Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBDFBD Boards & Discs are Available in ThreeStandard Thicknesses.

FEATURES• Rigid and Machinable• Our Most Dense, Highest Strength,
Fibrous Zirconia Material• High Purity Zirconia Bonded• Extreme High Temperature Stability• Fibers Stabilized with ~10 wt% Yttria• Low Thermal Conductivity• Can be Cemented with Zircar Zirconia
Cement Type ZR-CEM• Can be Surface Hardened with Zircar
Zirconia Rigidizer Type ZR-RIG• Pre-fired and Organic Free

Type FBD Boards, Discs and Cylinders are high strength, uniform, rigid, refractory structures composed of zirconia fibers stabilized with yttria. Type FBD is Zircar Zirconia's
strongest and most stable zirconia material. Type FBD is ideally suited for thermal insulation and protection applications under conditions of ultra-high temperatures and in varied
atmospheres. FBD has been high fired and is tightly bonded resulting in nearly dust freeuse. This tight bonding makes machining to tight tolerances possible.
FBD is dimensionally stable to 2000°C and can be used at higher temperatures in areas
where some sintering can be tolerated. FBD has good hot strength up to 1700°C and canbe used as a self supporting setter for loads equal to twice its own weight up to this temperature. It has exceptional resistance to oxidizing and reducing atmospheres at high temperatures. Zirconia does, however, lose a small amount of oxygen at very high temperatures in vacuum and inert or reducing atmospheres. Although this reaction results in acolor change from white to gray, other properties remain essentially unchanged and insulation effectiveness is not impaired.
FBD has exceptional resistance to most corrosive environments. It undergoes little attackby molten alkali metal chlorides and carbonates at temperatures as high as 700°C andwithstands aqueous solutions of alkali metal hydroxides at temperatures as high as 230°C.
FBD will tolerate exposure to inorganic acids at their boiling point for short lengths of time.
FBD contains no organic binders, produces no smoke or odor and undergoes no physicallydisruptive phase transitions when heated.
Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-DJanuary 2004
Page 1 of 6

Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBD
Shown below are SEM micrographs of FBD. The micrograph on the left is of the face of aboard and illustrates the serrated structure that is characteristic of all of our zirconia fibers.
It also shows how the tightly packed fibers are preferentially arranged parallel to the vacuum formed board face. This fiber orientation creates anisotropic behavior. Vacuum
formed ceramic fiber boards exhibit lower compressive strength and thermal conductivity
perpendicular to the fiber plane while shrinkage is greater. Standard FBD boards anddiscs have the fiber plane parallel to their faces. Standard FBD cylinders have the fibersaligned perpendicular to the radius of the cylinder. Custom cylinders and boards can bemade with fiber orientation as required for your application.
The micrograph on the right is an enlargement of the fiber that is highlighted by the whitebox in the micrograph on the left. This photo illustrates the highly sintered exterior and porous interior structure of the individual fibers. Because FBD is processed at a very hightemperature the individual fiber grains grow to be almost as large as the fiber diameter andmeld into a very smooth, highly sintered micro structure. The resulting FBD product is anunique fibrous ceramic material because of its high strength and ‘dust free’ nature
The very porous nature of Type FBD, including the porosity of the fibers themselves, isalso evident in the micrographs. This combination of open and closed porosity is unique toZircar zirconia fiber materials.

Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-D
January 2004
Page 2 of 6

Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBDCHEMICAL COMPOSITION
Zircar Zirconia’s Type FBD is nominally 90 wt% ZrO2 + HfO2 and 10 wt% Y2O3. 1 - 2 wt%
hafnia (HfO2,) occurs naturally with zirconia (ZrO2,) and does not affect performance. Only
the highest purity starting materials are used to make Type FBD minimizing trace oxides.
Trace Oxide

Typical Wt%

Trace Oxide

Typical Wt%

SiO2

0.12

Al2O30.01

TiO20.14

Na2O

0.01

CaO

0.09

SnO20.001

MgO

0.03

Cr2O30.0005

Fe2O30.04

Ag2O0.0005

MACHINING INFORMATION
Zirconia Type FBD has the consistency of hard chalk and should be dry machined withsolid carbide or carbide tipped tooling. Cutting wet is not recommended. For manual cutting, place the FBD part on a smooth clean surface and hold it in place with hand pressure.
When close tolerances are not required and the amount of cutting is limited, holes can bedrilled with a standard masonry bit or carbide grit hole saw powered by a hand held drilland boards can be cut with a carbide grit blade on a hack saw. If closer tolerances areneeded, holes can be drilled using carbide drills powered by a drill press and boards canbe cut with a composite or carbide tipped blade on a radial arm saw. Table saws are notrecommended without a carrier board since the motion of the material over the saw bed willtend to abrade away the material. For very close tolerances and large amounts of cutting,
CNC machining with solid carbide or carbide tipped tooling is recommended. High tool rotation rates and slow feed speeds are generally best. FBD boards can be held in place forCNC machining with a vacuum hold down set up. Hot glue can also be used to fixture FBD
and if applied sparingly will pull away from the machined part without breaking away material. Hot glue is best applied in small amounts and with the addition of some excess glueon the setter board which can act as a tab. The tab on the setter board can be grabbed
with a pliers and pulled to be made free of the setter and the FBD part.
Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-D
January 2004
Page 3 of 6

Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBDPROPERTIES & CHARACTERISTICS
Bulk Density, g/cc (pcf)

1.4 (90)

Porosity, %70Melting Point, ºC (ºF)

2590 (4694)

Flexural Strength, (Parallel to Thickness) MPa (psi)8.27 (1200)

Compressive Strength, (Parallel to Thickness), MPa (psi)@ 10% Compression

5.52 (800)

Outgassing in Vacuum

Nil

Dilatometric Softening Temperature, oC (oF) at 10psi

1400 (2552)

Thermal Expansion Coefficient RT - 1400oC (2552oF)(Perpendicular to Thickness)

10.7 x 10-6/C (6 x10-6/F)

Linear Shrinkage (Perpendicular to Thickness), %1 hour at 1650oC (3002oF)

0.0

24 hours at 1650oC (3002oF)

0.9

1/2 hour at 2000ºC (3632ºF)

2

Thermal Conductivity, (Parallel to Thickness)
W/mK (BTU/hr ft2 oF/inch) at 400oC (752oF)

0.24 (1.7)

W/mK (BTU/hr ft2 oF/inch) at 800oC (1472oF)

0.26 (1.9)

W/mK (BTU/hr ft2 oF/inch) at 1100oC (2012oF)

0.31 (2.1)

W/mK (BTU/hr ft2 oF/inch) at 1400oC (2552oF)

0.33 (2.3)

W/mK (BTU/hr ft2 oF/inch) at 1650oC (3002oF)

0.35 (2.5)

Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-D
January 2004
Page 4 of 6

Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBD
Application Information•FBD is used as self-supporting insulation in industrial furnaces operating up to 1700°
Celsius and as supported and back-up insulation in systems operating at much highertemperatures.

•FBD is used as protection sleeving in zirconia Oxygen / Carbon sensors.

•FBD insulation has been successfully used in Nuclear Meltdown Experiments•Zircar Zirconia Cement type ZR-CEM can be used to bond FBD boards and shapes
together to build up complex fixtures. Custom shapes can be easily machined.

Availability and Ordering Information
Zircar Zirconia Insulation Type FBD is available in standard sized Boards, Discs, and Cylinders which are listed below and on the following page with their ordering item number.
Please contact our Sales Department for Pricing and Availability.
•To order one of our standard sizes specify the Quantity you wish to order, Product
Type, Item #, and Size.
For example: 12 ea., FBD, Item # AD016, 10” x 10” x 1”

•Our forming process and machining capabilities allow for a wide variety of custom
parts to be made. Please contact us with your special requirements and we’ll be happy
to provide you with a quotation.

