MATERIAL SCIENCE AND ENGINEERING

CHAPTER 5: CERAMIC MATERIALS

Group 3 members:
Canlas, Marina Enoch B. Cuevas, Deon Malik
Casusi, Dan David B. Dalmacion, Maria Fe
Corvera, Kym Yebes, Danica

Section/time: Ceat-08-201a/5:00-7:00pm

RIZAL TECHNOLOGICAL UNIVERSITY

Instrumentation and Control Engineering
 Introduction
CERAMICS
Ceramics

Comes from
the Greek word
Which means

Keramikos “Burnt Stuff”

Ionic
Most ceramics are
compounds
Covalent
Comparison of Metals and ceramics
Covalent Bond Ionic Bond
Comparison of Metals and ceramics
Metals Ceramics

• Crystal Structure • Crystal Structure

• Large number of free electronics • Captive electrons
• Metallic bond • Ionic/covalent bond
• Good electrical conductivity • Poor conductivity
• Opaque • Transparent (in thin sections)
• Uniform atoms • Different-size atoms
• High tensile strength • Poor tensile strength
• Low shear strength • High shear strength
• Good ductility • Poor ductility (brittle)
• Plastic flow • None
• Impact strength • Poor impact strength
• Relatively high weight • Lower weight
• Moderate hardness • Extreme hardness
• Nonporous • High porosity
• High density • Low density
Nature of Ceramics

➢ Ceramics are crystalline solids composed of

metallic and nonmetallic materials. They are
inorganic materials.
➢ Are clay-based materials.
➢ Comes from the Greek word keramos meaning
burnt earth.
➢ Consist of Silicon, Aluminum, and Oxygen, the
most abundant elements in earth’s crust.

Materials that are classified as ceramics:

Glass and silicon carbide.
Nature of Ceramics
➢ Ceramics are by nature, generally porous
materials with varying degree of porosity.
Two types of porosity:
Open porosity and closed porosity

➢ Ceramics contain both crystalline and non-

crystalline phase.

Pores affect the strength of ceramics in two

ways:

1) They produce strength concentration.

2) Pore (size, shape and amount) reduce the
strength of ceramic.
Figure 1. Glass Figure 2. Silicon carbide

Figure 3. Porosity (Open and close)

Properties of Ceramics

1.) Extreme hardness (hardest known material is diamond)

2.) Heat resistant
3.) Corrosion resistant
4.) Low electrical and thermal conductivity
5.) Low ductility
6.) Brittleness
7.) Chemical inertness (not chemically reactive)
8.) Wear resistant
Ceramics are used in the following:
1.) Solid electrolytes in experimental batteries and fuel cells
2.) Automotive sensors
3.) Packaging for integrated circuits, electronic and optical devices
4.) Fiber optics
5.) Microchips
6.) Magnetic heads
7.) Computer and communication technologies
8.) Medical field (chemical inertness), where contact with body
fluids is less of problem than with most other materials.
9.) Big role in machine tool industry.
10.) Thermal and mechanical stability allows them to retain their
smooth, accurate cutting surfaces longer than metals do.
Structure of Ceramics
➢ Being a compound, ceramics are made of
different types of atoms of varying size.
Example: Aluminum Oxide

➢ The two most chemical bonds for ceramic

materials are covalent and ionic.
➢ Ceramics structure are more complex than
metallic structure.
Crystal Structure:
Governing Factors

1.) Charge magnitude on each ion

2.) The radius of each type of ion
1.) Charge magnitude on each ion

➢ The crystal must be electrically neutral

Example:

Charge neutrality: Net

charge in the structure
must be zero
2.) The radius of each type of ion
The size of cations are ordinarily smaller than anions.

The ratio of cations radaii and anions radaii is less than unity. (rC/rA )

Figure 2.1 Stable/unstable cation-anion coordination configuration

❖ Consider 3 anions touching with a cation in center.
Figure 2.2 Coordination numbers and geometries for various Cation-anion Radius ratio
Figure 2.3 Ionic Radaii for Several Cations and Anions for a Coordination number of 6
Common Ceramic crystal Structure

1.) AX – Type Crystal Structures

2.) AmXp – Type Crystal Structures

3.) AmBnXp – Type Crystal Structures

1.) AX – Type Crystal Structures

➢ Some of common ceramic materials are those in which there

are equal number of Cations and Anions.

