Sintered Metals & Ceramics: Possibly In Spyderco's Future?

#9

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Post by Cliff Stamp » Thu Dec 11, 2014 9:56 am

JD Spydo wrote: Titanium Nitride, Boron Carbide and several other coatings you see on many machine tool end mills and other cutting tools.

There has been more developed interest in this lately with use of titanium blades which are carbidized. They are pretty interesting in that the titanium will wear much faster than the solid line of carbide and thus as long as the cutting is on soft material (ropes, cardboard, etc.) you don't need to sharpen them at all, they will essentially cut forever. Now to be clear the sharpness isn't going to impress you if you are the type of person who uses a Sharpmaker when the knife doesn't shave, but for a lot of people who are just looking at having a knife that doesn't skid and is used to cut very harsh materials they are very attractive.

On the extreme end you can get diamond coatings on blades as well, these are much more wear resistant than the nitride coatings but there isn't any argument or data to show they would be of benefit on a blade over the standard carbide/nitride coatings. They are used in industry though, often they are used to actually coat carbide cutting tools. There are also solid diamond blades, but they are very thin and normally used to cut materials under very tight controls because they are made to optomize cutting ability and thus they are very thin and the apex is very narrow and the sharpness is an order of magnitude beyond steel.

In some cases we have to also step back and realize that the unknown is fairly difficult to predict. Just imagine talking to someone of last generation about sharpening when all they had seen was a benchstone and imagining all of what we have now with v-rods, jig based systems, and sharpening stones of all types of abrasives/bonds. There was a time, not very long ago when people would describe even S30V as being so difficult to grind/finish it was impossible to sharpen - but yet we now commonly work with steels which are much harder to grind/finish.

The abrasive technology development is huge because of the impact of better abrasives. Norton's development of SG abrasives to create an alumina based abrasive that actually sharpens itself as you use it to cut steel is the kind of thing that no one could imagine. The next step up in the TG wheels which allow an extremely high abrasive density combined with a very high bond strength (these are usually opposite) because of the shape of the abrasive (its like a bunch of worms vs cubes) produces some extremely high performance grinding tools :

-http://www.thegrindingdoc.com/files/cer ... wheels.pdf

At some stage we can maybe speculate, for example what would happen if we had a "smart" abrasive which could adjust its bond strength based on the load. Most of us have used stones at one point or another that are too hard or too soft. This is because the bond strength is adjusted for very high or low pressure applications accordingly. If for example you have a stone which works very well under the extreme pressure that is produced from putting a micro-bevel on a paring chisel, then it is going to be far too hard to use on the back of the same chisel.

After experimenting with stones a little, most people will have a collection of soft stones for when large contact areas are being used (because this means the pressure is very low) and then hard stones for when the contact area is small (as the pressure is very high then). In fact there are even companies that sell stones which are hard on one side and soft on the other with the same abrasive. This solution is however a bit awkward because different steels will need more/less pressure to cut as well and if you have a range of pressures you can end up with quite a range of stones.

For example, with the same 1 lbs load, this is the contact pressure produced :

-small detailed chisel / notching tool : > 100 psi

-narrow bevel on a knife : < 25 psi

-wide edge bevel on a knife : < 5 psi

-back of a plane : < 0.25 psi

If you have to work all of these tools, it isn't unreasonable that you might have a stone which works very well on each and has that nice gradual breakdown which is just strong enough to prevent excessive abrasive wear. If you try to use a stone which works well on the back of a plane it is likely to gouge insanely easy if you use it on the notching tool. Similar if you try a stone which works well on the notching tool it will likely be far too hard to cut well trying to flatten the back of a plane.

But imagine a stone which has a "smart" bond and it is able to respond to the pressure and just release fresh abrasive but not wear extensively. If this sounds crazy, well that is only because we can't think on how to do it yet. There are lots of smart materials which do similar things, there are ceramics for example which actually change their internal structure to absorb loads to keep them from fracturing. Who knows what we will have in the future - science can do wild and crazy things.

