Advanced Ceramic Materials

EMM 4410
Engineering Materials II
Advanced Ceramic Materials
By: Assoc. Prof. Dr. Azmah Hanim Mohamed Ariff
1
• Business Driven • Technology Oriented • Sustainable Development • Environmental Friendly
Main characteristic of ceramics

• Good strength under compression
• High melting temperatures
• High corrosion resistance
EMM 4410: Engineering Materials II 2

Applications

Properties of ceramics

Classification
Ceramic Materials
Glasses Clay Refractories Abrasives Cements Advanced

products ceramics
-optical -whiteware -bricks for -sandpaper -composites -engine
-composite -structural high T -cutting -structural rotors
reinforce (furnaces) -polishing valves
-containers/ Adapted from Fig. 13.1 and discussion in
bearings
household Section 13.2-8, Callister & Rethwisch 8e. -sensors

Ceramic Fabrication Methods (i)

GLASS PARTICULATE
FORMING FORMING CEMENTATION
• Blowing of Glass Bottles: • Pressing: plates, cheap glasses
Pressing
Gob
operation -- glass formed by application of
pressure
Parison -- mold is steel with graphite
mold lining
Compressed
• Fiber drawing:
air
Suspended
parison
Finishing
mold
Adapted from Fig. 13.8, Callister & Rethwisch 8e. (Fig. 13.8 is adapted from C.J.
EMM 4410: Engineering Materials II
wind up 6
Phillips, Glass: The Miracle Maker, Pittman Publishing Ltd., London.)
Sheet Glass Forming

• Sheet forming – continuous casting
– sheets are formed by floating the molten glass on a pool of molten
tin
Adapted from Fig. 13.9,

Callister & Rethwisch 8e. EMM 4410: Engineering Materials II 7
Glass Structure
• Basic Unit: Glass is noncrystalline (amorphous)
4- • Fused silica is SiO2 to which no
Si0 4 tetrahedron impurities have been added
Si 4+ • Other common glasses contain
O2- impurity ions such as Na+, Ca2+,
Al3+, and B3+
• Quartz is crystalline
Na +
SiO2:
Si 4+
O2-
(soda glass)
Callister & Rethwisch 8e.
Glass Properties
• Specific volume (1/r) vs Temperature (T):
• Crystalline materials:
Specific volume
-- crystallize at melting temp, Tm
-- have abrupt change in spec.
Supercooled Liquid
Liquid (disordered)
vol. at Tm
Glass • Glasses:
(amorphous solid)
-- do not crystallize
Crystalline -- change in slope in spec. vol. curve at
(i.e., ordered) solid
glass transition temperature, Tg
Tg Tm T -- transparent - no grain boundaries to
scatter light
Callister & Rethwisch 8e. EMM 4410: Engineering Materials II 9
Log Glass Viscosity vs. Temperature

• soda-lime glass: 70% SiO2
• Viscosity decreases with T balance Na2O (soda) & CaO (lime)
• borosilicate (Pyrex):
13% B2O3, 3.5% Na2O, 2.5% Al2O3
• Vycor: 96% SiO2, 4% B2O3
• fused silica: > 99.5 wt% SiO2
Viscosity [Pa-s]
14
10 strain point
annealing point
10 10
10 6 Working range:
glass-forming carried out
10 2
Tmelt Adapted from Fig. 13.7, Callister & Rethwisch
8e. (Fig. 13.7 is from E.B. Shand,
1 Engineering Glass, Modern Materials, Vol. 6,
200 600 1000 1400 1800 T(ºC) Academic Press, New York, 1968, p. 262.)
Heat Treating Glass
• Annealing:
-- removes internal stresses caused by uneven cooling.
• Tempering:
-- puts surface of glass part into compression
-- suppresses growth of cracks from surface scratches.
-- sequence:
before cooling initial cooling at room temp.
cooler compression
hot hot tension
cooler compression
-- Result: surface crack growth is suppressed.

