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Ceramics: ES311: Engineering Materials
Ceramics: ES311: Engineering Materials
Example:
◦ Electrical porcelain
◦ Dinner china
◦ Sanitary ware
Whitewares
Electrical porcelain
Whitewares
Dinner China
Whitewares
Sanitary ware
Structural Clay Products
Made of natural clay, which contains all
three basic components.
Example:
◦ Building brick
◦ Sewer pipe
◦ Drain tile
◦ Roofing tile
◦ Floor tile
Structural Clay Products
Building brick
Structural Clay Products
Sewer pipe
Structural Clay Products
Drain tile
Structural Clay Products
Roofing tile
Structural Clay Products
Floor tile
Brick and Tile
structural clay products, manufactured
as standard units, used in building
construction
is a small building unit in the form of a
rectangular block, formed from clay or
shale or mixtures and burned (fired) in a
kiln, or oven, to produce strength,
hardness, and heat resistance
Brick and Tile
Abrasives
is a material, often a mineral, that is
used to shape or finish a workpiece
through rubbing which leads to part of the
workpiece being worn away
a material often means polishing it to gain
a smooth, reflective surface which can
also involve roughening as in satin, matte
or beaded finishes
Abrasives
Refractories
is one that retains its strength at
high temperature
Example:
okiln linings
ogas fire radiants
osteel
oglass making crucibles
Refractories
KILN LININGS
Refractories
Gas fire radiants
Refractories
STEEL
Refractories
glass making crucibles
Cements
is a binder, a substance that sets and hardens
independently, and can bind other materials together
Soft Ferrites
o Ferrites that are used
in transformer or electromagnetic cores contain nickel, zinc,
and/or manganese compounds. They have a low coercivity
and are called soft ferrites. The low coercivity means the
material's magnetization can easily reverse direction without
dissipating much energy (hysteresis losses), while the
material's high resistivity prevents eddy currents in the core,
another source of energy loss. Because of their comparatively
low losses at high frequencies, they are extensively used in
the cores of RF transformers and inductors in applications
such as switched-mode power supplies.
Magnetic Ceramics
Hard Ferrites
o In contrast, permanent ferrite magnets are made of hard ferrites,
which have a high coercivity and high remanence after
magnetization. Iron oxide and barium or strontium carbonate are
used in manufacturing of hard ferrite magnets. The high coercivity
means the materials are very resistant to becoming demagnetized, an
essential characteristic for a permanent magnet. They also
conduct magnetic flux well and have a high magnetic permeability.
This enables these so-called ceramic magnets to store
stronger magnetic fields than iron itself. They are cheap, and are
widely used in household products such as refrigerator magnets.
Optical Ceramics
are polycrystalline materials produced through controlled
crystallization of base glass.
Glass-ceramic materials share many properties with
both glasses and ceramics.
Glass-ceramics have an amorphous phase and one or
more crystalline phases and are produced by a so-called
"controlled crystallization" in contrast to a spontaneous
crystallization, which is usually not wanted in glass
manufacturing.
Glass-ceramics have the fabrication advantage of glass as
well as special properties of ceramics.
Glass ceramics has a variety of properties such as, high
strength, toughness, translucency or opacity, opalescence,
low or even negative thermal expansion, high temperature
stability.
Optical Ceramics
High-pressure sodium-vapour
lamp bulb
Advance Structural Ceramics
ceramic materials that demonstrate enhanced
mechanical properties under demanding conditions.
Because they serve as structural members, often
being subjected to mechanical loading, they are given
the name structural ceramics. Ordinarily, for
structural applications ceramics tend to be expensive
replacements for other materials, such as metals,
polymers, and composites.
Advance Structural Ceramics
Classified to:
o Nuclear Ceramics
o Bioceramics
o Tribological Ceramics
o Automotive Ceramics
Nuclear Ceramics
nuclear ceramics, ceramic materials employed in the
generation of nuclear power and in the disposal of radioactive
nuclear wastes.
