Fakultas Teknik

Program Studi Teknik Mesin

Ceramics

Sofyan Djamil
 Fundamentals of ceramics
• Ceramics (ceramic materials) are non-metallic
inorganic compounds formed from metallic
(Al, Mg, Na, Ti, W) or semi-metallic (Si, B) and
non-metallic (O, N, C) elements.
• Atoms of the elements are held together in a
ceramic structure by one of the following
bonding mechanism: Ionic Bonding, Covalent
Bonding, Mixed Bonding (Ionic-Covalent).
Bonding of ceramics
Bonding 0f ceramics
 Bonding 0f ceramics
Ionic-Covalent (mixed) Bonding
• Ionic-covalent (mixed) bonding with various
ratios of the two fractions (ionic and covalent)
occurs in most of ceramic materials.
General classification of ceramics
Composition base classification of ceramic materials
 Methods of shape forming ceramic powders
The following techniques are involved in forming
ceramic powders into a desired shape:

Uniaxial (Die) Pressing

Isostatic Pressing
Injection Molding
Extrusion
Slip Casting
Gel Casting
Tape Casting
Methods of shape forming ceramic powders
Methods of shape forming ceramic powders
Methods of shape forming ceramic
powders
Methods of shape forming ceramic
powders
 Sintering of ceramics
Sintering (Firing) of ceramic
materials is the method involving
consolidation of ceramic powder
particles by heating the “green”
compact part to a high
temperature below the melting
point, when the material of the
separate particles difuse to the
neghbouring powder particles.
Ceramic properties and tests
Ceramic properties and tests
 Oxide ceramics
1.Alumina ceramics
• Alumina (aluminum oxide) is the most
important, widely used .
• The technical alumina ceramics contain at
least 80% of aluminum oxide (AL2O3).
• Small amounts of silica (SiO2), magnesia
(MgO) and zirconia (ZrO2) may be added to
alumina ceramics.
• Addition of zirconia to alumina ceramic
results in considerable increase of the
material fracture toughness.
Alumina possesses strong ionic bonding,
which determines the material properties:
• High mechanical strength (flexural strength)
and hardness;
• High wear resistance;
• High resistance to chemical attacks of
strong acids and alkali even at high
temperatures;
• High stiffness;
• Excellent insulating properties;
• Low coefficient of thermal expansion;
• Good fracture toughness;
• Good thermal conductivity;
• Aluminum ceramics parts are manufactured by
the following technologies: uniaxial (die)
pressing, isostatic pressing, injection molding,
extrusion and slip casting. The parts may be
machined in "green" condition before sintering
(firing).
• Aluminum ceramics are widely used in
electronics and electrical engineering,
metallurgical processes, chemical
technologies, medical technologies,
mechanical engineering, military equipment.
• Aluminum ceramics are used for manufacturing
insulators, capacitors, resistors, furnace tubes,
sealing refractory parts, foundry shapes, wear
pads, thermocouple protection tubes, cutting
tools and polishing/grinding powders, ballistic
armor, laboratory equipment, bio-ceramic parts
for orthopedic and dental surgery.
Properties of some alumina ceramics
• (Materials Data)
• Alumina ceramic (94% alumina)
• Alumina ceramic (97.5% alumina)
• Alumina ceramic (99.8% alumina)
2.Magnesia ceramics
• Magnesia Ceramic is a ceramic material consisting
of at least 90% of Magnesium Oxide (MgO).
• Magnesium Oxide is produced from natural
minerals such as magnesite (magnesium
carbonate), magnesium chloride rich brine, and
seawater.
• Magnesia is characterized by high melting
temperature 5070 ºF (2800 ºC) and high thermal
and chemical stability, therefore it is widely used
in refractory applications.
• Magnesia ceramics are stable up to 4170 ºF (2300
ºC) in oxidizing atmosphere and up to 3090 ºF
(1700 ºC) in reducing atmosphere.
Magnesia ceramics possess the following
properties:
• High thermal stability;
• High resistance to molten metals (iron, steel,
aluminum), slags and semiconductor
compounds;
• Good corrosion resistance even at high
temperatures;
• Good insulating properties;
• Good thermal conductivity;
• Magnesia ceramics are used for
manufacturing high temperature
crucibles, thermocouple tubes,
heating elements, linsulators, steel
making refractories, kiln furniture.
3. Zirconia ceramics

