Pertinent to Fiberfree™ Materials
Why do we need
It is believed that short fibers may pose health risk to those who
come in contact with them. Exposure to short fibers can happen during
manufacturing, use, repair, and disposal. The refractory industry
has invested in looking for ways to overcome the potential problems
posed by materials containing short fibers. Many new solutions
are in the making. Industry is trying to move towards a tough 0.5
fiber/cc (8 hr. TWA) recommendation. FiberFree™ materials
are, therefore, important. See
more about fiber materials. MATTECH Corporation has taken the
step to eliminate fibers from its products with new patented fractal
nano technology which allows use of light weight materials with
excellent controlled porosity.
A: NanoFractalAlumina™ (NFA) is a unique material only available from Mattech Corporation. This material displays extraordinary thermal shock resistance. It is also a high temperature material 2000°C capable. Other unique properties are that it can be made into any shape (see Custom Applications). Some standard products made from this material are listed on this site. For other volume applications, please contact Mattech.
A: Up to 2000°C, depending on the product and type of use. For example, we do not recommend using Fractalins™ for temperatures exceeding 1850°C, especially if the atmosphere is reducing. HAFractalins™ may be used to higher temperatures. FractalBalls™ made of HMG1 material may be used for temperatures as high as 1880-1900°C. HAFractalBalls™ may be used to even higher temperatures close to 2000°C.
A: The typical applications relate to thermal insulation, filters for liquid metals, general filtration where high surface area is required, chemical filtration, membranes, electronic substrates, liquid metal filtration, low density structural materials, fire resistance materials, filters, substrates for catalytic converter or diesel particle heaters, furnace insulation and repair (patch up). (Also see section on Typical Use of FRACTALBALLSTM.)
A. Use FractalPaste™ for filling cracks and patch-up. As the name implies, this is a thick paste, and has less water content than FractalGlue™. FractalGlue™ is much thinner. Both FractalPaste™ & FractalGlue™ may be mixed with FractalBalls™ and the mix is used much like a ceramic castable.
A. Fractalins™, HD Fractalins™, and UHD Fractalins™ have connected, open porosity whereas BR Fractalins™ have closed porosity. If your application requires a porous inter-connected material, please choose from FractalBalls™ or various types of Fractalins™. If your intended use is only for thermal applications then BR Fractalins™ are your best choice.
Q. I want to make myself a product which is approximately 12"x12"x1" in size for use up to 1800°C, by mixing FractalBalls™ and FractalPaste™. How much of FractalBalls™ do I need and how much FractalPaste™ do I need?
A. You will need about 0.5 gallons of FractalBalls™ (HMG1 material) and about 32 oz. of FractalPaste™ (note FractalPaste™ is sold in 8oz. sizes only).
Most of the Mattech boards are made from stacked FractalBalls™.
Alternately, the HMG1 or Alumina material is also available as plates
and discs (which are not made from FractalBalls™), and these are
listed under Setter
Plates and Monolithic
Boards. Setter plates may also be used as membranes, as they
have interconnected porosity.
A: These are pre-formed bricks and boards made from FRACTALBALLS™. HDFRACTALINS™ have a density of ~1.1g/cc, whereas FRACTALINS™ have ~0.7g/cc density. More information on these materials is available from clicking on Product Specs.
A: This depends on the usage. Generally about 60g of FRACTALBALLSTM with 40 cc of FRACTALGLUETM is recommended. After drying, fire to at least 1250°C to develop strength. You should expect minimal shrinkage ~1% when you fire.
A: If you require a furnace, please visit our technology partner for furnaces. We recommend that you experiment with a small lot and then decide on the optimum mix. Please e-mail email@example.com for information on dies and furnaces if required.
A. Use FractalPaste™ for filling cracks and patch-up. As the name implies, this is a thick paste. FractalGlue™ is much thinner and is used to bond FractalBalls™ or HAFractalBalls™ to make a shape. Both FractalPaste™ & FractalGlue™ may be mixed with FractalBalls™ and the mix is used much like a ceramic castable. FractalPaste™ has less water content than FractalGlue™.
