What is the Difference Between 96% and 99% Aluminum Oxide in Ceramic PCBs?

What is the Difference Between 96% and 99% Aluminum Oxide in Ceramic PCBs?

When it comes to designing high-performance electronic devices, choosing the right materials is crucial. Among the various options available, Aluminum Oxide (Al2O3) stands out as an excellent choice for ceramic printed circuit boards (PCBs) due to its exceptional thermal and electrical properties. However, not all Aluminum Oxide is created equal! In this comprehensive guide, we will delve into the nuances of two common variants: 96% Aluminum Oxide and 99% Aluminum Oxide.

Whether you're an electronics enthusiast, a professional engineer, or a curious learner, understanding the differences between these two materials will enable you to make informed decisions while designing and manufacturing ceramic PCBs.

So, without further ado, let's explore the unique characteristics and advantages of each variant!

What is Aluminum Oxide, and Why is it Used in Ceramic PCBs?

Alumina ceramic substrates primarily consist of alumina, a white amorphous powder commonly known as aluminum oxide or short for Al2O3. It boasts a density of 3.9-4.0g/cm3, a melting point of 2050℃, and a boiling point of 2980℃. Alumina is insoluble in water and exhibits excellent properties in various applications.

Ordinary alumina ceramics are categorized based on their Al2O3 content, including 99%, 95%, 90%, 96%, 85%, and sometimes 80% or 75% alumina variants. The 99% alumina variety refers to alumina with a purity of 99.5% or 99.8%. It comes in white or ivory colors and exhibits exceptional attributes such as high abrasion resistance, resistance to acid and alkali corrosion, and excellent performance under high temperatures (1600-1700 degrees Celsius). Additionally, it demonstrates good chemical stability, high electrical insulation, strong adsorption capabilities, and wear-resistant properties. Consequently, it is widely used in diverse applications, including lamps, electronic appliances, sandblasting nozzles, auto parts, and wear-resistant components.

On the other hand, 96% alumina contains a slightly lower purity than 99% alumina but remains cost-effective while offering good thermal conductivity and insulation properties.

96% Aluminum Oxide vs 99% Aluminum Oxide

Now that we have a brief overview, let's shift our focus to the main question at hand: What sets 96% and 99% Aluminum Oxide apart in the realm of ceramic PCBs?

Ⅰ. 96% Aluminum Oxide

As its name suggests, 96% Aluminum Oxide is made up of 96% pure alumina and 4% other trace elements. This type is widely used in various electronic applications due to its balanced properties and cost-effectiveness. Below are some typic properties of it.

- Thermal Conductivity: Decent thermal conductivity allows for effective heat dissipation from high-power components.

- Dielectric Strength: Satisfactory dielectric strength ensures reliable insulation between conducting traces on the PCB.

- Mechanical Strength: Its robust nature contributes to the overall mechanical integrity of ceramic PCBs.

- Cost-Effectiveness: Compared to its higher-purity counterpart, 96% Aluminum Oxide is more budget-friendly, making it an attractive choice for cost-sensitive projects.

Ⅱ. 99% Aluminum Oxide

In comparison to 96% alumina, 99% Aluminum Oxide stands out as a premium variant boasting an impressive 99% purity level, accompanied by minimal impurities. It finds application in the most demanding scenarios where exceptional mechanical, electrical, thermal, or corrosion-resistant properties are essential.

Here are the key advantages of 99% Aluminum Oxide:

- Uniform Heating and Fast Heat Dissipation: With its excellent thermal conductivity of 96% alumina, 99% Aluminum Oxide ensures uniform heating throughout the material, contributing to efficient heat dissipation. This feature is particularly valuable for devices that generate substantial heat during operation.

- Simple and Compact Structure with Small Volume: The material's inherent characteristics allow for a simple and compact design, leading to smaller device volumes. This advantage is especially crucial for space-constrained applications.

- Flat and Smooth Surface with High Strength: 99% Aluminum Oxide boasts a flat and smooth surface, which enhances its mechanical strength. This ensures that the material remains robust and less susceptible to damage during use.

- Acid and Alkali Corrosion Resistance, Durable: Due to its high purity, 99% Aluminum Oxide exhibits excellent resistance to corrosion by acids and alkalis, ensuring the longevity and durability of the material in corrosive environments.

- Precision and Stability: The higher purity of 99% Aluminum Oxide results in better precision and stability across various electrical properties. This characteristic is particularly advantageous for high-precision electronic applications that demand consistent and reliable performance.

What Sets Them Apart? A Side-by-Side Comparison

Now that we've examined the individual properties, let's put 96% and 99% Aluminum Oxide head-to-head in a side-by-side comparison to highlight their differences. Here's a handy table to make things crystal clear:

How to Choose the Right Material for Our Ceramic PCB?

Selecting the appropriate Aluminum Oxide material for your ceramic PCB depends on several factors, including project requirements, budget constraints, and device design.

1. Project Requirements:

Clearly define your project requirements. Assess the power demands, voltage requirements, and temperature conditions of electronic components in your project. If you need exceptional thermal conductivity and high dielectric strength, 99% Aluminum Oxide may be the better choice. For low to medium power requirements, 96% Aluminum Oxide can provide stable and cost-effective performance.

2. Budget Constraints:

Budget plays a crucial role in material selection. While 99% Aluminum Oxide offers excellent performance, it is also more expensive than 96% Aluminum Oxide. When choosing materials, balance project requirements with available budget to ensure the best value for money.

3. Device Design:

If your device involves multiple functional zones, each with different material performance requirements, dividing the PCB into regions with different purity Aluminum Oxide is a viable option. Use 99% Aluminum Oxide in areas requiring high performance, while using 96% Aluminum Oxide in other regions where performance demands are lower.

Now you should have a better understanding to 96% and 99% alumina ceramic substrate, so, whether you're building high-power electronics or intricate precision instruments, remember that the right choice of Aluminum Oxide can make all the difference in the success of your endeavor! Or if you have any other questions about this, welcome to leave your comments below or e-mail us at sales@bstceramicpcb.com  Happy engineering!