Structure name of name of the following AX - Crystal Structures:

A. Rock Salt Structure

B. Cesium Chloride Structure
C. Zinc Blende Structure
A. Rock Salt Structure
rNA = 0.102 nm
rNA/ rCl = 0.564
rCl = 0.181 nm

Coordination no. 6
B. Cesium Chloride Structure
rCs = 0.170 nm
rCs / rCl = 0.939
rCl = 0.181 nm

Coordination no. 8
C. Zinc Blende Structure

Zn

Coordination no. 4
S
2.) AmXp Type Crystal Structures
➢ If the charges on the cations and anions are not the same, a
compound can exist with the chemical formula AmXp, where m
and/or p ≠ 1.

Coordination no. 8
F -
3.) AmBnXp Type Crystal Structures

➢ It is also possible for ceramic compounds to have more than

one type of cation; for two types of cations (represented by A
and B), their chemical formula may be designated as AmBnXp.

Barium titanate (BaTiO3)

Coordination no. 6
Crystalline Silica (SiO2) Structure
➢ Is a compound that makes up many ceramics. Silicon
and oxygen are the most common minerals on earth.

Top view

Figure 1.Silicon-Oxygen
tetrahedron
Silicate ceramics includes the
following:
1.) Crystalline Silica (SiO2)

2.) Layered Silicates

3.) Non-crystalline Silica glasses

Silicate ceramics: Figures

Figure 1.1 Crystalline Silica (SiO2) Figure 2.1 Layered Silicates

Figure 3.1 Non-crystalline Silica

glasses
Designing Ceramics
Negative properties of ceramics

1.) Inherent brittleness

2.) Inability to yield
3.) Inability to change shape
4.) Inability to plastically deform
5.) Sensitivity to defects
6.) Tendency to break to any point of high concentration
7.) Their microstructure which occurs flaws that can
failure without being detected beforehand.
Designing Ceramics
Three general design models used by engineers

1.) EMPIRICAL DESIGN

2.) DETERMINISTIC DESIGN

3.) PROBABILISTIC DESIGN

THAT’S ALL

THANK YOU!!
 CH. 5 – GRP 3

CERAMIC PROCESSING
&
REFRACTORY MATERIALS
Reporter 2:
CANLAS, MARINA ENOCH
DIFFERENT KINDS OF CERAMICS MANUFACTURED IN INDUSTRIES:

TRADITIONAL CERAMICS
ADVACED CERAMICS

TECHNICAL CERAMICS
INDUSTRIAL CERAMICS
CERAMIC PROCESSING
 7 CERAMIC PROCESSING
● THERMAL PROCESSING - SINTERING / DENSIFICATION / FIRING
● TRADITIONAL PROCESSING
● ADVANCED CERAMIC PROCESSING
● CHEMICAL PROCESS
● MELT PROCESSING
● VAPOR PROCESSING
● FINISHING (MACHINING)
THERMAL PROCESSING-SINTERING / DENSIFICATION / FIRING

● Densification (Firing) – a
process by which a particular
compact is transformed into a
ceramic part that has adequate
properties to satisfy the needs of
a particular application.

● Densification is the act of

reducing porosity in a sample,
thereby making it more dense.
THERMAL PROCESSING-SINTERING / DENSIFICATION / FIRING
● Densification (Firing) – a
process by which a particular
compact is transformed into a
ceramic part that has adequate
properties to satisfy the needs of
a particular application.

● Densification is the act of

reducing porosity in a sample,
thereby making it more dense.
TRADITIONAL PROCESSING
● The first ceramic materials
produced by processing – were
bricks and lime plaster.

● Limestone were roasted to

produce lime when mixed with
water to the clay, straw or fibers
were added to provide building
material.

● This method includes blending,

pressing and firing.
TRADITIONAL PROCESSING
● The first ceramic materials
produced by processing – were
bricks and lime plaster.

● Limestone were roasted to

produce lime when mixed with
water to the clay, straw or fibers
were added to provide building
material.

● This method includes blending,

pressing and firing.
ADVANCED CERAMIC PROCESSING
The multi stage fabrication process
for ceramic includes:

● Powder production
● Powder conditioning
● Shaping (forming)
● Drying
● Densification (firing or sintering)
 ADVANCED CERAMIC PROCESSING
The multi stage fabrication process for
ceramic includes:
● Shaping (forming)
● Powder production ● Drying
● Powder conditioning ● Densification (firing or sintering)
 ADVANCED CERAMIC PROCESSING
2 Steps in ceramic processing:
1. COLD STEP – is where the ceramic part is
formed or shaped into a “green” part or
perform.
2. HOT STEP – where the green compact is
subjected first to heat to dry up any liquid
formed during the processing, then
subjected to higher heat (sintering) which
bonds the ceramic particles together
permanently to give it its strength.
CHEMICAL PROCESS
● Sol-Gel Processing – a chemical
process for producing powders
used in advanced ceramics.