Zirconia Ceramic is a ceramic material

consisting of at least 90% of Zirconium
Dioxide (ZrO2).
Zirconium Oxide is produced from
natural minerals such as Baddeleyite
(zirconium oxide) or zirconium silicate
sand.
The following characteristics are typical for
Zirconia Ceramics:
• High density – up to 380 lb/ft³ (6.1*10³ kg/m³);
• Low thermal conductivity – 10% of that of
alumina ceramics;
• High fracture toughness;
• Very high flexural strength and hardness;
• High maximum service temperature – up to
4350 ºF (2400 ºC).
• High chemical resistance;
• High resistance to molten metals;
• Good wear resistance;
• Zirconia ceramics are used for manufacturing
Extrusion dies, powder compacting dies,
cutting tools, balls and seats for ball
valves, pump seals, impellers and shaft
guides, engine parts, oxygen sensors, fuel
cells membranes,high temperature
heaters for electric furnaces, bearings for
submersible pumps.
4. Aluminum titanate ceramics
• Aluminum titanate is a ceramic material
consisting of a mixture of alumina (Al2O3) and
titania (TiO2) forming solid solution
• Aluminium titanate is prepared by heating of
a mixture of alumina and titania at
temperature above 2460°F (1350°C).
• The powder is then sintered at a temperature
in the range 2550 - 2910°F (1400 - 1600°C) in
air atmosphere.
The following characteristics are typical for
Aluminum Titanate Ceramics:
• Low coefficient of thermal expansion.
• Low Modulus of Elasticity.
• High Thermal Shock Resistance.
• Low Thermal Conductivity.
• Good chemical resistance.
• Good wear resistance.
• Aluminum Titanate ceramic materials
ceramics are used for manufacturing :
crucibles, nozzles, thermocouples for non-
ferrous metallurgy, cylinder liners in
automotive engines.
 Non-oxide ceramics
1. Carbide ceramics
• The most important carbide ceramic is Silicon
Carbide (SiC).
• Silicon Carbide materials are produced by in
either porous or dense form and by using
different technological methods:
Open Porous Silicon Carbides
Dense Silicon Carbides
Properties of some silicon carbide ceramics
2. Nitride Bonded Silicon Carbide (NSC)
• Nitride Bonded Silicon Carbide ceramics are
produced from a mixture of silicon carbide
and silicon powders
• Nitride Bonded Silicon Carbide materials
possess better corrosion resistance and
higher mechanical strength
3. Dense Silicon Carbides
• Liquid Phase Sintered Silicon Carbide (LPSC)
• Liquid Phase Sintered Silicon Carbideceramics
are produced from a mixture of silicon carbide
and oxides powders, which is sintered at a
temperature above 3630 ºF (2000 ºC) and
under high pressure up to 4400 psi (30 MPa).
• Fine Grain structure and absence of pores
provide high mechanical strength and fracture
toughness of the material.
4. Reaction Bonded Silicon Infiltrated Silicon
Carbide (SSC)
• Reaction Bonded Silicon Infiltrated Silicon
Carbide ceramics are produced from a mixture
of silicon carbide and carbon powders
• The material possesses high mechanical
strength, corrosion, wear and thermal shock
resistance at temperatures below 2515 ºF (1380
ºC).
5. Hot Pressed Silicon Carbide (HPSC)
• Hot Pressed and hot isostatically pressed Silicon
Carbide ceramics are produced under pressure
up 2000 atm. and they possess high mechanical
strength.
6. Sintered Silicon Carbide (SSIC)
• Sintered Silicon Carbide ceramics are
produced by conventional sintering
technique under natural pressure of inert gas
atmosphere and at temperatures 3630-4000
ºF (2000-2200 ºC).
• The material possesses high corrosion
resistance and high hardness and mechanical
strength up to 2900 ºF (1600 ºC).
The following characteristics are typical for the
most of Silicon Carbide Ceramics:
• Low density;
• High mechanical strength and hardness;
• Good high temperature strength;
• Good oxidation and corrosion resistance even at
high temperatures;
• Excellent thermal shock resistance;
• Good wear resistance;
• Low coefficient of thermal expansion;
• High thermal conductivity;
• Semi-conducting properties.
• Silicon Carbide ceramics are used for
manufacturing :
melting crucibles, kiln furniture, heat
exchangers, burner nozzles, sealing rings for
pumps, milling balls, wear plates, heating
elements.
 Nitride ceramics
The following groups of materials relate Nitride
ceramics:
 Silicon Nitride
 Gas Pressure Sintered Silicon Nitride (GPSSN)
 Low Pressure Sintered Silicon Nitride (SSN)
 Hot Pressed Silicon Nitride (HPSN)
 Reaction Bonded Silicon Nitride (RBSN)
 Aluminum Nitride
 Silicon Aluminum Oxynitride (SIALON)
 Properties of some nitride ceramics
1. Silicon Nitride