There has been more developed interest in this lately with use of titanium blades which are carbidized. They are pretty interesting in that the titanium will wear much faster than the solid line of carbide and thus as long as the cutting is on soft material (ropes, cardboard, etc.) you don't need to sharpen them at all, they will essentially cut forever. Now to be clear the sharpness isn't going to impress you if you are the type of person who uses a Sharpmaker when the knife doesn't shave, but for a lot of people who are just looking at having a knife that doesn't skid and is used to cut very harsh materials they are very attractive.On the extreme end you can get diamond coatings on blades as well, these are much more wear resistant than the nitride coatings but there isn't any argument or data to show they would be of benefit on a blade over the standard carbide/nitride coatings. They are used in industry though, often they are used to actually coat carbide cutting tools. There are also solid diamond blades, but they are very thin and normally used to cut materials under very tight controls because they are made to optomize cutting ability and thus they are very thin and the apex is very narrow and the sharpness is an order of magnitude beyond steel.In some cases we have to also step back and realize that the unknown is fairly difficult to predict. Just imagine talking to someone of last generation about sharpening when all they had seen was a benchstone and imagining all of what we have now with v-rods, jig based systems, and sharpening stones of all types of abrasives/bonds. There was a time, not very long ago when people would describe even S30V as being so difficult to grind/finish it was impossible to sharpen - but yet we now commonly work with steels which are much harder to grind/finish.The abrasive technology development is huge because of the impact of better abrasives. Norton's development of SG abrasives to create an alumina based abrasive that actually sharpens itself as you use it to cut steel is the kind of thing that no one could imagine. The next step up in the TG wheels which allow an extremely high abrasive density combined with a very high bond strength (these are usually opposite) because of the shape of the abrasive (its like a bunch of worms vs cubes) produces some extremely high performance grinding tools :At some stage we can maybe speculate, for example what would happen if we had a "smart" abrasive which could adjust its bond strength based on the load. Most of us have used stones at one point or another that are too hard or too soft. This is because the bond strength is adjusted for very high or low pressure applications accordingly. If for example you have a stone which works very well under the extreme pressure that is produced from putting a micro-bevel on a paring chisel, then it is going to be far too hard to use on the back of the same chisel.After experimenting with stones a little, most people will have a collection of soft stones for when large contact areas are being used (because this means the pressure is very low) and then hard stones for when the contact area is small (as the pressure is very high then). In fact there are even companies that sell stones which are hard on one side and soft on the other with the same abrasive. This solution is however a bit awkward because different steels will need more/less pressure to cut as well and if you have a range of pressures you can end up with quite a range of stones.For example, with the same 1 lbs load, this is the contact pressure produced :-small detailed chisel / notching tool : > 100 psi-narrow bevel on a knife : < 25 psi-wide edge bevel on a knife : < 5 psi-back of a plane : < 0.25 psiIf you have to work all of these tools, it isn't unreasonable that you might have a stone which works very well on each and has that nice gradual breakdown which is just strong enough to prevent excessive abrasive wear. If you try to use a stone which works well on the back of a plane it is likely to gouge insanely easy if you use it on the notching tool. Similar if you try a stone which works well on the notching tool it will likely be far too hard to cut well trying to flatten the back of a plane.But imagine a stone which has a "smart" bond and it is able to respond to the pressure and just release fresh abrasive but not wear extensively. If this sounds crazy, well that is only because we can't think on how to do it yet. There are lots of smart materials which do similar things, there are ceramics for example which actually change their internal structure to absorb loads to keep them from fracturing. Who knows what we will have in the future - science can do wild and crazy things.

If you’re in the market for a new kitchen countertop, you likely have one burning question: What are the most popular countertops? And then also these: Are they durable? Are they expensive? What are the pros and cons of them?... So many questions!

Luckily, today we will mainly discuss two types of popular countertop -sintered stone countertop and quartz countertop.Now let’s get into it!

#1.What is sintered stone?

Sintered stone is a super large new porcelain material made of natural raw materials through special process, pressed with a press of more than 10000 tons (more than 15000 tons), combined with advanced production technology and fired at a high temperature of more than 1200 ℃, which can withstand the processing processes of cutting, drilling, grinding and so on.

