QUTLINE OF TOPIC 3; Q Q a a Q Properties of ceramics Classification of ceramics Ceramic raw material Fabricating and processing of ceramic Application of Ceramics 1) Glasses 2) Clay Products 2.1) Structural clay product 2.2) Whitewares 3) Refractories: 3.1) Fireclay 3.2) Silica 3.3) Basic refractories 3.4) Special refractories 4) Abrasives 5) Cements 6) Advanced CeramicsCl ASSIFIC ATION OF MATERIAI SC Metals Polymers | Ceramics [composites Y High density Low density Very low density | <= Medium to high = High melting W Low melting {GB melting point & point = point = = medium to high || & Very high elastic 3 Low elastic ic modulus || GO modulus & modulus Reactive Unreactive Very reactive Ductile Brittle Ductile and Examples of ceramic materials ranging from household to high performance combustion engines which utilize both metals and ceramics. 21 November 2015 Prof. Dr. H.Z. Harraz Presentation 3PROPERTIES OF CERAMICS Extreme hardness: > High wear resistance > Extreme hardness can reduce wear caused by friction O Corrosion resistance O Heat resistance: > Low electrical conductivity > Low thermal conductivity > Low thermal expansion > Poor thermal shock resistance Clow ductilit Very brittle High elastic modulus 1 Low toughness: > Low fracture toughness > Indicates the ability of a crack or flaw to produce a catastrophic failure O Low density: > Porosity affects properties O High strength at elevated temperaturesComparison metals v ceramics Metals Cerami Crystal structure Large number of free electrons Metallic bond Good electrical conductivity Opaque Uniform atoms High tensile strength Low shear strength Good ductility Plastic flow Impact strength Relatively high weight Moderate hardness Nonporous High density Crystal structure Captive electrons Tonic/covalent bonds Poor conductivity ‘Transparent (in thin sections) Different-size atoms Poor tensile strength* High shear strength Poor ductility (brittle) None Poor impact strength Lower weight Extreme hardness Initial high porosity Initial low densityDefinition What is “Ceramic”? ooo oO Ceramic materials are inorganic, non-metallic materials and things made from them. They may be crystalline or partly crystalline. They are formed by the action of heat and subsequent cooling Most ceramics are compounds between metallic and nonmetallic elements for which the interatomic bonds are either totally ionic bond or predominantly ionic but having same covalent character. Clay was one of the earliest materials used to produce ceramics, but many different ceramic materials are now used in domestic, industrial and building products. A wide-ranging group of materials whose ingredients are clays, sand and felspar. >The term “ Ceramics” comes from the Greek word keramikos, which means “Burnt stuff or drinking vessel’, indicating that desirable properties of these materials are normally achieve through a high- temperature heat treatment process called Firing, but was later applied by the Greeks to all fired clay products.SPECTRUM OF CERAMICS USES EESEEE 3CLASSIFICATION OF CERAMICS 1) Traditional and Advanced Ceramic Materials ____ Traditional Ceramics Advanced Ceramics have been developed over the past half century and more generally known types. Pa uae Oinclude industrial inorganic chemicals (i.e, artificial raw materials) that exhibit specialized properties, require more sophisticated processing. Applications: “Applied as thermal barrier coatings to protect metal structures, wearing surfaces. “Engine applications (Silicon nitride (Si,N), Silicon carbide (SiC), Zirconia (ZrO,), Alumina (al,0,) eric “Building materials (brick, clay pipe, glass) Household goods (pottery, cooking ware) Suc euuaC eat ci al Ted) Traditional CeramicsComparison of the different aspects of traditional and ceramics —__epragas —_ = "eee ae ———__ aan aa eee eee —_— Pes Rapid prototyping: Hot | Flame bila ae eee. ete eau. tox _ Plasma spraying J Glanng poate : | ase - X-ray diffraction eT + Compares of the different aspects of traditio in terms of the type of raw materials used, the forming and shaping processas, and the mathods used for characterization1) Traditional and Advanced Ceramic Materials [Advanced Ceramics] ‘Advanced Structural ceramics Electroceramics a eee vnieenee Package Ceramics ‘Structural Clay ‘Capacitor Dielectric, os Prose [__stecerar |Piezoelectric Ceramics| TEI -fmncncoone ) (BREE i; (Aacraite Gomi + [Grin amie2) Amorphous and Crystalline Ceramics Materials Atoms (or ions) are arranged in a regularly repeating pattern in three dimensions (i.e., they have long- range order) QCrystalline ceramics are the “Engineering” ceramics: ¥ High melting points v Strong vHard v Brittle ¥ Good corrosion resistance Silicon nitride (SigN,), Silicon carbide (SiC), Zirconia (ZrO,), Alumina (Al,0,)3) Type of Ceramic by Elements vVNV VY VY oS Aluminates - (11) Arsenides - (5) Borides - (20) Carbides - (17) Ferrites - ® Phosphide - (6) Silicides - (5) Titanates - (22) Tungstates - (14) Zirconates - (7)4 of ceramic materials Based on composition of raw materials and type of ceramic materials: a) Silicate ceramics: compounds containing the anionic complex (SiO,) e.g. the silicate group. Carbide ceramics: * Porcelain + Magnesium Silicates (MgO.SiO,) = Mullite (or Porcelainite : 3A1,0,.2Si0,) 1) Oxide ceramics: + Aluminum Oxide (Al,0;) + Titanium Oxide (TiO,); Magnesium Oxide (MgO) Zirconium Oxide (Zr0,) Lead Lead oxide (PbO) ‘Aluminum carbide (Al,C,) Silicon carbide (SiC) Boron carbide (CB,) Calcium carbide (Ca02) Chromium carbide (Cr,C.) Hafnium(|V) carbide (HIC) ‘Molybdenum carbide (Mo.C) Nigbium(|V) carbide (NbC) Tantalum(\V) carbide (TaC) Titanium carbide (TiC) Tungsten({IV) carbide (WO) b) Advanced ceramics: ii) Non-oxide ceramics: carbides and nitrides are the ‘most important compounds of this group. ‘nate Titanate (Pb(Zr,Ti,..)0,) Aluminum Oxide -Titanium Oxide (Al,0, . TiO.) ceramics ‘Alurnirnar iid (AIN) Magnesium nitride (Mg3N,) * Carbide ceramics * Nitride ceramics * Boride ceramics * Silicide ceramics Silicide ceramics * Calcium sticide technical ( CaS Magnesium slice (Mars) + Molybdenum disilicide ( = Niobium silicide (NBS: = Tungsten silicide ( WSi, Silicon aluminum oxynitride (ALN,O,S!) | Boride ceramios Silicon nitride (SisN,) Barium nitvide (BagNs) Boron nitride (EN) Calcium nitride (Ca,Nz) Gallium nitride (GaN) Gormanium(til) nitrido(GouN,) Indium) nitride (InN) Lithium nitride (LigN) Strontium nitride (SrzNz) Tantalum nitride(TaNl) Titanium carbonitride (Ti,CN) Titanium nitride (TiN) Zirconium nitride (ZrtN) + Aluminum diboride (ALB) + Aluminum eodecaboride (AB) + Calcium hexaboride (CaB, } + Gadolinium boride (Gd) ‘+ Hatnium boride (HIB,) + Lanthanum boride (LaB,) + Lanthanum hexabordie(Lai) + Magnesium boride (MgB) + Nickel boride (Ni,B) + Niobiuen diboride (NbB.) 4 Nichiae manaborida (NR) + Siloon tetraboride (SiB,) ‘+ Tantalum boride (TaB) + Tantalum boride (TaB,) + Tungsten boride (WB) + Vanadium boride (VB)ey Magnesium Silicates, Mullite | Porcetain MgO.SiO, 3AL,0;.2Si0, Magnesium Oxide MgO Aluminum Oxte | eat Oxo ALO. TiO, Zirconium Oxide — 210, Aluminum Oxide eS Titanium Oxide Lead Zirconate Al, . TiO, Titanate Pb(Zr,Ti,..)O, Carbide Ceramics Boron Carbide | Silicon Carbide | | Tungsten Carbide oo) (sie) ‘B.0) Nitid mics Silicon Nitide | __Silcon Aluminum |__(ShNa Aluminum Nitride (AIN)Carbide Ceramics Carbide ceramics ‘Aluminum carbide (Al,C;) Boron carbide (CB,) Calcium carbide (CaC2) Chromium carbide (CreC,) Hafnium(IV) carbide (HFC) Molyodenum carbide (Mo,C) ‘Niobium(IV) carbide (NbC) Silicon carbide (SiC) Tantalum(IV) carbide (TaC) Titanium carbide (TiC) Tungsten(IV) carbide (WC) Automotive Components in Silicon carbide (SIC) Silicon carbide (SiC) is known under trade names Carborundum, Crystalon, and carbolon Chosen for its heat and wear resistanceMolybdenum disilicide (MoSi,, or molybdenum silicide) An intermetallic compound, a silicide of molybdenum, is a refractory ceramic with primary use in heating elements. It has moderate density, melting point 2030 °C, andis electrically conductive. At high temperatures it forms a passivation layer of silicon dioxide, protecting it from further oxidation. It is a gray metallic-looking material with tetragonal crystal structure (alpha- modification); its beta-modification is hexagonal and unstable. It is insoluble in most acids but soluble in nitric acid and hydrofluoric acid. 2 While MoSi, has excellent resistance to oxidation and high Young's modulus at temperatures above 1000 °C, it is brittle in lower temperatures. Also, at above 1200 °C it loses creep resistance. These properties limits its use as a structural material, but may be offset by using it together with another material as a composite material. Molybdenum disilicide (MoSi,) based materials are usually made by sintering. Plasma spraying can be used for producing its dense monolithic and composite forms; material produced this way may contain a proportion of B-MoSi, due to its rapid cooling. Q Used: > Molybdenum disilicide heating elements can be used for temperatures up to 1800°°C, in electric furnaces used in laboratory and production environment in production of glass, steel, electronics, ceramics, and in heat treatment of materials. >in microelectronics as a contact material. as a shunt over polysilicon lines to increase their conductivity and increase signal speed.