• Silicon Nitride (Si3N4) is the most important
nitride ceramic.
• Silicon Nitride ceramics are produced from a
mixture of fine sub-micron powder of Silicon
Nitride and binders (oxides). The powder is
compacted and then sintered at 3400 °F
(1870°C).
2. Gas Pressure Sintered Silicon Nitride
(GPSSN)
• In order to prevent decomposition of
Silicon Nitride sintering is conducted in
the atmosphere of Nitrogen under
increased pressure (up to 100 atm.).
3. Low Pressure Sintered Silicon Nitride (SSN)
• If sintering is conducted under normal
nitrogen pressure some of Silicon Nitride
decomposes forming metallic silicon (Si).
4. Hot Pressed Silicon Nitride (HPSN)
• Uniaxial (die) pressing or Isostatic pressing
techniques under pressure up to 2000 atm.
are used for manufacturing dense high
strength Silicon Nitride parts.
• The process application is limited by its
relatively high cost.
5. Reaction Bonded Silicon Nitride (RBSN)
• Reaction Bonded Silicon Nitride ceramics are
produced from metallic silicon powder by
sintering it in nitrogen atmosphere at 2550°F
(1400°C).
• The material is characterized by low density
and low oxidation resistance due to high
open porosity.
The following characteristics are typical for
Silicon Nitride ceramics:
• High fracture toughness;
• High mechanical strength and hardness even
at high temperatures;
• Good creep resistance;
• High thermal shock resistance;
• High wear resistance;
• Low coefficient of thermal expansion;
• Good chemical and oxidation resistance;
5. Low Pressure Sintered Silicon Nitride (SSN)
• If sintering is conducted under normal
nitrogen pressure some of Silicon
Nitride decomposes forming metallic
silicon (Si).
• The process is simpler and more cost
effective than GPSSN, but the resulted
materials possess lower mechanical
strength.
6. Hot Pressed Silicon Nitride (HPSN)
• Uniaxial (die) pressing or Isostatic
pressing techniques under pressure up
to 2000 atm. are used for manufacturing
dense high strength Silicon Nitride
parts.
• The process application is limited by its
relatively high cost.
7. Reaction Bonded Silicon Nitride (RBSN)
• Reaction Bonded Silicon Nitride ceramics are
produced from metallic silicon powder by
sintering it in nitrogen atmosphere at 2550°F
(1400°C).
• Silicon Nitride forms as a result of chemical
reaction between metallic silicon and gaseous
nitrogen.
• The material is characterized by low density and
low oxidation resistance due to high open
porosity.
• The main advantage of the method is low
volume change (low shrinkage) of the sintered
parts.
The following characteristics are typical for
Silicon Nitride ceramics:
• High fracture toughness;
• High mechanical strength and hardness even
at high temperatures;
• Good creep resistance;
• High thermal shock resistance;
• High wear resistance;
• Low coefficient of thermal expansion;
• Good chemical and oxidation resistance;
• Low wettability by molten metals.
• Silicon Nitride ceramics are used for
manufacturing :
cutting tools, turbine blades, bearing
balls and rollers, kiln furniture, valves
and turbocharger rotors for engines,,
molten metals tools, melting crucibles.
8. Aluminum Nitride
• Aluminum Nitride (AlN) ceramics are
produced by sintering of Aluminum Nitride
powder with or without binders.
• The materials possess high thermal
conductivity and good dielectric properties.
• Aluminum Nitride easily oxidizes at the
temperatures above 1300°F (700°C),
therefore it is not used in high temperature
applications.
The following characteristics are typical for
Aluminum Nitride ceramics:
• Very high thermal conductivity;
• Good dielectric properties;
• Good corrosion resistance;
• Silicon Nitride ceramics are used for
manufacturing
Housing and heat sinks, power transistors
bases, microwave device packages.
9. Hot Pressed Silicon Nitride (HPSN)
• Uniaxial (die) pressing or Isostatic pressing
techniques under pressure up to 2000 atm.
are used for manufacturing dense high
strength Silicon Nitride parts.
• The process application is limited by its
relatively high cost.
10.Silicon Aluminum Oxynitride (SIALON)
• Silicon Aluminum Oxynitride ceramics are
produced from a mixture of Silicon Nitride
powder and Aluminum Oxide powder.
• Silicon Aluminum Oxynitride possesses low
wettability by non-ferrous molten metals,
therefore is used in metallurgical applications.
• It is also used for cutting tools due to its high
toughness.
 Silicate ceramics
• Silicates are materials composed generally of
silicon and oxygen.
• The following groups of materials relate silicate
ceramics:

