Applications and Industries Driving the Growth of Super-Hard Materials

Super-hard materials are materials that have a hardness value exceeding 40 gigapascals (GPa) when measured by the Vickers hardness test. They are highly desirable for their ability to resist deformation, wear, and fracture, and to maintain their properties at high temperatures and pressures. Super-hard materials have a wide range of applications in various industries, such as automotive, aerospace and defense, electronics and semiconductor, healthcare and medical devices, and energy. In this blog post, we will explore how these industries use super-hard materials to enhance their products and processes, and what are the challenges and opportunities for the future of this market.

The global super-hard materials market size stood at a value of around USD 6.28 billion in 2023. The market is further expected to grow in the forecast period of 2024-2032 at a CAGR of 5.7% to reach about USD 10.33 billion by 2032. The major factors driving the growth of this market are the increasing demand for high-performance materials in various end-use industries, the technological advancements in the synthesis and processing of super-hard materials, and the rising awareness about the environmental and economic benefits of using super-hard materials.

Overview of Super-Hard Materials

Super-hard materials are classified into two categories: natural and synthetic. Natural super-hard materials include diamond and cubic boron nitride (c-BN), which are the hardest known materials in nature. Synthetic super-hard materials are artificially created by using high-pressure and high-temperature (HPHT) or chemical vapor deposition (CVD) methods, or by doping or coating natural super-hard materials with other elements. Some examples of synthetic super-hard materials are polycrystalline diamond (PCD), polycrystalline cubic boron nitride (PCBN), diamond-like carbon (DLC), and boron nitride nanotubes (BNNTs).

Super-hard materials have several characteristics that make them suitable for various applications. Some of these characteristics are:

High hardness and wear resistance: Super-hard materials can withstand high mechanical stresses and abrasive forces without deforming or breaking. They can also reduce friction and prevent material loss due to wear and tear.
High thermal conductivity and stability: Super-hard materials can conduct heat efficiently and resist thermal expansion and contraction. They can also maintain their properties at high temperatures and pressures, which are common in many industrial processes.
High electrical resistivity and optical transparency: Super-hard materials can act as insulators and prevent electrical currents from flowing through them. They can also transmit light without absorbing or reflecting it, which makes them useful for optical applications.
High chemical inertness and biocompatibility: Super-hard materials can resist corrosion and oxidation by various chemicals and fluids. They can also interact with biological tissues and fluids without causing adverse reactions or infections.

Automotive Industry

The automotive industry is one of the largest consumers of super-hard materials, especially diamond and its derivatives. Super-hard materials are used in various components and parts of vehicles, such as engines, transmissions, brakes, suspensions, tires, and exhaust systems. Some of the benefits of using super-hard materials in the automotive industry are:

Improving vehicle performance and fuel efficiency: Super-hard materials can reduce friction and wear in the engine and transmission, which can improve the power output and fuel economy of the vehicle. They can also enhance the braking and steering performance by increasing the grip and durability of the tires and the brake pads.
Reducing emissions and noise: Super-hard materials can lower the emissions of harmful gases and particles from the exhaust system by improving the combustion and catalytic processes. They can also reduce the noise and vibration generated by the engine and other parts of the vehicle by absorbing and damping the sound waves.
Increasing safety and reliability: Super-hard materials can increase the safety and reliability of the vehicle by preventing the failure and malfunction of critical components and parts. They can also withstand harsh environmental conditions and extreme temperatures and pressures, which can extend the lifespan and service intervals of the vehicle.

Some examples of super-hard materials used in the automotive industry are:

PCD and PCBN: These are composite materials made of diamond or c-BN grains bonded by a metal or ceramic matrix. They are used as cutting tools, inserts, and abrasives for machining and grinding various metals and alloys used in the automotive industry. They are also used as coatings for engine parts, such as pistons, cylinders, valves, and bearings, to improve their wear resistance and thermal conductivity.
DLC: This is a thin film of amorphous carbon that has diamond-like properties. It is used as a coating for various components and parts of the vehicle, such as camshafts, fuel injectors, gears, and pumps, to reduce friction and wear, and to increase corrosion resistance and hardness.
Diamond wire: This is a wire coated with diamond particles that is used for cutting and slicing various materials, such as silicon, sapphire, and glass, used in the automotive industry. It is also used for cutting and shaping carbon fiber reinforced plastics (CFRP), which are lightweight and strong materials used for making the body and chassis of the vehicle.