+ Titanium diboride (Ti8,) is an extremely hard compound composed of titanium and boron which has excellent resistance to mechanical erosion. Ti8, is also a reasonable electrical conductor, so it can be used as.a cathode material in aluminium smelting and can be shaped by electrical discharge machining + Current use of Ti8, appears to be limited to specialized applications in such areas as impact resistant armor, cutting tools, crucibles, neutron absorbers and wear resistant coatings 3B, is extensively used as evaporation boats for vapour coating of aluminium. It is an attractive material for the aluminium industry as an inoculant to refine the grain size when casting aluminium alloys, because of its wettability by and low solubility in molten aluminium and good electrical conductivity. + Thin films of TiB, can be used to provide wear and corrosion resistance to a cheap and/or tough substrate. * Silicon borides (also known as boron silicides: SiB, ) are lightweight ceramic compounds formed between silicon and boron, Several stoichiometric silicon boride compounds, SiB,, have been reported: silicon triboride, SiB,, silicon tetraboride, SiB,, silicon hexaboride, SiB,, as well as SiB,, (n = 14, 15, 40, etc.). The n= 3 and n = 6 phases were reported as being co-produced together as a mixture for the first time by Henri Moissan and Alfred Stock in 1900 by briefly heating silicon and boron in a clay vessel. The tetraboride was first reported as being synthesized directiy from the elements in 1960 by three independent groups: Carl Cline and Donald Sands; Ervin Colton; and Cyrill Brosset and Bengt ‘Magnusson. It has been proposed that the triboride is a silicon-rich version of the tetraboride. Hence, the stoichiometry of either compound could be expressed as SiB,., where x= 0 or 1. Allthe silicon borides are black, crystalline materials of similar density: 2.52 and 2.47 g em 4, respectively, for the n = 3(4) and 6 compounds. On the Mahs scale of mineral hardness, SiB, ., and SiB, are intermediate between diamond (10) and ruby (9). The silicon borides may be grown from boron-saturated silicon in either the solid or liquid state, *+ The Si, crystal structure contains interconnected icosahedra (polyhedra with 20 faces), icosthexahedra (polyhedra with 26 faces), as well as isolated silicon and boron atoms. Due to the size mismatch between the silicon and boron atoms, silicon can be substituted for boron in the B,, Icoszhedra up to a limiting stoichiometry corresponding to SiB, g. Ihe structure ot the tetraboride SiB, is isomorphous to that of boron carbide (8,Cl, BP, and 8,0. It is metastable with respect to the hexaboride, Nevertheless, it can be prepared due to the relative ease of crystal nucleation and growth. + Both SiB,_., and SiB, become superficially oxidized when heated in air or oxygen and each is attacked by boiling sulfuric acid and by fluorine, chlorine, and bromine at high temperatures. The silicon borides are electrically conducting. The hexaboride has a low coefficient of thermal expansion and a high nuclear cross section for thermal neutrons. + The tetraboride was used in the black coating of some of the space shuttle heat shield tiles.5) Oxide and Non-oxide Ceramic BETO US ee) AICarbides, Borides, Nitrides, Silicides CiParticulate reinforced, cc combinations of oie ond non ‘e125 (Silicon Aluminum OxyNitride (AlgN.O.Si) Brennen QLow oxidation resistance OToughness Pact gusty Qoxtreme hardness Ollow and high oxidation resistance (type related) chemically inert a variable thermal and electrical conductivity Dolectrically conducting Dramplex manufacturing processes faye ir) difficult energy dependent high cost. eet aque amici manufacturing and high cost. higher cost for zirconia. Silicon carbide cermic ae foam filter (CFS) Zirconia Ceramic Matrix Composite (CMC) rotorCERAMIC RAW MATERIAL Ceramics are made from three basic ingredients: clay, silica and feldspar A mixture of components used (50%) 1. Clay (25%) 2. Filler — e.g. quartz (finely ground) (25%) 3. Fluxing agent (Feldspar) binds it together \ aluminosilicates + K+, Na+, CatCOMMON RAW MATERIALS + In this chapter we briefly consider the nature of the starting materials, traditionally called raw materials, that can be purchased from a vendor and received at a manufacturing site. These materials can vary widely in nominal chemical_and mineral composition, purity, physical and chemical structure, particle size, and price. “Accordingly, a higher-quality and more expensive material may be acceptable for microelectronics, coatings, fibers, and some high-performance products But the average cost of raw materials for building materials and traditional ceramics such as tile and porcelain must be relatively low. Categories of raw materials include. Common examples are listed in Table. Table 1.2: shows Starting raw materials for ceramics shale, clay, crude bauxite, crude kyanite, natural Ball clay, Bentonite pyrophyllite, talc, feldspar, wollastonite, spodumene, glass sand, kyanite, bausite, zircon, rutile, calcined kaolin, dolomite clacined alumina, calcined magnesia, fused alumina, aluminum nitride, silicon carbide, silicon nitride, barium carbonate, titania, calcined titanates, calcined ferritesi) Crude materials Qa Non-uniform crude material from natural deposits. Q. Many early ceramics industries