ZIRCAR Refractory Composites, Inc. produces a comprehensive line of advanced high performance ceramic-ceramic composite materials and related products. Our materials are used around the world in the most demanding thermal, structural and electrical insulating applications ranging in temperatures from 600C(1112F) to 1650C(3002F). For over twenty-five years, we have been a problem-solver working with our customers to resolve their thermal management problems. We have developed products that have become industry standards for induction melting, forging and heat treating applications, investment casting, glass processing, hot pressing, as well as many high temperature electrical applications.

Refractory Sheet Type 100

A Case History


User: McDonnell Aircraft

Div. of McDonnell Douglas

St. Louis, Missouri U.S.A.

Application: Superplastic Forming/Diffusion Bonding of Titanium Aircraft Parts. In this process, metallic alloys are heated to 1650F-to a plastic state-then formed over a die.

How RS-100 is used: The steel box, which contains the forming die, is lined with RS-100. On the sidewalls: 1" thick RS-100 boards are machined and sandwiched into 5" wide x 18" tall wedges. Stainless steel wires and buttons are used to laminate the 1" boards together. The RS-100 wedges are placed along the perimeter of the box. For the floor: depending on which die is in use, thick layers of RS-100 are built up over a layer of lower density insulating board. Stainless steel wear surfaces are placed over the RS-100.

Benefits of using Refractory Sheet Type 100:

  • Before specifying RS-100, many die box linings of hydraulic refractories and 50 lb. Foam blocks were used. Each lining required casting or machining. The problem was that a forming temperature of 1650F, 300psi Argon gas pressure and dies weighing up to 1000 lbs. Combined to crush most other insulating products. RS-100 withstands these conditions, and holds the forming die in steady compression.
  • RS-100 helps to hold the die in place, which enhances proper forming of the alloy sheet.
  • According to Mr. Miles Zeller, Tooling Specialist at McDonnell Aircraft, "Refractory Sheet Type 100 is exhibiting extended life in the Superplastic Forming Process." He said "RS-100 has the strength at temperatures we require".
  • RS-100 is readily machinable with most standard tooling.


ZIRCAR Refractory Composites, Inc.

P.O. Box 489

Florida, NY, 10921 USA

Phone:  (845) 651-2200                          Fax: (845) 651-1515 
email: sales@zrci.com