Aerospace and Defense Sector

The aerospace and defense sector is another major user of super-hard materials, especially c-BN and its derivatives. Super-hard materials are used in various components and structures of aircraft, rockets, satellites, and missiles, such as engines, turbines, blades, nozzles, and heat shields. Some of the advantages of using super-hard materials in the aerospace and defense sector are:

Enhancing aerodynamics and propulsion: Super-hard materials can improve the aerodynamics and propulsion of the aircraft and rockets by reducing drag and increasing thrust. They can also withstand the high temperatures and pressures generated by the combustion and supersonic flight.
Increasing durability and survivability: Super-hard materials can increase the durability and survivability of the aircraft and rockets by resisting deformation, cracking, and erosion caused by the impact of foreign objects, such as birds, debris, and projectiles. They can also protect the components and structures from the thermal and mechanical shocks caused by the launch and re-entry.
Improving performance and accuracy: Super-hard materials can improve the performance and accuracy of the aircraft and rockets by enhancing the stability and control of the flight. They can also improve the guidance and navigation systems by providing high-precision sensors and actuators.

Some examples of super-hard materials used in the aerospace and defense sector are:

PCBN and BNNTs: These are composite materials made of c-BN grains bonded by a metal or ceramic matrix, or nanotubes made of c-BN. They are used as cutting tools, inserts, and abrasives for machining and grinding various metals and alloys used in the aerospace and defense sector. They are also used as coatings for engine parts, such as turbines, blades, and nozzles, to improve their wear resistance and thermal stability.
c-BN and h-BN: These are crystalline forms of boron nitride that have different structures and properties. c-BN is similar to diamond in hardness and thermal conductivity, while h-BN is similar to graphite in lubricity and electrical conductivity. They are used as additives and fillers for various materials, such as ceramics, polymers, and composites, used in the aerospace and defense sector. They are also used as thermal insulators and lubricants for various components and structures, such as heat shields, bearings, and seals.
Diamond and diamond composites: These are materials made of diamond or diamond grains bonded by a metal or ceramic matrix. They are used as cutting tools, inserts, and abrasives for machining and grinding various materials, such as ceramics, composites, and superalloys, used in the aerospace and defense sector. They are also used as coatings for various components and structures, such as sensors, actuators, and optical devices, to improve their hardness, corrosion resistance, and optical transparency.

Electronics and Semiconductor Industry

The electronics and semiconductor industry is another important consumer of super-hard materials, especially diamond and its derivatives. Super-hard materials are used in various processes and products of the electronics and semiconductor industry, such as lithography, etching, polishing, packaging, and testing. Some of the benefits of using super-hard materials in the electronics and semiconductor industry are:

Increasing productivity and quality: Super-hard materials can increase the productivity and quality of the electronics and semiconductor industry by enabling faster and more precise fabrication and processing of various materials, such as silicon, germanium, gallium arsenide, and silicon carbide, used in the electronics and semiconductor industry. They can also reduce the defects and failures caused by the wear and damage of the tools and equipment.
Advancing technology and miniaturization: Super-hard materials can advance the technology and miniaturization of the electronics and semiconductor industry by enabling the development of new and improved devices and components, such as transistors, diodes, lasers, LEDs, and solar cells, that have higher performance, lower power consumption, and smaller size. They can also enable the integration of various functions and features, such as sensing, communication, and computation, into a single device or component.
Improving reliability and durability: Super-hard materials can improve the reliability and durability of the electronics and semiconductor industry by enhancing the resistance and stability of the devices and components to various environmental and operational factors, such as temperature, humidity, pressure, radiation, and electromagnetic interference. They can also extend the lifespan and service intervals of the devices and components by preventing the degradation and deterioration caused by the oxidation, corrosion, and wear.

Some examples of super-hard materials used in the electronics and semiconductor industry are:

Diamond and diamond composites: These are materials made of diamond or diamond grains bonded by a metal or ceramic matrix. They are used as cutting tools, inserts, and abrasives for machining and grinding various materials, such as silicon, germanium, gallium arsenide, and silicon carbide, used in the electronics and semiconductor industry. They are also used as coatings for various devices and components, such as transistors, diodes, lasers, LEDs, and solar cells, to improve their hardness, corrosion resistance, and optical transparency.
DLC and diamond-like nanocomposites: These are thin films of amorphous carbon or nanocomposites of amorphous carbon and other elements that have diamond-like properties. They are used as coatings for various devices and components, such as sensors, actuators, and optical devices, to reduce friction and wear, and to increase hardness, corrosion resistance, and optical transparency.
Diamond wire and diamond slurry: These are wires coated with diamond particles or slurries containing diamond particles that are used for cutting and slicing various materials, such as silicon, sapphire, and glass, used in the electronics and semiconductor industry. They are also used for polishing and planarizing the surfaces of the devices and components to improve their smoothness and flatness.