In their nuclear-related functions, ceramics are of major
importance. Since the beginning of nuclear power generation,
oxide ceramics, based on the fissionable metals uranium and
plutonium, have been made into highly reliable fuel pellets for
both water-cooled and liquid-metal-cooled reactors. Ceramics
also can be employed to immobilize and store nuclear wastes.
Although vitrification (glass formation) is a favoured approach
for waste disposal, wastes can be processed with other
ceramics into a synthetic rock, or synroc, or they can be
mixed with cement powder to make hardened cements. All
these nuclear applications are extremely demanding. In
addition to severe thermal and chemical driving forces,
nuclear ceramics are continuously subjected to high radiation
doses.
Nuclear Ceramics
Femoral Head
of a Hip
Prosthesis Hip Prosthesis
Tribological Ceramics
Tribological ceramics, also called wear-resistant
ceramics, ceramic materials that are resistant to friction and
wear. They are employed in a variety of industrial and domestic
applications, including mineral processing and metallurgy.
Advanced structural ceramics offer unique capabilities as
tribomaterials.
They are being used today in diverse applications such as tips
for ball-point pens, precision instrument bearings, and cutting
tool inserts.
Tribological applications of ceramics can be divided into several
categories based on the properties of the ceramics. These
include: resistance to abrasion and erosion; resistance to
corrosive wear; wear resistance at elevated temperatures; low
density; and electrical, thermal and magnetic properties.
Tribological Ceramics
NITRIDE CERAMICS
Applications:
o Wear Guides
o Seals and Bearings
o Grinding Media
Aluminum Nitride
a covalently bonded ceramic is synthesized from abundantly
available elements Al and N. The ceramic does not occur
naturally. AlN has a Wurtzite crystal structure and is stable in
inert atmospheres at temperatures in excess of 2000°C. It
exhibits high thermal conductivity property while remaining a
strong dielectric. This unusual combination of properties is
what makes Al N a critical advanced materials for many future
applications in Optics, lighting, electronics and green
environmental technologies.s an intermetallic inorganic
compound with the chemical formula Pb[ZrxTi1-x]O3 0≤x≤1).
Also called PZT, it is a ceramic perovskite material that shows
a marked piezoelectric effect, which finds practical
applications in the area of electroceramics. It is a white solid
that is insoluble in all solvents.
Aluminum Nitride
APPLICATION
opto-electronics
dielectric layers in optical storage media
electronic substrates, chip carriers where
high thermal conductivity is essential
military applications
Silicon Aluminum Oxynitride
are a specialist class of high-temperature refractory materials,
with high strength (including at high temperature), good
thermal shock resistance and exceptional resistance to
wetting or corrosion by molten non-ferrous metals, compared
to other refractory materials such as, for example, alumina. A
typical use is with handling of molten aluminium. They also
are exceptionally corrosion resistant and hence are also used
in the chemical industry. Sialons also have high wear
resistance, low thermal expansion and good oxidation
resistance up to above ~1000 °C.
Silicon Aluminum Oxynitride
APPLICATION
oThermocouple protection tubes for nonferrous metal melting
oImmersion heater and burner tubes
oDegassing and injector tubes in nonferrous metals. Metal feed
tubes in aluminum die casting
oWelding and brazing fixtures and pins
*Classification of Advanced Ceramics based on
COMPOSITION
SILICATE CERAMICS
Porcelain Tile
Magnesium Silicate
• is a chemical compound consisting of magnesium, silicon,
and oxygen. It exists in several forms, both natural and
manufactured. One of the most common forms of this
compound is the mineral talc, which can be found in
deposits around the world and is used in many industrial
and everyday applications. Synthetic forms are also widely
used, especially as filters and additives in the food
industry.
