0 MPa	High (poor dimensional accuracy, large allowance removal)
Slip Casting	High (up to 2.8%)	Low (plaster molds wear easily)	High	~ 1.0 - 1.5 MPa	Medium (prone to pores and internal defects)
Gel Casting	Very Low (≤ 0.8%)	Low (aluminum, plastic, or 3D printed molds)	Very High (near-net-shape, seamless)	Up to 3.0 - 8.0 MPa	Low (supports green machining in green body stage)

Key Advantages & Commercial Benefits

High Cost-Efficiency (Green Machining): By machining complex features—such as vacuum grooves, micro-holes, and blind steps—during the robust green body stage prior to sintering, we reduce much of the expensive diamond grinding costs. This passes significant savings directly to your supply chain.

High Densification & Minimized Micro-cracks: Isotropic shrinkage ensures a highly uniform 3D molecular network. Combined with low-temperature sintering (preventing abnormal grain growth), our discs achieve a high density of ≥ 3.90 g/cm³, offering excellent vacuum integrity.

Large Format & Near-Net Shape Precision: Our process ensures excellent circularity and dimensional stability across large-diameter discs (up to 600mm), delivering highly flat surfaces straight out of the furnace and reducing the need for extensive post-processing.

Technical Specifications Matrix

Engineered for demanding industrial applications. Below are the tested properties of our Gel-Casted 99.5% Alumina Discs.

Property	Unit	Typical Value (99.5% Al&sub2;O&sub3;)	Testing Standard
Bulk Density	g/cm³	≥ 3.90	ASTM C1039
Water Absorption	%	0	ASTM C373
Compressive Strength	MPa	2000 - 2500	ASTM C1211
Flexural Strength	MPa	350 - 450	ASTM C1161
Vickers Hardness (500g)	GPa	15 - 19	ASTM C1327
Thermal Conductivity	W/m·K	25 - 30	ASTM C1470
Thermal Expansion (CTE)	10&supmin;&sup6;/°C	8.0 - 8.2	ASTM E228
Volume Resistivity (25°C)	Ω·cm	> 10¹&sup4;	ASTM D257
Dielectric Constant (1 MHz)	-	9.6 - 9.8	ASTM D150
Dielectric Strength	kV/mm	> 15	ASTM D149

Source: Advanced Materials Technical Data Sheet

Advanced Application

Photomask Substrates: Precision positioning bases for lithographic micro-patterns on wafers and large flat panel displays.
Showerheads: Used in chemical vapor deposition (CVD) chambers to achieve uniform spraying of reaction gases.
Chemical Mechanical Planarization (CMP) Polishing Plates: Carrier substrates used in high-precision wafer polishing processes.
Chamber Lids/Domes: Provide a clean, inert, and plasma-resistant sealed environment in etching or deposition chambers.
Wafer Stages & Tables: Ultra-flat bases for wafer defect inspection machines.
Epitaxial Susceptors: Bases used for supporting and heating wafers during semiconductor epitaxial growth.
Deposition Rings: Cover wafer edges to protect critical chamber components from plasma erosion and extend their service life.
Sintering Setter Plates: Carrier base plates for powder metallurgy or special ceramic sintering in high-temperature furnaces.
High-Temperature Crucible Covers: Used as sealing protection covers for high-temperature rectangular or circular alumina crucibles.
Refractory Boards: Used for extreme high-temperature kiln lining isolation in the steel and glass industries.
Miniature Heater Insulation Bases: Fixing bases for high-temperature electric heating components such as serpentine miniature heaters.
Thermocouple Insulators: Used for insulation and protection of the measuring end in high-temperature measurement equipment.
Combustion Trays: Porous designed circular or square plates for corrosion-resistant metal smelting and laboratory thermal analysis.
Power Electronics Substrates: Circuit carrier boards providing excellent thermal conductivity and electrical insulation in high-power electronic components.
Microwave Dielectric Ceramic Bases: Low dielectric loss transmission substrates used in high-frequency communications and microwave integrated circuits.
High Voltage Feedthroughs: High-voltage isolation components used in vacuum equipment and high-voltage switchgear.
Thick Film Substrates: Provide flat and stable substrates for surface-mount devices (SMD) and high-end hybrid integrated circuits.
Sensor Housings & Support Bases: Insulating packaging and bottom support for sensors in harsh aerospace and industrial environments.
Heavy-Duty Pump Plunger Guide Plates: Key wear-resistant parts in industrial pumps handling highly corrosive or abrasive fluids.
Cyclone Liners: Protective layers in mining or material handling systems to prevent metal loss from abrasive materials.
Wire Drawing Dies: Wear-resistant guide base components used in metal wire manufacturing.
Seal Rings: Anti-leakage hard friction rings for the end faces of centrifugal pumps and compressors.
Ballistic Armor Plates: Used as armor protection layers for personal body armor ballistic inserts or tactical vehicles due to their extremely high hardness and low density.
Transpiration Cooling Panels: Porous alumina circular plates manufactured using gel casting, used for thermal protection structures in simulated hypersonic wind tunnel tests.

Frequently Asked Questions (FAQ)

Q: How exactly does Gel Casting reduce my procurement costs?

A: Traditional ceramics must be hard-machined with diamond tools after sintering. Gel casting allows the "green body" to achieve 3-8 MPa tensile strength, meaning we can CNC machine complex grooves, blind holes, and threads more efficiently before the ceramic is hardened in the furnace.

Q: Can these discs handle vacuum environments?

A: Yes. Thanks to isotropic shrinkage during the gel-casting process, the discs achieve a high density (≥ 3.90 g/cm³), providing the low outgassing rates required for semiconductor vacuum chambers.

Q: Do you accept custom dimensions and tolerances?

A: Yes! We supply standard sizes and offer custom prototyping up to 600mm. Post-sintering, we utilize advanced laser machining and diamond lapping to achieve tight micron-level tolerances and specific hole positioning.

Trust & Compliance

Every batch of our Alumina Ceramic is subjected to strict quality control under ISO 9001 standards. The material is free of lead, toxic binders, and compliant with RoHS 2.0 and REACH SVHC regulations.