Sintered stone can be used for almost anything natural stone can be. It is commonly used for the following:

· Countertops
· Bathroom vanities
· Furniture（shelf, table, cabinet/wardrobe door panel, invisible door panel)
· Wall and floor tiling

· Stairs
· Fireplace surrounds
· Patios and outdoor flooring
· Exterior wall cladding
· Spas and wet rooms
· Swimming pool tiling

The primary constraint to consider is the size of the slabs produced. When aiming for exceptionally large items, it may be necessary to connect multiple slabs together. The good news is that sintered stone slabs exhibit a remarkable consistency compared to natural stone slabs, making it straightforward to achieve a seamless match. At WIFi Ceramics, we produce slabs in various thicknesses and dimensions tailored to diverse applications. These slabs are generally well-suited for nearly all residential and a wide range of commercial purposes, ensuring versatility in design and functionality.

To discuss more applications of sintered stone and whether it is the best choice for your project, contact an expert at WIFi Ceramics.

Browse sintered stone products from WIFi Ceramics.

What is sintering?

Sintering is the process of using extreme heat and pressure to combine various materials into one solid piece. This process actually imitates the natural process of creating granite.

Basically, the sintering process is an artificial version of the high temperature and high pressure produced by the earth on the material to form a specific surface.

What is a sintered surface?

The sintered surface is made of natural materials through the engineering sintering process, simulating the natural compression and heat of the environment.

The sintered surface gives people the illusion of natural defects and unique quality. Sintered stones can look like natural stones, wood, or even smooth surfaces.

This kind of stone can be made into various colors, shapes, sizes and textures, while still using natural materials. This stone is a relatively light material that requires less surface structural elements.

What is the thickness of a sintered slab?

In general, the common thickness of sintered slabs is 12 mm. Of course, 20 mm or thinner 6mm and 3mm sintered slabs are also available.

Looking for another thickness? Or want to know which thickness is suitable for your project? Order a free consultation.

Related article：Home Sintered Stone - A Must Read Guide

#2.What are the pros and cons of a sintered stone countertop?

Pros

1.it is of through-body material

Sintered stone is homogenous throughout its thickness, which means that its color and pattern run consistently from the surface to the core. This through-body composition ensures that any surface scratches or chips are less noticeable, as there is no contrasting layer beneath the surface.

2.it is the most ever-lasting surface you can get

The Mohs hardness of a sintered stone countertop is grade 6-7, which can resist scratching and trying to scratch. The higher the Mohs hardness, the less likely it is to leave scratches on the surface.The hardness of quartz is between 5-6.

with A1 grade fire resistance , a sintered stone countertop will not deform in direct contact with high-temperature objects. It will not produce any physical changes (shrinkage, rupture, discoloration) or emit any gas or smell when encountering an open fire of 2000 ℃.

A sintered stone countertop is also corrosion-resistant.It is resistant to various chemicals, including solutions, disinfectants, etc.

Helpful Tip: According to information obtained from another source, it has been demonstrated that a metal weight weighing approximately 1.1 pounds, when dropped from a height of 21 inches, is capable of causing a fracture in the surface of a sintered stone with a field area measuring 20 millimeters. Furthermore, if the same weight is dropped from a height of 1 foot onto the edge of the material, it will result in chipping of the material.

3.it is of binder-free composition

Sintered stone countertops are crafted without the use of synthetic binders or resins. Instead, they rely solely on the natural fusion of mineral components through a high-temperature sintering process. This binder-free composition enhances the material's purity and environmental friendliness, as it contains no artificial chemicals or additives.

4.it is very easy to clean

A smooth texture, making a sintered stone countertop easy to clean and maintain. The surface is not porous which means that spills will be easily wiped away while dirt or dust won't stick to the surface, so you don't need to worry about time consuming cleaning routine.

With the water absorption less than 0.05%, water is not easy to penetrate. It can keep the dry surface all the time and is not easy to be polluted.

