MODERATOR: Pottery known to mankind thousands of years. And the main drawback — fragility. In my hands, too, ceramics, but made with modern technologies. Look, I throw it on the floor. And it does not break. What’s the matter? And today we know as the modern nanotechnology of brittle ceramic material made with fantastic features. Today more and more difficult to find high-tech industry, which would not have been used, the so-called nanoceramics. Where it is necessary to resist high temperature, a powerful electric current, increased friction, which is required to ensure rapid cooling of microelectronics — everywhere successfully works is a new generation.
Dmitry LISENKOV, Managing Director of RUSNANO: Contemporary ceramics market is estimated to be in ’15, in fact after 2 years in the amount of 73 billion U.S. dollars.
MODERATOR: This is a 5 part of the annual budget of Russia. That’s how much America today spends on the development and adherence to new types of weapons. So for what is going to pay the world in the coming years? Where do these incredible opportunities to initially fragile natural material? This is one of the oldest Russian electronics industry —
Oleg mole cricket, executive director of the company NEVZ-CERAMICS: It ceramics for the electronics industry, ceramics for medicine, ceramics for armor protection of personnel, military vehicles, this ceramic insulators for power engineers. And the fifth area — it’s ceramics for the oil and gas sector.
MODERATOR: Born opportunities nanoceramics in a closed laboratory of the enterprise. Here, using exclusive formulation components admixed future material.
— I have a feeling that here you have a real alchemy lab. You ordinary pottery making high impact. How does this happen?
Love BOGDANOVA, deputy head of the technical department of the company NEVZ-CERAMICS: Now we are just preparing shlekera, from which then obtained ceramic substrate.
— Shleker — what’s this?
Love BOGDANOVA: Shleker — a ceramic slurry, which in a certain thermal processing enters into a solid ceramic. The basis is, of course, in the preparation of — a powder AL2About3.
And plus supplements — minerals and a bit of nano-additives. Nano additives provide mechanical strength.
MODERATOR: Most clearly see the difference between an ordinary material and nanobratom possible under the electron microscope. Here’s a loose and porous structure has a traditional brittle ceramics. And just like that, with the addition of nano-powders, changing the structure of nanoceramics. When overheated supplements as it stuck to the large grain of the material and begin to attract them to each other at a distance of up to 100 nanometers. The result is a fine-grained, uniform structure of high strength and thermal conductivity.
Dmitry LISENKOV: The industry is developing very active in recent years in Russia. Products that are being done in our CERAMICS, first of all can be used in LED products, bright light-emitting diodes, which are already being produced in Russia. However, still do not have all hardware components, produced in Russia.
MODERATOR: Today most of the LED substrates comes from Italy and China. Company NEVZ-CERAMICS intends to put an end to this expansion. This modern production line can produce annually a million cards substrates for LEDs. The process is almost entirely automated. The operator must first download a container with a liquid ceramic composition into the machine. Next machine automatically begins to pour a thin layer of the solution on the polymer film. It moves on a conveyor slowly through the drying chamber. It has a total length of 26 meters.
— Casting ended. What’s next?
Evgeny Kalashnikov, CTO NEVZ-CERAMICS: Of course, after completion of the casting operator pulls the finished product, and places it in the next installation.
— And how to change the material?
Evgeny Kalashnikov: Physico-chemical properties of the material have not yet changed. We’re installing molding made from liquid rubber-like material. It is bent and fit for further use in the manufacture of substrates.
— Why it is loaded in this setting?
Evgeny Kalashnikov: This installation will roll onto the cutting of individual piece-zagotovochki 8 by 8 inches.
MODERATOR: Cut the blank — this is the future nonoceramic substrate layers. In each automatic hit with micron precision holes. Then the robot like a pie, all collected into a single high-tech construction of a dozen layers.
— What is this plant? I see here some of the target. Perhaps now would be some shooting?
Evgeny Kalashnikov: This apparatus for positioning the various layers of the substrate member to that of the apparatus with an accuracy less than one micron are collected in a stack. Imagine a multi-layer ceramic fee. Before fees and fees for microelectronics now made of fiberglass. Inside the ceramic plate we just as the inside steklotekstolitovoy board can accommodate galvanic contacts galvanic track different topologies to provide the passage of electrical signals between two of the layers and surfaces of the substrate above and below.
MODERATOR: Further assembled multilayer structure is fired in an electric furnace at 1600 degrees is the final sintering of the metal components and the substrate conductor. It remains only to check its quality. Typically, only one outgoing marriage of 25 plates.
Oleg Medvedki: From the point of view of cost parameters we have to offer our customers not less than 30% in relation to the major foreign suppliers. That’s our goal. Especially the case, of course, primarily on the European market. We assume that, in comparison with European, international peers, our products will cost at least 30% cheaper.