A: If FractalGlue™ is too thick it may have gelled; it can be diluted with distilled water. The amount varies with the amount gelled but about 3cc to a 60gms gelled glue while mixing should bring it back to the original consistency of about 1.2g/cc. Some experimentation is required so a good way to do this is take a small amount (sample) of gelled glue and add water to determine the right mix.
A: Mixing 67% FractalGlue™ and 33% of 1mm FractalBalls™ yielded a pasty mixture which was dried for one day. It was fired to 1350C (approximately 5C/minute) and the material came out hard and fired. (also see question above)
A: Please send us your dimensions and we will contact you. E-mail us at firstname.lastname@example.org. You may also elect to purchase the standard sizes with a 0.5" or 1" thickness. You may directly add these to the shopping cart by going to the "Price List" section of this site.
A: Monolithic boards are extremely easy to machine. Fractal boards such as Fractalins™, HDFractalins™, and HAFractalins™ are more difficult to machine but may be machined with diamond tip tools. However, the machining is a delicate operation - please be careful during machining. It is best again to use a qualified ceramics machinist or contact us for machining. We cannot replace a board if you break it. Broken boards may be glued together with FRACTALGLUETM.
A: See section on "Typical Use" and scroll to the bottom of the page.
A: Please check with us before you attempt this. Unlike fiber materials, you can recycle the HA FRACTAL materials if you break the board before use. We do not recommend recycling the HMG1 material after use.
A: FRACTALBALLSTM, FRACTALINSTM and FRACTALGLUETM do not contain fibers and are environmentally safer all around when compared to fiber containing refractory and especially safer to you during operation, machining, usage, and disposal.
A: Plenty. All you do is e-mail us your question and we will respond.
A: For shipping damage you must contact your shipper for insurance claim. Please retain the original packaging and product and report any external and internal damage immediately to the shipper. All shipments from MATTECH are insured for you. If the insurance agrees to pay, which they do if they confirm shipment damage, you should collect the insurance and reorder from MATTECH (buyrefractory.com). In the event that the insurance does not agree to pay we cannot replace such boards, but we have an engineering solution for you. If the break is clean, you can acquire the FRACTALGLUETM and join the board. Remember it requires heating by furnace or AirtorchTM . As a free service we will connect you to discounted prices for furnaces, heating elements, hot air generators up to 1300°C or any other ceramic processing equipment. This service costs you nothing. All you need to do is e-mail your requirement to us, then we will find the best price for you (if we can) and send you the name of the company you can directly deal with and a copy of the best price offer we have received for you. We will simultaneously contact the company with your information and bring both of you together. We do not charge you or the equipment company any commission, and you get a negotiated price from us on which you may act as you wish. It's free.
Please read Purchasing Instructions:
Prior to shipping you will receive an acknowledgment. You
should read this carefully and point out any problems at that stage.
Your credit card is not charged unless both you and MATTECH have
understood the order properly. Not withstanding please be
careful during ordering process as you are responsible for the payment
of any order placed.
A: The FRACTALIN™ material and the FRACTALGLUE™ bonded FRACTALBALLS™ materials are bulk materials consisting of stacked/bonded FRACTALBALLS™. However, because of differences in the manufacturing process, they display slightly different properties. FRACTALINS™ are factory produced shapes/boards made by a special joining process. The FRACTALGLUE™ bonded FRACTALBALLS™, on the other hand, are made into shapes/boards with the mixing and firing of FRACTALBALLS™ and FRACTALGLUE™ by the user. (See section on how to bond FRACTALBALLS™ with FRACTALGLUE™). The HMG1 material of which the FRACTALBALLS™ are made and FRACTALGLUE™ material may be used to temperatures in excess of 1850°C.