were based near a natural deposit containing a combination of crude minerals that could be conveniently processed into usable products. Some crude materials are of sufficient purity to be used in heavy refractories: Y Crude bauxite, a nonplastic ore containing hydrous alumina minerals, clay minerals, and mineral impurities such as quartz and ferric oxides, is used in producing some refractories. QO. Construction materials such as brick and tile and some pottery items are historical examples, and many are still identified by the regional name. Today, however, most ceramics are produced from more refined minerals. ii) Industrial minerals (Refined crude materials) a a a Refined industrial minerals that have been beneficiated to remove mineral impurities to significantly increase the mineral purity and physical consistency. Industrial minerals are used in large tonnages for producing construction materials, refractories, whitewores, and some electrical ceramics They are used extensively as additives in glazes, glass, and raw materials for industrial chemicals. iii) Industrial inorganic chemicals High-tonnage industrial inorganic chemicals that have undergone extensive chemical processing and refinement to significantly upgrade the chemical purity and improve the physical characteristics, portant industrial ceramic chemicals include tabular and calcined aluminas (Al,O. icon earbide (SiC), silicon nitride, alkaline earth titanates soft and hard femntes, sta pigments, Extensive chemical beneficiation reduces the content of accessary minerals and may increase the chemical purity up to about 99.5 For many materials, the scale of operation is extremely large, which aids in lowering the unit processing costs and selling price ide (MeO), sso eel.FABRICATING AND PROCESSING OF CERAMICS Material Preparation Forming, Shaping Coasting Drying Glaze processes ——)_ Firing Raw Material ——+ | Microstructure properties Q Most traditional and technical ceramics product are manufactured by | compacting powder or particles into Final product} shapes which are heated to high Propertios temperature. Q The basic steps in the processing of ceramics are: > Material Preparation Aasleaton > Forming & Casting | Spe eaton| > Thermal treatment by dryingTHE MANUFACTURING PROCESS + This consists of four basic stages: shaping, drying, firing and glazing. + Sometimes the glaze is applied before firing (once-firing), and sometimes the item is fired, then the glaze is applied and then the item is refired (twice-firing). Step 1 - Shaping: The ingredients are mixed together and soaked in water. The excess water is squeezed out to make a clay with a moisture content of about 20%, and the mixture is shaped appropriately. This is either done by forcing the clay into a mould or by pressing a mould into the clay while itis spinning on a turn-table. Processing techniques:- > Tape casting > Slip casting > Injection molding Step 2 - Drying: + The items are dried slowly in an oven, during which stage they lose all of the water except that which is bound up in crystal lattices. Before the ware can be fired to high temperatures it must first be dried to remove water. UU Ihis results in a 3 - 7% volume reduction. 1 Water is added to increase the plasticity of the clay; this water is still present in the body after it has been formed, and can be removed only slowly as it must migrate through the spaces between the particles of clay, silica and feldspar to evaporate from the surface. During the drying period the body will shrink by a significant amount. Shrinkage stops when the particles come into contact. However, if drying is not uniform, stresses can build to the extent that the body warps or possibly cracks. 1 Castware is in the mould for 0.5 - 1 hour, where some drying occurs, and then air-dried for 1 - 4 days. Jiggered-ware is dried at a little above ambient temperature for a little over an hour in a "mangle drier" and then air-dried for 1 - 5 days.CERAMIC PROCESSING (mo | s Ge | ecenteey | ga ene, B00 777 Dense/Porous Compact | BD | Final Product ‘Machining 777 21 November 2015 Prof. Dr. H.Z. Harraz Presentation 24 Feldspar GroupsTraditional Ceramic Processin Processing sequence ~ Preparing powders — Shaping of wet clay The more water in the mixture, the — Drying easier to form. But cracking during — Firing drying and sintering. a fA (1) Preparation of powders (2) Shaping of wet clay Loose powders Clay and water ©Crushing & Grinding (to get ready ceramic powder for shaping) Jaw crusher Rotary crusher Crushing rollers ‘Cylindrical container ‘Grinding media with integral bottom ‘tumbling as Tet emovable id sil ore ‘Schematic of the jaw, rotary, crushing rolers, and hammermill x él crushing equipment and ball mil ‘muponaion of VV nil ning (grinding) equipment. Hammermill being sized ‘comnected by a belt and paley toa dete met Typical ball mill (grinding)Tape casting: A process