● This process provides the means

for designing & controlling the
composition & structure of a
ceramic at a molecular level

● Benefits: increased impurity,

lower process temperature, finer
grain size, etc.
CHEMICAL PROCESS ● Sol-Gel Processing – a chemical
process for producing powders
used in advanced ceramics.

● This process provides the means

for designing & controlling the
composition & structure of a
ceramic at a molecular level

● Benefits: increased impurity,

lower process temperature, finer
grain size, etc.
MELT PROCESSING ● Most glasses & many ceramics are
melted before being processed.
Abrasives, glass shapes & bricks of
alumina are made by casting from a
melt.

● Glass fibers for fiberglass composite

are drawn or spun from a molten
state.

● Molten droplets made from ceramic

particles are sprayed onto surfaces
through a variety of spray techniques
that provide corrosion, wear &
thermal protection to a wide variety
of metal, plastic & ceramic products.
VAPOR PROCESSING
● Vapor processing – involves
heating a solid substance to a
temperature as to transform the
solid into a vapor, which is then
deposited onto surface

● - when the vapor contacts a solid

substrate or when a gas reacts on
contact with a hot substrate, the
solid produce on that hot surface
solidifies so quickly that the atoms
fail to form a crystalline structure.
FINISHING (MACHINING)
● In some instances the shaped
compact (preformed) has not
acquired the final shape or met the
specified tolerance.

● Machining of the surfaces of the

ceramic is done to meet dimensional
tolerances, improve surface finish or
remove surface flaws.

● It is given that all machining will still

have flaws of some size on the
surface of the ceramics.
IMPROVING STRENGTH IN CERAMICS
▪ Reduce ceramic flaw size:
- Use fine powders
- Quality control / clean processing room
- Uniform (controlled size of grain)
- Limited porosity / achieve high density

▪ Improve toughness:
- Addition of fiber reinforcement
- Transformation toughening
- Tempering (for glasses)
REFRACTORY MATERIALS
 REFRACTORY MATERIALS
● Refractory material is one with a very high melting point
and other properties that make it suitable for such uses
like: Furnace linings and Kiln construction.
 SOME COMMON REFRACTORY CERAMICS:

ALUMINA CHROMITE BAUXITE KAOLIN

SILICON CARBIDE MAGNESITE GRAPHITE

 REFRACTORY MATERIALS:
● Ceramics with weak ionic bonds just have relatively resistance
to chemical attack. While Refractory materials possess strong
covalent/ionic bonding which are stable as linings for furnaces
and used for melting metal alloys and glasses at extremely high
temperatures.

● Lastly, the main purpose of refractory material is to contain the

heat generated by combustion, the material has a high melting
point that maintains it's structure at very high temperatures.
 THANKS FOR
LISTENING!
NEXT REPORTER:
MR. DEON CUEVAS

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CEMENTS AND CONCRETS
Reporter 3:
CUEVAS, DEON MALIK
INTRODUCTION

CEMENTS AND CONCRETES

Cements are a group of chemical materials
in which consolidation occurs by means of
chemical reactions at low temperature
rather than by firing or sintering at high
temperature.
Setting and Hardening are caused by the chemical reaction
between the cement and water. Setting (stiffening) occurs within
hours. Hardening (subsequent development of strength) is
largely completed in a month.
Cementitious materials includes pozzolans (containing
natural hydrating or water incorporating material)
such as shale, lime, gypsum, asphalt, tar, synthetic
plastics and cement. Ceramic cement are most
familiar to us in the form of concrete and mortar.

The term CEMENT can include any materials that act as an

adhesive to bond components together.
 Concrete and mortar use cement to bond together
that aggregates (rocks and sand which combine
through adhesion with cement) which adds bulk to
the material.