5.it is really healthy

The surface of a sintered stone countertop can be in direct contact with food. It is made of pure natural material. It is 100% recyclable, non-toxic and radiation-free.

At the same time,a sintered stone countertop also fully meets the needs of human sustainable development, health and environmental protection.

6.it is resistant to ice and freezing
Sintered stone is a material that is resistant to both ice and freezing. This makes sintered stone countertop suitable for outdoor applications in cold climates, as it will not crack or break due to exposure to the elements.

7.it is resistant to UV rays
Resistance to UV rays means that sintered stone countertop will not fade or discolor over time when exposed to sunlight. Thus, you can set the position of your countertop as you like, even if it is near the window and exposed to sunlight all year round.

8.it is light in weight
The 3mm sintered slab is only 7kg/㎡ and the 12 mm sintered slab ,30 kg/㎡.

9.it has endless styles

A sintered stone countertop can provide innovative elements to kitchen architectural decoration design. Variety of thicknesses,sizes,details,colors can inspire creativity making your kitchen decoration more unqiue.

10.it has versatile surface treatments

Sintered stone countertops offer a wide range of surface finishes, catering to various design preferences. You can choose from matte, satin, polished, high-gloss, or textured finishes, depending on your aesthetic and functional requirements. This versatility allows for customization to suit different interior styles.

By now, your curiosity must be piqued, and your desire to incorporate sintered stone countertop into your home must be growing. Waste no time and embark on an exciting journey through our captivating collection of  sintered stone products. Our latest product catalog is brimming with an array of options, ensuring that you'll find the perfect one that speaks to your unique style and vision.

Cons

1. Lack of comprehensive training

Sintered stone is a relatively recent addition to the market, which means that not all professionals in the industry may have received extensive training on the optimal methods for installing sintered stone countertop.

2. Relatively high production cost

The surface of the sintered stone is very hard, not easy to cut, and has high requirements for processing equipment and technology. Because of the complexity of the production techniques, the production cost of a sintered stone countertop is also relatively high.

See here, you may have a question：how much does sintered stone cost?

Sintered stone is typically measured and priced by square footage. The price range is around $60-$100 installed per sq. ft.But this may vary by design, color, shape. The price may also change a little according to the required area, installation personnel and installation materials.

Worried that the price of sintered stone products going exceed your budget? Here at WIFi Ceramics,we not only offer premium sintered stone products but also 10% off for our VIP’s first purchase.So, join our VIP list now!

Related article：Sintered Stone Tiles VS Other Material Tiles

                         Sintered Stone and Quartz-5 Facts You Need to Know

What to consider when buying sintered stone countertops?

If you're in the market for sintered stone countertops, it's essential to consider some key factors to make the most of your design choices:

Upstands or Splashbacks:

You have the option to incorporate upstands or splashbacks into your kitchen design. Upstands are narrow strips of countertop material that run along the back of your cabinets. They not only add a touch of elegance but also provide a polished finish to your kitchen.

On the other hand, splashbacks are larger sintered stone panels installed on your walls. They are particularly useful in areas prone to splashes, such as behind the stove and sink, as they protect your walls from food and liquid stains. When opting for upstands and splashbacks that match your countertops, remember to order them simultaneously to ensure a perfect color match from your supplier.

Undermount Sink or Flush-Mounted Hob:

You can also decide between an undermount sink and a flush-mounted hob to enhance the aesthetics of your kitchen.

An undermount sink is positioned beneath the countertop, creating a cleaner and more streamlined appearance compared to traditional sinks. This choice can be further improved by incorporating a recessed drainer or drainer grooves, which are precision-cut into the countertop surface, adding both style and functionality.

If you prefer a sleek and modern look for your kitchen, a flush-mounted hob is an excellent option. It's seamlessly integrated into a shallow recess cut into the countertop, ensuring the hob's surface aligns perfectly with the countertop's surface. This not only elevates the overall design but also simplifies cleaning.