for making thin sheets of ceramics using a ceramic slurry consisting of binders, plasticizers, etc. The slurry is cast with the help of a blade onto a plastic substrate. Slip Casting Figure showing Schematic of a tape casting machine. ‘Assemble pour Trim Remove ; : 2° romota (un meld” —_ Slip casting: Forming a hollow ceramic part by ‘mold Drain residue introducing a pourable slurry into a mold. Figure shows Steps in slip casting of ceramicsInjection Molding Fusion Pellet Heater Compact (Green Parts) Cylinder hitpolobalkyocera.com/feworkifirst/process06.him| Hot Injection Cooling Solidification = Raw materials are mixed with resin to provide the necessary fluidity degree. = Then injected into the molding die * The mold is then cooled to harden the binder and produce a "green" compact part (also known as an unsintered powder compact).Step 3 ~ Firing: The item is heated to temperatures up to 170°C, during which time the clay undergoes some chemical changes and the silica and feldspar undergo physical changes. The reactions of the clay can be summarised as follows: 6AI,Si,0,(OH), — 6AI,Si,0; —> SAl,Si,0,2 —» 2Al,Si0,5 kaolinite metakaolinite _ silicon spinel mullite Silica and water (from the crystal lattice) are also expelled during firing, resulting in a further 5 - 7% volume reduction. This silica mixes with the silica already present and melts to form a glass. It is this glass, which also includes metallic ions from the feldspar, that makes the ceramic item non-porous and water-tight. Q Once drying is complete the body is ready for firing. All unglazed articles and many glazed ‘ones are fired using the "once-firing" method. However, a small number of articles are fired twice in a method whereby the glaze is applied after the first, biscuit, firing and is fixed on by a second, glost, firing. In this method the dried articles pass through the first, biscuit (or "bisque"), firing at a slow rate. For hollow-ware, such as cups, the total time from cold through the kiln and back to cold is about 26 hours, while for other articles it is 44 hours, although modern kiln design is able to significantly decrease both these times. After this the glaze is applied and the ware is fired again. The maximum temperature in both kilns is 1170°C. Q To understand this process it necessary to consider what happens to the individual components of the body when they are heated to high temperatures.Chemical reactions of clay When heated to 1100°C, kaolinite decomposes by first order Kinetics (.e., This means that the reaction rate is proportional to the concentration of the substances reacting) according to the following sequence of steps: Step 1 is a very important step, and the temperature must be caretully controlled as the clay decomposes. The water given off by this reaction is not water remaining between the particles, but water bound into the mineral lattice. The loss of this water causes the lattice and hence the clay particles and therefore the clay body to shrink. If this step is not carefully controlled, the body can be destroyed by thermal stresses and by the rapidly escaping steam. The weight loss during Step 1 is about 14%, which means that the volume of steam evolved at 5500C from a 3 kg lump of clay would be ~ 2m? at S. T. P. Large masses of clayware being fired in a kiln must be well ventilated. ‘Steps 2 and illustrate that the mineral undergoes further solid state reactions where the parent crystal is rearranged and silica is rejected in the form of a glass. Finally, at about 1250°C, mullite and silica glass remain.Chemical reactions of silica + Silica will not decompose at the temperature encountered in firing kilns and melts at 1725°C. Chemical reactions of feldspar + Pure feldspar grains begin to melt at about 1140°C to form a solid and a viscous liquid; as the temperature is raised the solid decomposes to form more liquid. Combined chemical reaction + When a clay body consisting of the above components (clay, silica and feldspar) is heated sufficiently, all of the above reactions occur as well as several others. These other reactions are between the components themselves. + Illustrated in Step 1 in the decomposition of kaolinite reaction. This is then followed by Step 2, the decomposition of metakaolinite to form silicon spinel, and then between 1000 - 1100°C mullite crystals form and SiO2 glass begins to form (Step 3). The mullite crystals remain in the vicinity of the clay particles. + At 1140°G, feldspar grains smaller than about 1Um have completely disappeared by reaction with the surrounding clay. The alkali metal ions diffuse out of the feldspar and the remaining solid decomposes to form mullite and a silica-rich liquid. + If the body is fired to about 1250°C the alkali metal ions, Na* and K* dissolve on to the outer layers of the quartz particles in a silica glass containing alkali metal ions. This glass cements