Masonry mortar consists of masonry cements plus a

fine aggregate sand. Masonry cement is comprised
of Portland cement with hydrated (water
incorporating) lime silica, slag and other additives to
improve plasticity and slow setting time.
Classification of cement
according to their bond
mechanism:
1. Hydraulic bonding: cures or set
by interaction with water 2. Reaction bonding:
A) Portland cement- the most common High temperature cements are produced by chemical
hydraulic cement is composed primarily reaction not involving water. One common reaction
of anhydrous CaSiO3 cement is monoaluminum, phosphate, produced by
B) Gypsum cement- re-crystallize to a the reaction between aluminum oxide and
higher crystalline structure that has low
phosphoric acid.
degree of adhesion.

3. Precipitation bonding:
Precipitaiton cement is acid resistant
and has good abrasion resistance.
TWO FACTORS THAT AFFECT THE STRENGHT OF
CEMENT
● SIZE OF PORES ARISING FROM THE
ENTRAPMENT OF AIR
● INCOMPLETE PACKING CEMENT PARTICLES
 TECHNIQUES IN IMPROVING
CEMENTS

● Densified with Small Particles (DSP): Silicon dioxide particles of very

fine size (ultra-fine) are added, being smaller than the cement particles
fill void spaces between the cement particles, decreasing the overall
porosity and pore size.

● Macrodefect-free (MDF): Additives such as small amounts of polymers

and other ingredients are added to achieve better particles dispersion
and packing.
 CLAY
Reporter 4:
YEBES, DANICA
 ➢ Composed of 28% Silicon, 8% Aluminum, and small
amount of Cabon.

CLAY

➢ Classified as either residual or sedimentary materials.

Residual Clay

Results from the wearing down of rocks

from the mechanical and chemical action
of wind, water, earth movements and
chemicals in the soil. They are found
where they are formed.
Sedimentary Clay

➢ Formed through mechanical

and chemical erosion of rocks,
but they are moved by wind or
water to places other than
where they are formed.
 Common Clay
Kaolin (Al2O3-2SiO2-2H2O) Ball Clay Fire Clay

Stoneware Clay Slip and Flint Clay

APPLICATIONS
1. As ingredients in most traditional ceramics
2. As structural product of brick and tile
3. Raw materials for sculpture art
4. As china dishes
5. As electronic component
6. Important ingredient in paper making.
 NUCLEAR FUEL
➢ material used in nuclear
power stations to produce
heat to power turbines. Heat
is created when nuclear fuel
undergoes nuclear fission.
Uranium Dioxide
➢ A ceramic material is used as a fuel in
the current generation o nuclear
reactors for the production of electric
power.

Uranium Oxide
➢ Is chemically stable and has high
melting temperature (2750°C). It is
made into pellets form by pressing and
sintering. These pellets are then
inserted into tubes made of corrosion
resistant alloy of zirconium called
zircalloy.
ABRASIVES CERAMIC
Reporter 5:
CORVERA, KYM
 ABRASIVES
- A very hard particles used for grinding, sanding, and polishing .

FLINT SILICONE CARBIBE

GARNET EMERY CORUNDUM

DIAMOND PUMICE (PULVURIZED VOLCANIC ASH)

ALUMINUM OXIDE ROTTEN STONE

FLINT GARNET DIAMOND ALUMINUM OXIDE
 PUMICE
SILICONE CARBIBE EMERY CORUNDOM (PULVURIZED VOLCANIC ASH) ROTTEN STONE
 GRINDING WHEELS – Consist of abrasive particles held
together by a tough bonding material.

- The particles constantly fracture on the wheel to

sharpen and cutting edges.

- Abrasive particles are also used in loose for sand

blasting, hand rubbing or abrasive drilling.

- Particles size is called grit (number of particles/inch)

such as 60 grit or 600 grit.
Hand
rubbing
Abrasive
Sand Drilling
Blasting
SUPER ABRASIVE - are synthetic diamond and cubic
boron nitride (CBN) in the form of grinding
wheels or sintered, polycrystalline cutting tools
for milling and tunings.
SUPER ABRASIVE
RENDERS
1. High material removal rate
2. Achieve better quality (Tolerance and
surface finishes)
3. Less residual stress
4. Reduce Scrap
5. Lower overall manufacturing cost

PROPERTIES OF
GOOD ABRASIVE 1.
2.
Hardness
Wear resistance
3. Thermal Conductivity
4. Sharp
5. Long lasting
6. Can operate at high temperature and
speed
 PROTECTIVE
COATING
- A protective coating is a layer of material applied to the surface of another
material with the intent of inhibiting or preventing corrosion.

- A protective coating may be metallic or non-metallic.