When considering an undermount sink with additional features like a recessed drainer or drainer grooves, or when opting for a flush-mounted hob, it's crucial to include these specifications when ordering your countertops. Furthermore, the installer will need to inspect the sink and hob during the worktop template creation to ensure precise cut-outs can be made in their workshop. This attention to detail ensures a flawless installation that complements your kitchen's aesthetic and functionality.

If you are looking for more details, kindly visit Sintered Metal Filters Suppliers.

Can I install a sintered stone countertop myself?

We do not recommend you to install sintered stone countertop by yourself.It needs professional tools and professional personnel to do it.

On the one hand, because of the thin and light nature of the sintered stone, it needs special support and protection so that it will not break during the handling process.

On the other hand, before installing a sintered stone countertop, the floor needs to be professionally leveled so that it does not cause the floor tiles to crack when it is placed on the floor.

#3.What is quartz?

Quartz stone, is a new type of stone synthesized by more than 90% quartz crystal plus resin and other trace elements. It is a large-size plate pressed by a special machine under certain physical and chemical conditions. Its main material is quartz.

#4.What are the pros and cons of a quartz countertop?

Pros

1.it is relatively stain-resistant

All kinds of oil, salt, soy sauce, vinegar or fruit juice encountered in daily life will not cause any corrosion to the quartz countertop. In addition, as a decoration material which has been treated by complex synthetic process, its structural compactness is very high.

Therefore, even if soy sauce and vinegar stay on the countertop for a long time, they will not penetrate into the interior of the countertop. It has stain resistance and is not easy to penetrate stains.

2.it requires low maintainance

A quartz countertop is a low-maintenance option because it doesn't require sealing or waxing . It also doesn't have to be resealed every few years, so you can save money on your renovation costs by choosing a quartz countertop over other materials that need to be treated more often.

3.it has various colors and patterns

There is a variety of colors and patterns that are available for quartz countertops. This means that you can find a color and pattern that perfectly matches your style and personality.

Cons

1.it is not heat tolerant

When using a quartz countertop, the buyer's daily life shall be carefully managed. Hot pots or other utensils with too high temperature directly removed from the stove, oven and microwave oven will cause damage to the countertop.

Over time, this so-called "indestructible" surface may slowly become a color and texture that was not originally bought as.

2.veins look more engineered rather than natural

As an engineered product, artificial veins can become overwhelming in a large area, especially the chance that multiple slabs could make the quartz countertop look artificial.

The size limitations of quartz can restrict the amount that the veins go along the surface, making it look more engineered, rather than natural.Seams are inevitable for large quartz countertop designs.

3.it is scratch-resistant but not scratch-proof

Although scratch resistance is a major advantage for a quartz countertop, it can scratch. Natural stone has natural pores and flaws that make it scratchable. The same goes for man made material such as quartz which uses stone dust from crushed rocks to create homogenous mixture of minerals called resin.

To achieve a granite countertop look, it is mixed with stone dust, pigments and infused with resin. The mixture gives a quartz countertop scratch resistance but not scratch proof.

4.it is not suitable for very small kitchens

Since a quartz countertop can be quite heavy, so it may not be the best option for very small kitchens and requires professional installation.

#5. Summing it up：sintered stone vs. quartz countertops

Similarities: Sintered stone countertops and quartz countertops both emulate natural stone aesthetics and offer impressive durability. They excel in scratch resistance and are highly resistant to water absorption. Notably, neither of them requires regular sealing maintenance.

Differences: Sintered stone countertops stand apart from quartz countertops due to their composition. Sintered stone is devoid of resins, which play a crucial role in safeguarding quartz countertops against potential cracks and chips from impacts. Consequently, sintered stone can exhibit a more brittle characteristic when subjected to sharp blows, akin to porcelain. Importantly, sintered stone showcases remarkable heat resistance, making it impervious to high temperatures. In contrast, quartz countertops can darken or scorch when exposed to temperatures exceeding 150°F.

Helpful Tip: The key distinction lies in quartz countertops' composition, comprising 90-percent minerals that offer excellent heat resistance. It's the remaining 10-percent resin content that accounts for quartz's relatively lower heat resistance threshold of 150°F.