• The material is lower in cost than Alumina but offers
reduced mechanical properties. However it has very good
electrical resistance properties, which are retained at high
temperatures, along with moderate mechanical strength
and temperature resistance. It has been used in electrical
insulation for many years in both large-scale electrical
systems and electronic and domestic appliances.
Magnesium Silicate
Applications:
CARBIDE CERAMICS
APPLICATION
o Padlocks
o Abrasives
o Cutting Tools
o Grit Blasting nozzles
Silicon Carbide (SiC)
exceedingly hard, synthetically produced crystalline
compound of silicon and carbon.
Its chemical formula is SiC.
an important material for sandpapers, grinding wheels,
and cutting tools.
More recently, it has found application in refractory linings
and heating elements for industrial furnaces, in wear-
resistant parts for pumps and rocket engines, and in
semiconducting substrates for light-emitting diodes.
Silicon Carbide (SiC)
APPLICATIONS:
o Abrasives or Cutting Tools (e.g. Grinding Wheel, Sandpaper)
o Burner Nozzle
o Spray Nozzle
o Automobile Parts (e.g. Disc Brakes)
Tungsten Carbide
is an inorganic chemical compound (specifically,
a carbide) containing equal parts of tungsten and carbon
atoms.
APPLICATION
o Drill Bits
o Surgical Imstruments
o Jewelry
*Classification of Advanced Ceramics based on
COMPOSITION
OXIDE CERAMICS
APPLICATIONS
◦ Medical prostheses
◦ Ballistic armour
◦ Electrical insulators
◦ Grinding media
◦ Wear components
Magnesium Oxide (MgO)
is a white hygroscopic solid mineral that occurs naturally
as periclase and is a source of magnesium.
It has an empirical formula of MgO and consists of a lattice
of Mg2+ ions and O2− ions held together by ionic bonding.
According to evolutionary crystal structure prediction,
MgO2 is thermodynamically stable at pressures above 116
GPa, and a totally new semiconducting suboxide Mg3O2 is
thermodynamically stable above 500 GPa.
Magnesium oxide is produced by
the calcination of magnesium carbonate or magnesium
hydroxide or by the treatment of magnesium chloride with
lime followed by heat.
Magnesium Oxide
APPLICATIONS
◦ Heating elements
◦ Thermocouple tubes
◦ High temperature crucibles
◦ Cement
Zirconium Dioxide (ZrO2)
is one of the most studied ceramic materials.
ZrO2 adopts a monoclinic crystal structure at room
temperature and transitions to tetragonal and cubic at
higher temperatures. The volume expansion caused by
the cubic to tetragonal to monoclinic transformation
induces large stresses, and these stresses cause ZrO2to
crack upon cooling from high temperatures. When the
zirconia is blended with some other oxides, the
tetragonal and/or cubic phases are stabilized.
Zirconium Dioxide (ZrO2)
APPLICATIONS
◦ Dental Ceramics
◦ Technical Cutters
◦ Tubes and Pipes
◦ Seal Rings, Bearings, Sealings
Aluminum Titanate (Al2TiO5)
a ceramic material consisting of a mixture
of alumina (Al2O3) and titania (TiO2) forming solid
solution with stoichiometric proportion of the
components: Al2O3*TiO2 or Al2TiO5.
prepared by heating of a mixture of alumina and
titania at temperature above 2460°F (1350°C).
The distinctive property of Aluminum Titanate ceramics
is their high thermal shock resistance which is a result
of very low coefficient of thermal expansion.
Disadvantage of Aluminum Titanate ceramics is
relatively low mechanical strength caused by micro-
cracks formed as a result of anisotropy of thermal
expansion along the three primary axes of the crystal
lattice (a single crystal of Aluminum Titanate expands
along two axes and contract along the third axis when
heated).