the whole structure together and makes it non-porous and water tight.Step 4- Glazing Glaze is a thin layer of glass or glass and crystals that adheres to the surface of the clay body. + It provides a smooth, non-absorbent surface that can be coloured and textured in a manner not possible on the clay body itself. + Glazes are composed of various oxides combined in proportions that will yield the desired properties. * Silica, Si02, and boric oxide, B203, are the glass formers, but oxides such as Na2O, K20, CaO, PbO and Al203 must be present in the stoichiometric sense to give the desired properties. These include, for example, lowering the viscosity of the molten glass so that the glaze will flow smoothly over the surface of the clay body at the temperature at which the glaze is fired. The glaze is either applied before firing or between a first and second firing. Glazes are glassy substances used to provide a smooth surface on the item (which can then be textured if necessary) and to colour the ceramic surface. Glaze application = Ifa plain coloured article is being produced, the glaze is either applied by dipping or spraying. * For patterns, the pattern is printed on, on a special machine, one colour at a time, with a maximum of three colours. = Some patterns are hand painted. When the glaze is applied the articles go through a second glazing kiln, taking up to twelve hours cold to cold to go through and reaching a maximum temperature of 1050°C. = Some patterns are put on after glazing by a transfer process, and these articles then go through another oven at a temperature of 720°C.Colours of glazes Some of the substances commonly used in forming glazes are listed below in Table Cobalt. When Co?* ions are in a tetrahedral environment a blue colour results. In Matte blue, cobalt is present as a cobalt aluminate. Royal blue, mazarine and willow are Co** in tetrahedral environments in silica glazes. Many green glazes contain Cr203, with Cr? in an octahedral environment. As Cr203 is not soluble in most glazes, the glazes are opaque. Virtually all complexes and compounds of Cu2* are blue or green. CuO (green) dissolves in boric oxide (B203) glaze, giving transparent green shades. If SnO2 is added to this glaze it becomes opaque and if alkalis, e.g. Na2O or K2O, are added, a blue colour may be produced. Many red coloured glazes contain the red oxide Fe203 where the ferric ion, Fe**, is held in an octahedral environment. This is achieved by dissolving Fe203 in Al203 to form a solid solution, particles of this solid being suspended in the glaze. If Fe203 is dissolved directly into a silica containing glaze, the red colour is lost because the two components react to give an iron silicate that is brown. Acombination of CoO (blue), Cr203 (green) and MnO (black). Lead chromate, PbCrO4 24.41.2015 33‘Secondary macining ‘or other operations Figure Shows Different techniques for nal sine eae pro processing of advanced ceramics.Application of CeramicsAPPLICATION AND PROCESSING OF CERAMICS 1) Glasses 2) Clay Products 2.1) Structural clay product 2.2) Whitewares 3) Refractories: 3.1) Fireclay 3.2) Silica 3.3) Basic refractories 3.4) Special refractories 4) Abrasives 5) Cements 6) Advanced Ceramics2) Clay Products 2.1) Structural clay product : >» Ceramic products intended for use in building construction. » Typical structural clay products are building brick, paving brick, terra-cotta facing tile, roofing tile, and drainage pipe. » These objects are made from commonly occurring natural materials, which are mixed with water, formed into the desired shape, and fired in a kiln in order to give the clay mixture a permanent bond. » Finished structural clay products display such essential properties as load-bearing strength, resistance to wear, resistance to chemical attack, attractive appearance, and an ability to take a decorative finish.2.2) Whitewares Any of a broad class of ceramic products that are white to off-white in appearance and frequently contain a significant vitreous, or glassy, component. Uincluding products as diverse as Fine china dinnerware Crockery > Floor and wall tiles > Sanitary-ware (lavatory sinks and toilets) > Dental implants Electrical porcelain (spark-plug insulators) > Decorative ceramics GAY! depend for their utility upon afelatvely small set Of properties: imperviousness to fluids, low. cone uecivity, of eee chemicaL ingress, and Sn ability 10 be formed into complex shapes CThese properties are determined by the mixture fw jnaterials chosen for the products as well as by the forming and firing pracestes employed in their manufacture, Whiteware: Bathrooms3) Refractories Q Firebricks for furnaces and ovens. Q Have high Silicon or Aluminium oxide content. Q Brick products are used in the manufacturing plant for iron and steel, non- ferrous metals, glass, cements, ceramics, energy conversion, petroleum, and chemical