Beruflich Dokumente
Kultur Dokumente
Ceramic Materials
Content
What are ceramics?
Types of ceramics
Structure and bonding
Properties of ceramics
Processing of ceramics
Applications
Modern trends
The Word Ceramics
a. Traditional Ceramics
b. Engineering Ceramics
Traditional Ceramics:
Traditional ceramics include clay
products, silicate glass and cement
Engineering Ceramics:
They consist of carbides (SiC), pure
oxides (Al2O3), nitrides (Si3N4), non-silicate
glasses and many others
Structure and Bonding
Ceramic materials are inorganic compounds consisting of
metallic and non-metallic elements which are held
together with ionic and/or covalent bonds.
Where:
XA = Electro-negativity of A element
XB = Electro-negativity of B element
Example
Calculate ionic and covalent characters of CaF2 and SiC
H CaF 2: Large He
2.1 -
Li Be C F Ne
1.0 1.5 SiC: Small 2.5 4.0 -
Na Mg Si Cl Ar
0.9 1.2 1.8 3.0 -
K Ca Ti Cr Fe Ni Zn As Br Kr
0.8 1.0 1.5 1.6 1.8 1.8 1.8 2.0 2.8 -
Rb Sr I Xe
0.8 1.0 2.5 -
Cs Ba At Rn
0.7 0.9 2.2 -
Fr Ra
0.7 0.9 Table of Electronegativities
For CaF2
Using formula:
Percentage of ionic character = {1 – exp[-0.25(XA-
XB)2]}x100
= {1 – exp[-0.25(1-4)2]}x100
= {1 – exp[-0.25(3)2]}x100
= {1 – exp[-2.25]}x100
= {1 – 0.105}x100
= 89.5%
So Percentage of covalent character = 10.5%
For SiC
Using formula:
Percentage of ionic character = {1 – exp[-0.25(XA-
XB)2]}x100
= {1 – exp[-0.25(2.5-1.8)2]}x100
= {1 – exp[-0.25(0.7)2]}x100
= {1 – exp[-0.1225]}x100
= {1 – 0.88}x100
= 12%
So Percentage of covalent character = 88%
Properties of Ceramics
Of oxide ceramics
Oxidation resistant
Chemically inert
Electrically insulating
Generally low thermal conductivity
Of other compounds ceramics
Low oxidation resistance
Extreme hardness
Chemically inert
High thermal and electrical conductivity
High melting points of ceramics
Si3N4 1750-1900ºC
Al2O3 2050ºC
SiC 2300-2500ºC
ZrO2 2500-2600ºC
WC 2775ºC
ThO2 3300ºC
HfO2 3890ºC
High hardness of ceramics
ZrO2 NaCl
Grain boundary structure
Typical grain size of ZrO2
Processing of Ceramics
Raw materials selection criteria
Powder sizing
Pre-consolidation
Shape forming processes
– Pressing
– Casting
– Plastic forming
– Other forming processes
Sintering
Final machining
Quality control
Non-destructive testing
Raw material selection criteria
Purity
– Effect of any impurity depends upon chemistry of both matrix
material and the impurity, distribution of impurity and service
conditions. Example of Ca in Si3N4.
– It effects high temperature properties of the ceramic material.
Particle size and reactivity
– Consolidation/shaping depends upon particle size and its
distribution. Explanation.
– Reactivity of ceramic powder play an important role during
sintering (of the compacted shape).
Polymorphic form
– Polymorphic transformations can play an important role in the
sintering operations. Example of Si3N4 and SiC
Powder Sizing
Screening
Air classification
Elutriation
Ball milling
Attrition milling
Vibratory milling
Fluid energy milling
Hammer milling
Precipitation
Freeze drying
Laser
Plasma
Calcining
Pre-consolidation
These are special treatments done before
compacting/consolidation
Organic Inorganic
Casting
– Slip casting
– Thixotropic casting
– Soluble mold casting
Shape forming processes (Cont)
Plastic forming
– Extrusion
– Injection moulding
– Transfer moulding
– Compression moulding
Others
– Tape forming
– Flame spray
– Green machining
Processes for shaping crystalline ceramics: (a) pressing,
(b) isostatic pressing, (c) extrusion, (d) jiggering, and (e)
slip casting.
©2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.
Sintering
The densification of a particulate ceramic compact is
technically referred to as sintering
Sintering is essentially a removal of the pores between
the starting particles, combined with growth together
and strong bonding between adjacent particles
The following criteria must be met before sintering can
occur:
– A mechanism for material transport must be present
– A source of energy to activate and sustain this
material transport must be present
Sintering Mechanism
Sintering can occur by a variety of mechanisms. The
main mechanisms are:
©2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.
Effect of sintering temperature on density
Effect of sintering time on density
Joining Ceramics
Final Machining
The tool must have higher hardness than the ceramic being
machined
Functions:
– Act as flux (promoting fusion) during heating
– Increase fluidity in molten glass for processing
– Improve chemical resistance against attack by acids,
basic substances, or water
– Add color to the glass
– Alter index of refraction for optical applications
Glass Products
Window glass
Containers – cups, jars, bottles
Light bulbs
Laboratory glassware – flasks, beakers, glass tubing
Glass fibers – insulation, fiber optics
Optical glasses - lenses
Glass‑Ceramics
A ceramic material produced by conversion of glass into
a polycrystalline structure through heat treatment
Ceramic Rotor
Candidate Materials for
Turbocharger
CONCLUSION
In the past few decades Ceramics
materials have over powered many
metallic and polymeric materials due to
their superior and wide range of
properties.
With times to come they will gain more
and more importance and the coming
time will bring a revolutionary era in this
fascinating material.
BACK
Example of Si3N4 & SiC
BACK
BACK
BACK
BACK
BACK
BACK
BACK
BACK
BACK
BACK
Schematic of a tape casting machine. (Source: From
Principles of Ceramics Processing, Second Edition, by
J.S. Reed, p. 532, Fig. 26-6. Copyright © 1995 John
Wiley & Sons, Inc. Reprinted by permission.)
BACK
BACK
Ceramic - Composite Armor
Ceramic armor systems are used to protect military personnel
and equipment.
Advantage: low density of the material can lead to weight
efficient armor systems.
Typical ceramic materials used in armor systems include
alumina, boron carbide, silicon carbide, and titanium diboride.
The ceramic material is discontinuous and is sandwiched
between a more ductile outer and inner skin.
The outer skin must be hard enough to shatter the projectile.
Most of the impact energy is absorbed by the fracturing of the
ceramic and any remaining kinetic energy is absorbed by the
inner skin, that also serves to contain the fragments of the
ceramic and the projectile preventing severe impact with the
personnel/equipment being protected. (as shown in diagram)
Ceramic - Composite Armor
Ceramic-
Outer hard Discontinuous
skin
Projectile
Personnel
and
Equipment
Inner
ductile
skin
Zimmer HA coated
Plasma Spray HA coating on Dental APR® Hip Stem
Implants (Sun et al., 2001)
BACK
Ceramic in medical (Bio-ceramics)
Zimmer PureForm
Ceramic Crowns Ceramic Copings Zinc Phosphate
Dental Cements
BACK
All the material presented
in this presentation is
included in the course.
Thank you