Aluminum Titanate (Al2TiO5)
APPLICATIONS
◦ Riser Tubes
◦ Tubes and Pipes
◦ Thermocouples
◦ Dosing Tubes
Lead Zirconate Titanate
is an intermetallic inorganic compound with
the chemical formula Pb[ZrxTi1-x]O3 0≤x≤1). Also
called PZT, it is a ceramic perovskite material
that shows a marked piezoelectric effect, which
finds practical applications in the area
of electroceramics. It is a white solid that is
insoluble in all solvents.
Lead Zirconate Titanate
APPLICATIONS
◦ Undersea exploration (sonar, beacons, imaging, current meters)
◦ Aerospace (gyroscopes, accelerometers, level sensing)
◦ Telecommunications (optical switching of telecom lines, buzzers
and alarms, Haptics feedback, mobile phone cameras)
◦ Automotive (power seat controls, reversing/collision avoidance
sensors, anti-knock sensors)
◦ Scientific research (nano positioning stages and analytical tools,
scanning probe microscopy, advanced acoustics)
Amorphous Ceramics: Glasses
a ceramic material which is an inorganic
product of fusion that has cooled to a
rigid condition without crystallization
has a noncrystalline or amorphous
structure
The molecules in a glass change their
orientation in a random manner
throughout the solid material.
*Types of Glasses based on Composition
Fused silica glass, vitreous silica glass
◦ silica (SiO2). Has very low thermal expansion, is
very hard and resists high temperatures (1000–
1500 °C). It is also the most resistant against
weathering (alkali ions leaching out of the glass,
while staining it). It is used for high temperature
applications such as furnace tubes, melting
crucibles, etc.
◦ the most important singe-component glass, has a
high spectral transmission and is not subject to
radiation damage, which cause browning of other
glasses
◦ ideal glass for space vehicle windows, wind tunnel
windows, and optical system in spectrophometric
devices
◦ difficult to process and expensive
Fused silica glass, vitreous silica glass
Lead-oxide glass,
crystal glass
◦ silica 59% + soda (Na2O) 2.0% +
lead oxide (PbO) 25% + potassium
oxide (K2O) 12% + alumina 0.4%
+ zinc oxide (ZnO) 1.5%. Has a
high refractive index, making the
look of glassware more brilliant
(crystal glass). It also has a high
elasticity, making glassware 'ring'.
It is also more workable in the
factory, but cannot stand heating
very well.
*Types of Glasses based on Composition
Aluminosilicate glass
oA small, but important type of glass,
aluminosilicate, contains 20% aluminium
oxide (alumina-Al2O3) often including calcium
oxide, magnesium oxide and boric oxide in
relatively small amounts, but with only very
small amounts of soda or potash.
oIt is able to withstand high temperatures and
thermal shock and is typically used in
combustion tubes, gauge glasses for high-
pressure steam boilers, and in halogen-
tungsten lamps capable of operating at
temperature as high as 750°C.
*Types of Glasses based on Composition
Halogen-Tungsten Lamps
Fiber-Optic Waveguides
PROCESSING OF CERAMICS
Most traditional and engineering ceramic
products are manufacture by compacting powders
or particles into shapes that are subsequently
heated to a high enough temperature to bond the
particles together.
3 Types of Pressing:
1. Dry Pressing
2. Isostatic Pressing
3. Hot Pressing
Dry Pressing - used commonly for
products such as structural refractories (high-
heat-resistant materials) and electronic
ceramic components.
- defined as the simultaneous
uniaxial compaction and shaping of a granular
powder along with small amounts of water and/
or organic binder in a die.
- used extensively because it can
form a variety of shapes rapidly with uniformity
and close tolerance.
Dry Pressing
Isostatic Pressing– ceramic
powder is loaded into a flexible
(usually rubber), airtight
container (called a bag) that is
inside a chamber of hydraulic
fluid to which pressure is
applied.
- after cold
isostatic pressing, the part
must be fired (sintered) to
achieve the required properties
and microstructure.
- examples
ceramic products manufactured
are: refractories, bricks and
shapes, spark plug insulators,
radomes, carbide tools,
crucibles, and bearings.
Hot Pressing