industries. >» Used to provide thermal protection of other fnaterials' i Bee) high temperature applications, such as steel making (T, metal foundry operalions, elc. > They are usually composed of alumina (T,,=2050°C: an silica along with other oxides: MgO (T,,; =2850°C), Fe,Oz, TiOs, etc., and have intrinsic porosity typically greater than 16% by ‘volume.3) Refractories 7 O Refractories - A group of ceramic materials capable of withstanding high temperatures for prolonged periods of time. » Acid Refractories: Common acidic refractories include silica, alumina, and fireclay (an impure kaolinite). » Basic Refractories: A number of refractories are based on MgO (magnesia, or periclase). » Neutral Refractories: These refractories, which include chromite and chromite-magnesite, might be used to separate acid and basic refractories, preventing them from attacking one another. & Special Refractories: Other refractory materials include zirconia (ZrO,), zircon (ZrO; - SiO,), and a variety of nitrides, carbides (SiC), and borides, mullite, and graphite with low porosity are also used. 40TABLE 14-7 = Compositions of typical refractories (weight percents) Refractory Sid. A203 Mg0 Fe203 61203 Acidic Sica 95-97 Superduty frebrick 51-53 43-44 High-aluming trebrick 10-49 50-80 Basic Magnesite 83-93 27 Olivine 8 57 Neutral Chromite 313 12-30 10-20 12-25 30-50 Chromite-magnesite 2-8 20-24 30-29 12 30-50 ‘From Ceramic Data Book. Cainers Publishing Co.. 1982. 1800 2 L & 1600 i 1400 (Mg, Fe): SiO, 1200 Mg2Si04 20 40 60 80 Fe2SiO4 Figure shows the Mg,SIO,-Fe,SIO, phase ‘Weight peresnt:KeySilig diagram, showing complete solid solubility.+ Need a material to use in high temperature furnaces. * Consider the Silica (SiO9) - Alumina (Alg03) system. + Phase diagram shows: Mullite (or porcelainite: 3A),0,.2SiO,), Alumina, and Crystobalite as candidate refractories. 2200 | 2a a Adapted from Fig. 12.27, Callister 72. (Fig. 1227 is adapted from Fi. Kiug and R.H. Doremus, Als03 "Alumina Silica Phase Bagram in tho Maio ite 7] Region’, J. American pan Ceramic Society 70(10), p. /98, 1987.) Temperature (°C) 80 Al2O3 Weight percent Al,O3 Figure shows a simplified SiO,-Al,O, phase diagram, the basis for alumina silicate refractories.) clay: Q It is a type of clay which is used in the production of heat resistant clay items, such as the crucibles used in metals manufacturing. Q This type of clay is commonly mined from areas around coal mines, although other natural deposits are also available as potential sources, with many nations having deposits of clays suitable for use in high temperature applications. O Fireclay can also be refined and treated to make it suitable for specialty applications.3.2) Silica O They are made from quartzites and silica gravel deposits with low alumina and alkali contents. Q They are chemically bonded with 3 to 3.5% lime. Q Silica refractories have good load resistance at high temperatures, are abrasion- resistant, and are particularly suited to containing acidic slags. Q Of the various grades coke-oven quality, conventional, and super-duty the super- duty, which has particularly low impurity contents, is used in the superstructures of glass-melting furnaces. .4) Special refractories 3.3) Basic refractories6) Advanced Ceramics Q Advanced ceramic materials have been developed over the past half century Include industrial inorganic chemicals (i.e, artificial raw materials) that exhibit specialized properties, require more sophisticated processing. a Engine applications are very common for this class of material which includes (Silicon nitride (Si,N,), Silicon carbide (SiC), Zirconia (ZrO,), Alumina (Al,03) Q Heat resistance and other desirable properties have lead to the development of methods to toughen the material by reinforcement with fibers and whiskers opening up more applications for ceramics » Structural: Applied as thermal barrier coatings to protect metal structures, wearing surfaces, Wear parts, , or as integral components by themselves; bioceramics, engine components, armour. » Electrical: Capacitors, insulators, integrated circuit packages, piezoelectrics, magnets and superconductors > Coatings: Engine components, cutting tools, and industrial wear parts » Chemical and environmental: Filters, membranes, catalysts, and catalyst supportsApplication of advanced ceramics Engine Components adit ye @ [=> i ) SS BORIDE Inc WC blast nozzle Rotor (Alumina) Kundan MgO refractory bricks (furnace liners)Applications: Advanced Ceramics Electronic Packaging * Chosen to securely hold microelectronics & provide heat transfer * Must match the thermal expansion coefficient of the microelectronic chip & the electronic packaging material. Additional requirements include: > good heat transfer coefficient > poor electrical conductivity * Materials currently used include: * Boron nitride (BN) * Silicon Carbide (SiC) * Aluminum nitride (AIN) » thermal