Standard Sizes

Item No.

Standard Sizes

Item No.

Board, 3” x 3” x 0.50” TK

AD001Board, 10” x 10” x 0.50” TK

AD017

Board, 3” x 3” x 0.75” TK

AD002

Board, 10” x 10” x 0.75” TK

AD018

Board, 3” x 3” x 1.00” TK

AD003

Board, 10” x 10” x 1.00” TK

AD016

Board, 6” x 6” x 0.50” TK

AD004

Disc, 6” DIA x 0.50” TK

AD301

Board, 6” x 6” x 0.75” TK

AD005

Disc, 6” DIA x 0.75” TK

AD302

Board, 6” x 6” x 1.00” TK

AD006

Disc, 6” DIA x 1.00” TK

AD303

Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-DJanuary 2004
Page 5 of 6

Zircar Zirconia, Inc.
“Manufacturer of the original ZIRCAR products” ©

ZIRCONIA BOARDS, DISCS & CYLINDERSTYPE FBD
STANDARD CYLINDER ORDERING ITEM NUMBERS
ID” x OD”

LengthID” x OD”

Length

2”

4”

6”

2”

4”

6”

0.5 X 0.75

AD5001AD5002

AD5003

2.0 X 4.0

AD501N

AD502

AD5020

0.5 X 1.0AD5004

AD5005AD5006

3.0 X 3.25

AD5021

AD5022

AD5023

0.5 X 1.5

AD5007AD5008AD5009

3.0 X 3.5

AD5024

AD5025

AD50260.75 X 1.0

AD500A

AD500B

AD500C

3.0 X 4.0

AD5027

AD5028AD50290.75 X 1.25

AD500D

AD500E

AD500F

3.0 X 5.0

AD502A

AD503

AD50300.75 X 1.75

AD500G

AD500H

AD500J

4.0 X 4.25

AD5031

AD5032

AD5033

1.0 X 1.25

AD500K

AD500L

AD500M

4.0 X 4.5

AD5034

AD5035

AD5036

1.0 X 1.5

AD500N

AD500P

AD500Q

4.0 X 5.0

AD5037

AD5038AD5039

1.0 X 2.0

AD500R

AD500S

AD500T

4.0 X 6.0

AD503A

AD504

AD5040

1.0 x 3.0

AD500V

AD501

AD5010

5.0 X 5.25

AD5041

AD5042

AD5043

1.5 X 1.75

AD5011

AD5012AD5013

5.0 X 5.5

AD5044

AD5045AD5046

1.5 X 2.0

AD5014AD5015AD5016

5.0 X 6.0

AD5047AD5048AD5049

1.5 X 2.5

AD5017AD5018AD5019

5.0 X 7.0

AD504A

AD504B

AD504C

1.5 X 3.5

AD501A

AD501B

AD501C

6.0 X 6.25

AD504DAD504E

AD504F

2.0 X 2.25

AD501DAD501E

AD501F

6.0 X 6.5

AD504G

AD504HAD504J

2.0 X 2.5

AD501G

AD501H

AD501J

6.0 X 7.0

AD504K

AD504LAD504M

2.0 X 3.0

AD501KAD501L

AD501M

6.0 X 8.0

AD504NAD504P

AD504QSTANDARD SIZE TOLERANCES
Boards and Discs: +/- 1/16” on Length, Width, Diameter and Thickness
Cylinders: +/- 1/16” on ID, OD and Length

Zircar Zirconia, Inc.
PO Box 287
Florida, NY 10921-0287
USA

Tel: 845-651-3040
Fax: 845-651-0074
email: sales@zircarzirconia.com
web: www.zircarzirconia.com

Product Data
Bulletin #A-D
January 2004
Page 6 of 6