Other useful guide for you：

• Sintered Stone vs. Granite:

  
  

When comparing sintered stone to granite, several notable distinctions emerge:

Appearance: Granite, being a natural stone, can present challenges in achieving a seamless, uniform appearance due to its inherent variability. Some may appreciate the unique beauty of this natural variation.

Durability: Granite tends to have lower resistance to stains, impacts, and chemicals in comparison to sintered stone.

Maintenance: Granite is porous and requires periodic resealing to maintain its integrity, while sintered stone has low porosity and is relatively easier to maintain.

Weight: Sintered stone is lighter than granite, which can be an advantage in some applications.

In summary, sintered stone is an engineered material with diverse design options, low porosity, and convenient maintenance. On the other hand, granite, a natural stone, is prized for its unique aesthetics but demands more upkeep and is more porous. The choice between the two hinges on personal preferences, design objectives, and maintenance considerations.

• Sintered Stone vs. Marble:

When comparing sintered stone with marble, the following distinctions become apparent:

Seam Quality: Marble tends to have lower seam quality, and it is less resistant to abrasions, stains, impacts, heat, and chemicals when compared to sintered stone.

Maintenance and Repair: Sintered stone is generally easier to maintain and repair.

Porosity: Marble is highly porous, making it susceptible to quick absorption of spills and stains. It necessitates sealing, which must be regularly maintained to prevent wear.

Weight: Marble is heavier than sintered stone.

Cost: Sintered stone can be pricier than marble.

In summary, marble may be considered a less favorable choice due to its susceptibility to spills, scratches, and breakage, as well as its need for diligent maintenance. Sintered stone, in contrast, boasts resistance to spills, scratches, and breakage, and can endure harsh chemicals found in cleaning products. The decision between the two materials hinges on your specific preferences and project requirements.

#6.Which kind of countertop should I choose?

If you have a relatively high budget, you can choose the sintered stone countertop, because as you can see above, it has only one disadvantage - the price is relatively expensive, but it is completely worth it, because it contains all the advantages of other kinds of countertop, and it can definitely bring you a very wonderful experience.

Related article：Everything You Want to Know about Sintered Stone

#7. Where can you use sintered stone and quartz at home?

Sintered stone and quartz are versatile materials that share similar attributes, making them suitable for various applications within your home. Here are some ideal uses for each material:

Sintered Stone: Sintered stone excels in durability and resistance, making it a smart choice for different purposes. You can use sintered stone for vanity and kitchen countertops, as well as shelving, wall cladding, flooring, and even furniture. Its ability to withstand UV rays without yellowing also makes it a viable option for external applications.

sintered stone table

Quartz: Quartz is another versatile material that finds its place in various areas of your home. It is commonly used for kitchen worktops, backsplashes, bathroom countertops, and flooring.

In summary, whether you opt for sintered stone or quartz, you can be confident in their ability to perform admirably in a range of interior design applications.

Conclusion

So there you have some aspects of sintered stone countertop and quartz countertop.

Both sintered stone countertop and quartz countertop are extremely hard,stain-resistant as well as require low maintainance.In addition, both materials can be selected and made into various colors. This is because the color can change during the manufacturing process.

The biggest difference of the sintered stone countertop and quartz countertop, is that the sintered stone countertop is made from natural materials, while quartz countertop includes man-made products like resin and binders.

But for countertops, what needs to be remembered is that if quartz is exposed to extreme heat, it has the possibility of getting burnt, while sintered stone can withstand the high temperatures.

Also, if your countertop will be set up outdoors, then you must consider a sintered stone countertop because it is weatherproof, water resistant, and UV resistant. Whereas quartz countertop may have burn marks or discoloration when exposed to sunlight and moisture for a long time.

After going through this related introduction, I hope you can pick out the perfect kind of countertop based on your needs and preference.

Here at WIFi Ceramics,we suggest you a sintered stone countertop for its Superior Performance.We are also confident to provide you with sintered stone countertops of great value!  So contact us now.

If you want to learn more, please visit our website pipe metal filter.