14

Ceramic Materials
1442 The specific gravity of Al2O3 is 3.96 g/cm3. A ceramic part is produced by sintering alumina powder. It weighs 80 g when dry, 92 g after it has soaked in water, and 58 g when suspended in water. Calculate the apparent porosity, the true porosity, and the closed pores. Solution: From the problem statement, r 3.96, Wd 80 g, Ww 92, and Ws 58. From the equations, apparent porosity Ww Wd 92 80 100 100 35.29% Ww Ws 92 58

The bulk density is B Wd(Ww Ws) 80(92 58) 2.3529 g/cm3. Therefore: true porosity rB 3.96 2.3529 100 40.58% 100 r 3.96

closed porosity 40.58 35.29 5.29% 1443 Silicon carbide (SiC) has a specific gravity of 3.1 g/cm3. A sintered SiC part is produced, occupying a volume of 500 cm3 and weighing 1200 g. After soaking in water, the part weighs 1250 g. Calculate the bulk density, the true porosity, and the volume fraction of the total porosity that consists of closed pores. Solution: The appropriate constants required for the equations are: r 3.1 g/cm3 Ww 1250 g Therefore: B 2.4 Wd 1 Ww Ws 2 1200 1 1250 Ws 2 or Ws 750 g B 1200 g 500 cm3 2.4 g/cm3 Wd 1200 g

157

158

The Science and Engineering of Materials

Instructors Solution Manual Ww Wd 1250 1200 100 100 10% Ww Ws 1250 750 1r B2 1 3.1 2.4 2 100 22.58% r 3.1

apparent porosity true porosity

closed porosity 22.58 10 12.58% fclosed 12.58 22.58 0.44 1454 Calculate the O:Si ratio when 20 wt% Na2O is added to SiO2. Explain whether this material will provide good glass forming tendencies. Above what temperature must the ceramic be heated to be all-liquid? Solution: MWsoda 2 1 22.99 2 16 61.98 g/mol 20 g 61.98 g/mol 0.1951 20 61.98 80 60.08

MWsilica 28.08 2 1 16 2 60.08 g/mol mole fraction Na2O OSi

Since the OSi ratio is less than 2.5, it should be possible to produce a glass. From the Na2OSiO2 phase diagram (Figure 1411), we find that, for 20 wt% Na2O, the liquidus temperature is about 1000C. We must heat the material above 1000C to begin the glass-making operation. 1455 How many grams of BaO can be added to 1 kg of SiO2 before the O:Si ratio exceeds 2.5 and glass-forming tendencies are poor? Compare this to the case when Li2O is added to SiO2. Solution: We can first calculate the required mole fraction of BaO required to produce an O:Si ratio of 2.5: OSi 2.5 fBaO 0.33 1 1 OBaO 2 fBaO 1 2 OSiO2 21 1 fBaO 2 1 1 Si/SiO2 21 1 fBaO 2 and fsilica 0.67

1 1 ONa2O 21 0.1951 2 1 2 OSiO2 21 0.8049 2 2.24 1 1 SiSiO2 21 0.8049 2

The molecular weight of BaO is 137.3 16 153.3 g/mol, and that of silica is 60.08 g/mol. The weight percent BaO is therefore: wt% BaO 1 0.33 mol 21 153.3 g/mol 2 100 55.69% 1 0.33 21 153.3 2 1 0.67 21 60.08 2

For 1 kg of SiO2, the amount of BaO is: 0.5569 x g BaO x g BaO 1000 g SiO2 or x 1257 g BaO

The mole fraction of Li2O required is: OSi 2.5 fLi2O 0.33 1 1 OLi2O 2 fLi2O 1 2 OSiO2 21 1 fLi2O 2 and fsilica 0.67 1 1 Si SiO2 21 1 fLi2O 2

CHAPTER 14

Ceramic Materials

159

The molecular weight of Li2O is 2(6.94) 16 29.88 g/mol, and that of silica is 60.08 g/mol. The weight percent Li2O is therefore: wt% Li2O 1 0.33 mol 21 29.88 g mol 2 100 19.7% 1 0.33 21 29.88 2 1 0.67 21 60.08 2 or x 245 g Li2O

For 1 kg of SiO2, the amount of Li2O is: 0.197 x g Li2O x g Li2O 1000 g SiO2

Much larger amounts of BaO can be added compared to Li2O and still retain the ability to form a glass. 1456 Calculate the O:Si ratio when 30 wt% Y2O3 is added to SiO2. Will this material provide good glass-forming tendencies? Solution: MWyttria 2 1 88.91 2 3 1 16 2 225.82 g/mol MWsilica 60.08 g/mol The mole fraction of yttria is (assuming a base of 100 g of ceramic): fyttria 30 g 225.82 g/mol 0.102 30 225.82 7060.08 1 3 OY2O3 21 0.102 2 1 2 OSiO2 21 0.898 2 2.34 1 1 SiSiO2 21 0.898 2

The OSi ratio is then: OSi

The material will produce a glass. 1457 Lead can be introduced into a glass either as PbO (where the Pb has a valence of 2) or as PbO2 (where the Pb has a valence of 4). Such leaded glasses are used to make what is marketed as crystal glass for dinnerware. Draw a sketch (similar to Figure 14 10) showing the effect of each of these oxides on the silicate network. Which oxide is a modifier and which is an intermediate? Solution: PbO2 provides the same number of metal and oxygen atoms to the network as does silica; the PbO2 does not disrupt the silicate network; therefore the PbO2 is a intermediate. PbO does not provide enough oxygen to keep the network intact; consequently PbO is a modifier.

Pb Pb

160

The Science and Engineering of Materials

Instructors Solution Manual

1458 A glass composed of 65 mol% SiO2, 20 mol% CaO, and 15 mol% Na2O is prepared. Calculate the O:Si ratio and determine whether the material has good glass-forming tendencies. Estimate the liquidus temperature of the material using Figure 14 16. Solution: Based on the mole fractions, we can determine the O:Si ratio: OSi 1 2 OSiO2 21 0.65 2 1 1 OCaO 21 0.20 2 1 1 ONa2O 21 0.15 2 1 1 SiSiO2 21 0.65 2

OSi 2.54

The glass-forming tendencies are relatively poor and special attention to the cooling rate may be required. To determine the liquidus, we must find the weight percentages of each constituent. The molecular weights are: MWsilica 60.08 g/mol MWCaO 40.08 16 56.08 g/mol MWsoda 2 1 22.99 2 16 61.98 g/mol wt% SiO2 1 0.65 21 60.08 2 100 1 0.65 21 60.08 2 1 0.20 21 56.08 2 1 0.15 21 61.98 2 65.56% 1 0.20 21 56.08 2 100 1 0.65 21 60.08 2 1 0.20 21 56.08 2 1 0.15 21 61.98 2 18.83% 1 0.15 21 61.98 2 100 1 0.65 21 60.08 2 1 0.20 21 56.08 2 1 0.15 21 61.98 2 15.61%

wt% CaO

wt% Na2O

From the ternary phase diagram, this overall composition gives a liquidus temperature of about 1140C.