Manufacturing Alumina Insulators for Aircraft Spark Plugs via Cold Isostatic Pressing: A Numerical and Experimental Study

چکیده مقاله

Abstract: This research examines the production of the alumina ceramic insulator for a jet engine spark plug via cold isostatic pressing (CIP). To enhance the mechanical properties of ceramic insulators, the optimal CIP parameters were investigated using the Taguchi method in conjunction with Gray relational analysis. Numerical simulation of the cold isostatic press in Abaqus, conducted during the design phase, determined that the mold must withstand pressures greater than 350 MPa. To evaluate the quality of the cold isostatically pressed ceramics, they underwent a series of tests including density and hardness measurements, as well as microstructural examination using scanning electron microscopy (SEM). To simultaneously increase density and hardness, the Gray relational analysis determined that the optimal configuration involves a pressure of 350 MPa, a processing time of 950 s, and the use of a cellophane coating. A ceramic insulator was produced using the optimal CIP parameters to verify the optimization results, which successfully showed improved hardness and density. Microstructural examination confirmed that the improvement in mechanical properties was due to markedly fewer cracks and pores, as well as stronger inter-particle bonding within the alumina matrix.