*Laminated glass = Two
annealed glass pieces
sandwich a polymer
(polyvinyl butyral or
PVD). Eg. Car
windshields.


Ceramic Fabrication Methods (iia)
GLASS PARTICULATE CEMENTATION

FORMING FORMING
Hydroplastic forming:
• Mill (grind) and screen constituents: desired particle size
• Extrude this mass (e.g., into a brick)
Ao
container die holder
force Adapted from
ram billet extrusion Ad Fig. 12.8(c),
Callister &
container die Rethwisch 8e.
• Dry and fire the formed piece

Ceramic Fabrication Methods (iia)

FORMING FORMING
Slip casting:
• Mill (grind) and screen constituents: desired particle size
• Mix with water and other constituents to form slip
• Slip casting operation
pour slip absorb water pour slip drain “green
into mold into mold into mold mold ceramic” Adapted from Fig.
“green 13.12, Callister &
ceramic” Rethwisch 8e. (Fig.
13.12 is from W.D.
Kingery, Introduction
to Ceramics, John
Wiley and Sons,
Inc., 1960.)
solid component hollow component
• Dry and fire the cast piece

Typical Porcelain Composition
(50%) 1. Clay – e.g. kaolinite

(25%) 2. Filler – e.g. quartz (finely ground)
(25%) 3. Fluxing agent (Feldspar)
-- aluminosilicates plus K+, Na+, Ca+
-- upon firing - forms low-melting-temp. glass

Hydroplasticity of Clay
• Clay is inexpensive Shear
• When water is added to clay
-- water molecules fit in between
layered sheets charge
-- reduces degree of van der Waals neutral
bonding
-- when external forces applied – clay
particles free to move past one
weak van
another – becomes hydroplastic
der Waals
• Structure of bonding
4+
Kaolinite Clay: charge Si
3+
Adapted from Fig. 12.14, Callister & neutral Al
Rethwisch 8e. (Fig. 12.14 is adapted from -
W.E. Hauth, "Crystal Chemistry of
OH
2-
Ceramics", American Ceramic Society O
Bulletin, Vol. 30 (4), 1951, p. 140.)

Shear 17
Drying and Firing
• Drying: as water is removed - interparticle spacings decrease

– shrinkage .
Adapted from Fig.
13.13, Callister &
Rethwisch 8e. (Fig.
13.13 is from W.D.
Kingery, Introduction
to Ceramics, John
Wiley and Sons,
Inc., 1960.)
wet body partially dry completely dry
Drying too fast causes sample to warp or crack due to non-uniform shrinkage
micrograph of porcelain
Si02 particle
• Firing: (quartz)
-- heat treatment between glass formed
900-1400ºC around
the particle
-- vitrification: liquid glass forms
from clay and flux – flows
between SiO2 particles. (Flux 70mm
Adapted from Fig. 13.14, Callister & Rethwisch 8e.
lowers melting temperature). (Fig. 13.14 is courtesy H.G. Brinkies, Swinburne
University of Technology, Hawthorn Campus,
Hawthorn, Victoria, Australia.)
18
Ceramic Fabrication Methods (iib)

FORMING FORMING
Powder Pressing: used for both clay and non-clay compositions.
• Powder (plus binder) compacted by pressure in a mold

-- Uniaxial compression - compacted in single direction
-- Isostatic (hydrostatic) compression - pressure applied by
fluid - powder in rubber envelope (cold isostatic pressing
CIP)
-- Hot pressing - pressure + heat
-- HIP (Hot isostatic pressing)
Sintering
Sintering occurs during firing of a piece that has

been powder pressed
-- powder particles coalesce and reduction of pore size

Aluminum oxide powder: Callister & Rethwisch 8e.
-- sintered at 1700ºC Adapted from Fig. 13.17, Callister

for 6 minutes. & Rethwisch 8e. (Fig. 13.17 is from
W.D. Kingery, H.K. Bowen, and
D.R. Uhlmann, Introduction to
Ceramics, 2nd ed., John Wiley and
Sons, Inc., 1976, p. 483.)
15 mm
Tape Casting
• Thin sheets of green ceramic cast as flexible tape