- Protective coatings are applied using a variety of methods, and can be used for
many other purposes besides corrosion prevention.
 CERAMIC MAGNETS
Ceramic magnets contains suffiecient numbers of dipoles and
atom with electron spin in the same direction are called
ferromagnetic can either be soft or hard magnets. The high
electrical resistvity of ceramic magnets gives them advantage over
metal magnets for use in the high frequency devices, their
permanent magnetic behavior finds application in microwave
devices. The ferrite are iron oxide contains of ion of elements
such as zinc, iron, magnesium, and nickel and combines with
oxygen
Ceramic Magnet Disc
Ceramic magnets are popular magnets for crafters, used for arts and crafts as well as
modeling projects, perfect for refrigerator magnets, science projects, POP displays,
signage, jewelry clasps, furniture parts, motor components and much more.

Ceramic Block Magnets

It is mainly used for recorders, pickups, loudspeakers, and magnetic cores of various
instruments in telecommunication devices.
Ceramic Ring Magnets
Ceramic ring magnets are similar to ceramic disc magnets, but they have a hole in
the middle which makes them a versatile magnet option

Ceramic Cup Magnets

Cup Magnets are also known as pot magnets, round cup magnets, round base
magnets, RB magnets and magnetic cup assemblies. These strong cup magnets are
composed of a ceramic ring magnet, in a nickel-plated steel cup for maximum
gripping power. The steel cup provides protection to the magnet while
concentrating the magnetic force on the working surface.
Thick and thin –Film Ceramic Device

Thin film resistors have a metallic film that is vacuum deposited on

an insulating substrate. Thick film resistors are produced by firing
a special paste onto the substrate. The paste is a mixture of glass
and metal oxides. Thin film is more accurate, has a better
temperature coefficient and is more stable.
 GLASS
Reporter 6:
DALMACION, Maria Fe

An organic product of fusion that is

closed to a rigid condition without
crystalizing. It cannot be classified as
ceramic because it lacks
polycrystalline.
 NATURE OF GLASS

The base raw material of glass is the very pure, white silica sand , the
vetrious state of glass is mechanically amorphous like a liquid. Oxide such
as Si 02, B2 03, Ge02, and V205 are glass formers.
Glass formers or network former are those oxides that promote the ionic
linking or polymerization of oxide molecules in the glass compound.
Network modifier such as lead, zinc and alkali ions lower the liquid
temperature , improve workability and thermal and optical properties.
Stabilizers like Ca0 improve chemical properties.
01
ANNEALING OF GLASS

Through slow cooling provides a homogeneous

structure by reducing internal stresses to give
isotropic properties.

02
TEMPERING

Involve rapid cooling of outer surface of glass while

still in the plastic internal stresses to give isotropic
properties.
SIX GLASS
CATEGORIES
SODA LIME ALUMINO
SILIXATE

LEAD ALKALI 96% SILICA

BOROSILICA FUSED SILICA

 SOFT GLASSES
Those that soften does not denote
mechanical hardness but rather the
abilability to resist heat

TWO CLASSIFICATIONS
OF GLASSES
HARD GLASSES
Have higher heat resistance and lower
coefficient of thermal expansion, include
borosilicate and aluminosilicate, and the
hardest high silica glass that is 96%
silica and fused silica.
 • GLASS
SPECIALTY OF GLASSES Are developed with unique properties to
special need, includes ;temperes, optical,
colored, sintered, glazing, fibrous laminated,
cellular, photosensitive and slight sensitive
device. The hard, stable nature of glass
permits grinding and polishing of optical
lenses for telescope to 1/600 of 1%

• PHOTOCHROMIC LENSES
Provide eyeglasses that darken in bright
light but lightened with subdued light. This
ability to change the transmittance of light
results frim the use of silver ions.
CHEMICALLY TEMPERED GLASS
GLAZING
A variety of glass serve as
glazing or glass windows
insulating glasses are
constructed of two or three
panes that fused together in the
edges.
GLASS FIBER

These thread are produced by drawing and

blowing operation . Fibers can produced as
thin continuous filament. This thin fiber serve
as reinforsers in standard woven for plastic
resins such as fiber glass.
OPTICAL FIBER

Used to transmit light. Optical fiber of

glass or plastic have been used in medical
profession and by engineers as inspection
tube.
GLASS CERAMICS

Are polycrystalline glass

that have four to five times
the strength of glass with
mechanical hardness that
equal to the tool of steel.
This polycrystalline is
capable of developing
structure that resist
extreme thermal shock.
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