Dmitry LISENKOV: On the demand side, it is relevant, is obvious. From the point of view of the product that we produce now, we realize that it is on the highest world standards. It is a technology that was created by NEVZ-CERAMICS, respectively intellectual rights reserved. And we plan to capitalize the value of our company based on, including this product. And potentially go to Western markets.
MODERATOR: At the moment, the total investment in the project amounted to 1.5 billion rubles. Of these, 590 million rubles invested by RUSNANO. All the money spent on the purchase of the most advanced technological equipment. To produce a new generation of material involved is not only finances, but also a science. A regional scientific-industrial consortium "Siberian ceramics."
Oleg Medvedki: We managed jointly with the Siberian Branch of the Russian Academy of Sciences to create a new material, called nitride ceramics, heat-conductive ceramics, which, on the one hand, is an insulator, on the other hand, it is a thermally conductive substrate. And that’s at the expense of the interesting properties we were able to significantly improve the reliability of the instruments, which are made on the basis of our substrates.
MODERATOR: Another trend that is expanding the project — the production of insulators for power. Today, there is also strong competition from foreign manufacturers. Two thirds of ceramic insulators for Russian electricity supplies in Japan, Germany and, of course, China. But Novosibirsk offer a new generation of power engineers Nanoceramics. It is capable of withstanding extremely high loads, voltage spikes of more than 20 kilovolts. These unique properties in ceramics appear after prolonged high-temperature tempering in chambers. On refractory pan insulators slowly charged into the gas furnace.
— A feeling that you are a spaceship. What’s going on here now?
Olga Panina, deputy head of the technical department of the company NEVZ-CERAMICS: This is not a spaceship. This final calcination furnace for ceramic insulators at a certain temperature. Insulators are fired at a temperature of about 1,600 degrees. That is, the earlier fires burned, get baked crock. We now have a more modern ceramics. It requires higher firing temperatures. And after firing has already obtained all the properties of ceramics. Electrical insulating properties, mechanical strength.
— How long this process takes time?
Olga PANINA: The process will take about 52 hours.
MODERATOR: Chips, which are now rolled out from under the press, so, you would not believe, the armor of the future. The unique strength and weight of material specialists together called bronekeramikoy. From it’s going to special lightweight panel. They successfully defend against bullets and shrapnel light armored vehicles, helicopters cabin, marine ships. In addition, a plate of bronekeramiki about to replace steel in protective vests and police commandos.
Oleg Medvedki: Our ceramics withstand bullets from 762 SVD rifle from 10 yards, ending with heavy machine guns. It is 12.7 and 14.5 degrees of protection. We have already had the appropriate tests in France, it is in Europe. And also our bronekeramika showed his best side.
MODERATOR: The unique properties of ceramics can not create due to the method of ultrasonic pressing. In the mold, filled with ceramic powder to ultrasonic waves are instantly compressed and expanded material. This leads to a more uniform and dense distribution of the particles within the mold. By pressing the particulate material more compacted and sintered to converge nanoscale distances. The result is a uniformly dense structure of ceramics in all directions, the quality of protection is not inferior to steel armor.
Yuri untouched, Head Science and Technology Department of NEVZ-CERAMICS: Ceramic armor at a meeting with the kinetic energy of a bullet take
s the bullet and compressed. This is accompanied by the destruction of the bullet itself to pieces. And the pottery itself is destroyed, but its task — to accept a blow to extinguish the kinetic energy of the bullet. A bullet in the future, have scattered into pieces, it is not harmful.
MODERATOR:Nanoceramics today are expected not only military but also doctors. In the near future in Novosibirsk will start production of the ceramic prosthesis for the hip and spine implants. They will replace the titanium structures that have a lot of shortcomings.
Oleg Medvedki: Metalloimplantaty have some bad properties when the migration of metal ions tissues lead to various bad consequences in the body. Ceramics, it fortunately has properties such that there are processes postintegratsii. That is, the splice bone and ceramics. Due to this, there is a stable bone-ceramic block that allows you to … that is, the body perceives as part of the implant and the bone does not reject it.
MODERATOR: Another promising direction for nanoceramics — oil production. Ceramic assemblies for valves have a high thermal stability, good resilience to mechanical wear, no corrosion. Lifetime nanoceramics at least 4 times greater than steel. However, in terms of Novosibirsk provide material of new generation, not only Russian industry, but foreign manufacturers. Go test samples are prepared contracts. So nanoceramics market is constantly expanding, so after 5 years of annual turnover should reach 3 billion rubles. And most of its products to be delivered abroad.