conductivity 10x that tor Alumina > good expansion match with Si aT Heat Engines e v R it higher te it v Brittl Possible parts — engine block, SESH ee SMES St le piston coatings. jet engines v Excellent wear & ¥ Too easy to have voids- Ee BN wei vaziO corrosion resistance weaken the engine XI Sl. i eee 2 Y Low frictional losses ¥ Difficult to machine Y Ability to operate without a cooling system ro Y LowdensityCeramic Armour Typical ceramic materials used in armour systems include: Alumina (Al,0,), Boron carbide (8,C), carbide (SiC), and Titanium diboride (TiB,). Extremely hard materials: > shatter the incoming projectile > energy absorbent material underneath Ceramic armour is armor used by armored vehicles and in personal armor. Ceramic armour systems are used to protect military personnel and equipment. Advantage: low density of the material can lead to weight-efficient armour systems. 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 tho fracturing of the ceramic and any remaining kinotic energy ie abeorbed by the inner ekin, that aleo serves to contain the fragments of the ceramic and the projectile preventing Severe impact with the personnel/equipment being protected Alumina ceramic/Kevlar composite system in sheets ~20mm thick are used to protect key areas of aircraft (cockpit crewlinstruments and loadmaster station). This lightweight solution provided an efficient and removable/replaceable armour system. Similar systems used on Armoured Personnel Carrier's.Biomaterials * Biomaterials, defined as synthetic or natural materials used in contact with biological systems, are enabling tools for many advances in biomedical research. The field of biomaterials is interdisciplinary and includes aspects of materials science, chemistry, biology, and medicine. * Here you will find biocompatible materials, including biocompatible metals and ceramics Microelectromechanical System (MEMS) Mechanical parts and electronic circuits combined to form miniature devices, typically on a semiconductor chip, with dimensions from tens of micrometers to a few hundred micrometers (millionths of a meter). Common applications for MEMS include sensors, actuators, and process- control units.Ceramic ball bearings * A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the moving parts of the bearing. The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads. It achieves this by using at least two races to contain the balls and transmit the loads through the balls. Usually one of the races is held fixed. As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surtaces were rotating on each other. * Optical fibers - is a thin, flexible, transparent fiber that acts as a waveguide, or "light pipe", to transmit light between the two ends of the fiber.REFERENCES Cardarelli,F,, 2005, Materials Handbook: A Concise Desktop Reference. 2~ edn, Springer Verlag London Limited, London, 848p. Bourne, H.L, 1994, Glass raw materials: in Carr, 0.0, and others, eds., Industrial minerals and rocks (6th edition): Littleton, CO, Soc. for Mining, Metallurgy and Exploration, Inc., p, 543-550. Kauffman, R.A. and Van Dyk, D., 1994, Feldspars: in Carr, 0.0. and others, eds., Industrial minerals and rocks (6th edition): Littleton, CO., Soc. for Mining, Metallurgy, and Exploration, Inc., p. 473-481. Lesure. £.G., 1968, Mica deposits of the Blue Ridge in North Carolina: U.S. Geol. Sur. Prof. Paper 577. 129 p. Potter, M.J., 1991, Feldspar, and Nepheline Syenite, and Aplite: Annual Report, US Dept. of Interior, US Bureau of Mines. Potter, M.J., 1996, Feldspar and Nepheline Syenite: Minerals Yearbook, US Dept. of Interior, US Geological Survey; Ufminerals.eruses.gov/minerals}. Potter, M.l., 1997, Feldspar: Mineral Commodity Summaries, US Dept. of Interior, US Geological Survey; U/minerals.erusgs.gov/minerals) USM 1993, Short Course on : Industrial Processing of Kaolin, quartz/silica sand and Feldspar, 20"-22™. April 1993, School of Materials and Mineral Resources Engineering in Collaboration with The Department of Mining and Metallurgical Engineering, University of Queensland, Australia. hittp://www.azom.com/details.asp?ArticleID=2123 wwwaccuratus.com/materlals.htm! http://global.kyocera.com/fcworld/charact/heat/thermaexpan.htm! hittp://www.keramverband.de/brevier_engi/5/4/5_4.htm http://www.ts. mah.se/utbild/mt7150/051212%20ceramics pdt http://www.virginia.edu/bohr/mse209/chapter13.htm http://ceramics.org/learn-about-ceramics/structure-and-properties-of-ceramics/ http://www koramvarhand da/brevinr_ang)/5/5_A htm hnttp://me.queensu.ca/courses/MECH270/documents/Lecture20CeramiesA.pat http://www.tarleton.edu/~tbarker/2033/Notes_Handouts/Powerpoint_notes/Ceramic_Materials_Module_7.pdf http://users.enes.concordia.ca/~mmedraj/mech221/lecture%2018, pdf http://modia 2.web.britannica.com/cb media/85/1585 004 16897201. gif http://global.kyocera.com/feworld/first/processO6.html