• Technical Porcelain
• Magnesium Silicates
• Mullite Ceramics
• Properties of some silicate ceramics
• Technical Porcelain generally consists of silica
(SiO2) and alumina (Al2O3).
• Depending on the proportion of silica and
alumina in material composition two types of
porcelain may be prepared: quartz porcelain
or alumina porcelain.
• Alumina porcelain contains higher amount of
more expensive alumina and possesses higher
mechanical strength, than silica porcelain.
The following characteristics are typical for
Technical Porcelain:
• High mechanical strength;
• Excellent dielectric properties;
• High chemical resistance.
• Technical porcelain is generally used in
electrical engineering as a good insulator.
1. Magnesium Silicates
• Magnesium Silicates (Steatite and
Cordierite) consist of silica (SiO2),
magnesia (MgO) and some alumina
(Al2O3).
The following characteristics are typical for
Steatite:
• High mechanical strength;
• Good dielectric properties;
• Very low loss factor;
• Steatite is used in heat engineering and in
electrical engineering for manufacturing
sockets, control housings
The following characteristics are typical for
Cordierite:
• Low coefficient of thermal expansion;
• High thermal shock resistance;
• Good mechanical strength.
• Cordierite is used mostly in heat engineering
for manufacturing supports of heating
elements, parts of water heaters, pipes of
heating element.
2. Mullite Ceramics
• Mullite Ceramics consist of mullite
(3Al2O3*2SiO2), alumina (Al2O3) and
glass (SiO2).
• Sintered Mullite Ceramics have porosity
up to 10%, which may be considerably
reduced by increasing the content of
glass phase above 10%.
The following characteristics are typical for
Mullite Ceramics:
• High strength;
• High thermal shock resistance;
• Relatively low thermal expansion;
• Good creep resistance.
• Mullite Ceramics are used for manufacturing
high temperature parts, kiln furniture, slide
gates, ladles for molten metal, protection
tubes for thermocouples, glass industry
refractories.
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