• Used for integrated circuits and capacitors
• Slip = suspended ceramic particles + organic liquid
(contains binders, plasticizers)
Fig. 13.18, Callister &

Rethwisch 8e. 21
Ceramic Fabrication Methods (iii)

FORMING FORMING
• Hardening of a paste – paste formed by mixing cement
material with water
• Formation of rigid structures having varied and complex
shapes
• Hardening process – hydration (complex chemical
reactions involving water and cement particles)

Effect of processing on ceramic properties:

Porosity
- Pores can be interconnected or closed
- Apparent porosity measures interconnected pores and determine
permeability (ease of gas or liquid passing through the material)
- Formula for apparent porosity: [(Ww-Wd) / (Ww – Ws)] x 100
Wd = Weight of dry ceramic
Ws = Weight of ceramic in water
Ww = Weight of ceramic after removed from water
unit = gram and cm3
- True porosity include both interconnected and closed pores. Formula
True porosity = [(ρ – B) / ρ] x 100
B = Bulk density = Wd / (Ww – Ws) = weight of ceramic divide by volume
ρ = true density or specific gravity

Example
Silicon carbide particles are compacted and fired at a
high temperature to produce a strong ceramic shape. The
specific gravity of SiC is 3.2 g/cm3. The ceramic shape
subsequently is weighed when dry (360 g), after soaking
in water (385 g), and while suspended in water (224 g).
Calculate the apparent porosity, the true porosity and the
fraction of the pore volume that is closed.


What is it?
1- Switchable glass
2- Photochromatic lenses
3- Glass-ceramics (eg use. Cooking utensils, ceramic top for
stoves)
4- Basic refractories
5- Si-C sand papers for grinding and polishing
6- Portland cement
7- Glazes
8- Enamels
9- Sol-gel
10- Chemical-vapor deposition (CVD)
11- Joining of ceramic components. Is there any options?

Advanced Ceramic Materials

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Advanced Ceramic Materials

Uploaded by

Copyright:

Available Formats

EMM 4410

Main characteristic of ceramics

EMM 4410: Engineering Materials II 2

EMM 4410: Engineering Materials II 3

EMM 4410: Engineering Materials II 4

Glasses Clay Refractories Abrasives Cements Advanced

EMM 4410: Engineering Materials II 5

Ceramic Fabrication Methods (i)

Sheet Glass Forming

Adapted from Fig. 13.9,

Log Glass Viscosity vs. Temperature

-- Result: surface crack growth is suppressed.

EMM 4410: Engineering Materials II 12

EMM 4410: Engineering Materials II 13

Ceramic Fabrication Methods (iia)

GLASS PARTICULATE CEMENTATION

• Dry and fire the formed piece

• Business Driven • Technology Oriented • Sustainable Development • Environmental Friendly

GLASS PARTICULATE CEMENTATION

• Dry and fire the cast piece

Typical Porcelain Composition

(50%) 1. Clay – e.g. kaolinite

EMM 4410: Engineering Materials II 16

EMM 4410: Engineering Materials II

• Drying: as water is removed - interparticle spacings decrease

Ceramic Fabrication Methods (iib)

GLASS PARTICULATE CEMENTATION

• Powder (plus binder) compacted by pressure in a mold

Sintering occurs during firing of a piece that has

Adapted from Fig. 13.16,

-- sintered at 1700ºC Adapted from Fig. 13.17, Callister

• Thin sheets of green ceramic cast as flexible tape

Fig. 13.18, Callister &

Ceramic Fabrication Methods (iii)

GLASS PARTICULATE CEMENTATION

EMM 4410: Engineering Materials II 22

Effect of processing on ceramic properties:

EMM 4410: Engineering Materials II 23

EMM 4410: Engineering Materials II 24

EMM 4410: Engineering Materials II 25

EMM 4410: Engineering Materials II 26

EMM 4410: Engineering Materials II 27

You might also like