A research team from the SUSU Department of Materials Science, Physical and Chemical Properties of Materials in cooperation with OOO “NPO “SilKaM” company, have begun developing a technology for producing high-strength ceramics based on reaction-bonded silicon carbide (RBSC) for import-substituting mechanical engineering products.
Within the frameworks of a strategic project under the Priority 2030 program, South Ural State University has launched research and development work aimed at determining the optimal technological parameters for producing dense, high-strength ceramic components from reaction-bonded silicon carbide.
The industrial partner, OOO “NPO “SilKaM” company, provides access to its equipment for silicon infiltration of ceramic preforms. The total funding for the first stage of the project, scheduled for three months, amounts to 2.4 million roubles, with one half provided by the industrial partner and the other half financed through the Priority 2030 program.
The goal of the study is to develop a technology for manufacturing silicon carbide ceramics for friction pairs and other structural components in cooperation with OOO “NPO “SilKaM” company. The project includes the development of a complete set of technological operations for producing complex-shaped products (including rings with diameters of up to 200 mm and pipes up to 500 mm in length) with high performance characteristics.
A potential product that SilKaM will be able to manufacture as a result of the project is plain bearings for pump equipment used in oil and gas industry. The main consumer of such bearings is KONAR Industrial Group. Currently, KONAR uses bearings imported from the United States and Germany in its pumps. South Ural State University, jointly with OOO “NPO “SilKaM” company, is developing a new import-substituting material.
Silicon carbide (SiC) is a promising material for friction units operating under extreme conditions. Its potential is ensured by a unique combination of properties: high hardness (9.5 on Mohs scale), wear resistance, corrosion resistance in aggressive environments (acids, alkalis, molten metals), and heat resistance up to 1500°C. In terms of mechanical and tribological properties, reaction-bonded silicon carbide outperforms the less expensive oxide ceramics.
Unlike siliconized graphite currently produced by SilKaM (with SiC content of 25–50%), reaction-bonded silicon carbide is characterized by a significantly higher carbide phase content (92–95%), increased strength, and fine-grained structure, which determine its superior performance. At the same time, the RBSC technology requires precise adjustment of many interrelated parameters, including filler and binder content, particle size distribution and phase composition of the batch, pressing modes, and high-temperature reaction sintering (silicon infiltration). Existing patent descriptions usually specify broad parameter ranges, making their direct application for producing specific products impossible without additional in-depth R&D.
At the current stage of research, the SUSU scientists have produced more than ten experimental ceramic samples in the form of disks 25 mm in diameter and have determined their structural and mechanical characteristics.
Further development of the project may involve applying for a grant from the Russian Science Foundation. If funding is obtained, the research group led by Doctor of Sciences (Chemistry) Dmitry Zherebtsov plans to move on to producing prototype bearing rings during the second year of research and master the technology for manufacturing RBSC pipes during the third year. Publication of results will be carried out in agreement with the industrial partner.
Creation of a domestic technology for producing RBSC components is of strategic importance for import substitution in the Chelyabinsk Region and Russia as a whole. Potential application areas, in addition to bearings for oil and gas and power engineering, include high-temperature process tooling, heat exchanger components for nuclear power engineering, defence industry components (such as armour tiles for personal and vehicle protection), and refractory materials for metallurgy.
The use of silicon carbide ceramics will expand the capabilities of friction units (plain bearings) in mechanical engineering, oil, chemical, and semiconductor industries, where chemically resistant and heat resistant ceramics are required for chemical reactors.
The Chelyabinsk Region is known for its wide range of metallurgical, chemical, mechanical engineering, and defence enterprises, all of which require access to import-independent production of silicon carbide ceramic components.
Implementation of the project will enable the creation of a high-tech manufacturing facility in the Chelyabinsk Region focused on the needs of key regional industries.