MT2171 Ceramic Engineering

Ceramic Engineering
is the design, develop and manufacture of improved
ceramic materials for modern applications.

Ceramics were the first engineered materials. From

the humble beginnings of clay-based pottery, ceramics
are now at the heart of nearly every modern
technology. Ceramics play pivotal roles in electronics,
in transportation, in defense systems, and in
environmental technologies. Ceramic engineers
design, develop and manufacture improved ceramic
materials.
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MT2171/ SUA/2023 2
 Introduction to Ceramic Materials

 Introduction to Ceramics
 Classification of Ceramics
 Glass and Glass ceramics
 Cement
 Traditional Ceramics
 Advanced Ceramics
 Refractories
 Advanced Manufacturing Technologies

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90% of ceramics are hidden in industrial applications Biomaterials
Artificial Bone
Automotive Dental Implants
Sensors Joint Prostheses
Magnets Cancer Treatments
Catalytic Converter
Brake Pads Refractories
Wear resistant Parts
Fire Brick
Insulation
Information Kiln Furniture
Technology
Packaging & Substrates Whitewares
Magnetic Storage Dinnerware
Displays Insulators
Optical Fibers Electronics Sanitoryware
photonics Insulators Tile
Structural
Packaging Wear Resistant
Capacitors High temperature
Piezoelectric Glass
Cement
Ferrite Magnets
Superconductors
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sensors
 Introduction to Ceramics
What are Ceramics?
Ceramics can be broadly defined as inorganic,
nonmetallic solids, which arguably provide the
broadest range of functions of all known materials.

 They are synthesized as glasses, polycrystals, and

single crystals, and in many forms dictated by their end
use, including fine powders, monoliths, thin films, and
composites.

They are also frequently integrated with other materials in

advanced structures andMT2171/
devices.
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 The word ceramic is derived from keramos, the Greek word for
ware made from clay and fired. Wide range of products such as
pottery, tile, cooking ware, glass, refractories, electronic devices,
magnets, etc.
 Most ceramics have ionic bonding which leads to very high
strength. These ceramics are typically a combination of a metal
and a non-metal, e.g. Alumina Al2O3. Some ceramics, however,
have covalent bonding. These are either a combination of two
non-metals, e.g. silica SiO2.
 Ceramics are hard, brittle, high melting point materials with low
electrical and thermal conductivity, good chemical and thermal
stability and high compressive strengths.
 Glass and cements can also be considered as ceramics which
possess special properties and applications than that of traditional
and advanced ceramics.
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 Introduction to Ceramics
ISSUES TO ADDRESS...

 How do we classify ceramics?

 What are some applications of ceramics?

 How is processing of ceramics is different from

other materials?

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Classification of Ceramics

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Type of Ceramic Materials and Their Fabrication Methods

Ceramic Classification Fabrication Method

Glasses Glass Forming

Clay Products
Refractories
Abrasives Particulate Forming
Advanced Ceramics

Cements Cementation
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Ceramic Fabrication Methods

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 INTRODUCTION -GLASS
When a liquid phase is cooled to below its freezing temperature, it
usually transforms into a crystalline solid. Some liquids, because of
complex molecular configuration or slow molecular transport, do not
“crystallize” upon being cooled to low temperatures, but instead form
a rigid disordered network, known as glass, which is very similar in
structure to that of the liquid.

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 Glass forming liquids are those that are able to bypass the
melting point, Tm
Liquid may have a high viscosity that makes it difficult for
atoms of the liquid to diffuse (rearrange) into crystalline
structure
Liquid maybe cooled so fast that it does not have enough time
to crystallize

The molecules in a
glass are not arranged in
a regular repetitive long-
range order as exists in
a crystalline solid.

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Glass Forming Oxides- Most inorganic glasses are based on the
glass-forming oxides silica, SiO2.
 Glass-modifying Oxides- Oxides which break up the glass network
are known as network modifiers. e.g. Na2O and K2O
 Intermediate oxides in glasses- Some oxides can join into an existing
network. These oxides are known as intermediate oxides. e.g. Al2O3, can
enter the silica network as AlOMT2171/
4
-4 tetrahedra, replacing some of the SiO -4
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groups
Glass SiO2 Na2O K2O CaO B2O3 Al2O3 Othe Remarks
r

Soda-lime 71-73 12-14 10-12 0.5-1.5 MgO Easily fabricated.

1-4 widely used for
Plate glass
windows,
containers and
electric bulbs.
96% silica 96.3 <0.2 <0.2 2.9 0.4 Fabricate from
relatively soft
borosilicate glass
Borosilicate 80.5 3.8 0.4 12.9 2.2 Low expansion,
good thermal shock
Low expansion
resistance and
chemical stability.
Widely used in
chemical industry.
Low alkali 54.5 0.5 22 8.5 14.5 Widely used for
fibers in glass
(E-glass)
reinforced
composites.
Glass - Ceramic 40-70 10-35 MgO Crystalline ceramic
10-30 made by
TiO2 devitrifying glass.
Easy fabrication,
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Manufacture of glass bottles
by glass blowing process
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 INTRODUCTION TO CEMENT
The most common cement is Portland cement. The basic raw materials for
Portland cement are lime (CaO), Silica (SiO2), alumina (Al2O3) and iron
oxide (Fe2O3). These components are appropriately proportioned to
produce various types of Portland cement.

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From a practical standpoint, Portland cement can be considered to
consist of four principal compounds which are,
 Tricalcium silicate 3Cao.SiO2 - C3S
 Dicalcium silicate 2Cao.SiO2 - C2S
 Tricalcium aluminate 3Cao.Al2O3 - C3A
 Tetracalcium aluminoferrite 4CaO.Al2O3.Fe2O3 - C4AF
Various types of Portland cement are produced by varying the
amounts of the above chemical compositions.
Hardening of Portland Cement
Portland cement hardens by reactions with water which are called
hydration reactions.
C3S and C2S compounds react with water during the hardening of the
cement and the principal hydration product is tricalcium silicate
hydrate. This material is formed in extremely small particles ( < 1mm)
and is a colloidal gel.
2C3S + 6H2O → C3S2.3H2O + 3Ca(OH)2
2C2S + 4H2O → C3S2.3H2O + Ca(OH)2
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Each of these reactions emphasizes that cement does not harden by
drying, but by the chemical reaction of hydration.
C3S hardens rapidly and is mostly responsible for the early strength of
Portland cement.
C2S has a slow hydration reaction with water and is mainly responsible
for strength increases beyond 1 week. C3A hydrates rapidly with high
rate of heat liberation and contributes slightly to early strength
development.
Typical compound compositions of Portland Cement

Cement Type ASTM C150 C3S C 2S C 3A C3AF

designation
Ordinary I 55 20 12 9

Moderate heat of II 45 30 7 12
hydration, moderate
sulfate resistance
Rapid hardening III 65 10 12 8

Low heat of hydration IV 25 50 5 13

Sulfate - resistant VMT2171/ SUA/2023

40 35 3 14 18
INTRODUCTION TO
 CLAY BASED CERAMICS
 REFRACTORIES
 ABRASIVES
 ADVANCED CERAMICS

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Evolution in Ceramic Industry……New Trends….
Most people, when they hear the word ceramics, think of
dinnerware, pottery, tiles, bricks and sanitary ware. These
products are commonly referred to as traditional or silicate-
based ceramics.
While these traditional products have been, and continue to be,
important to society, a new class of ceramics has emerged that
most people are unaware of. These advanced or technical
ceramics are being used for applications such as
 Space shuttle tile
 Engine components
 Artificial bones and teeth
 Electronic components
 Cutting tools MT2171/ SUA/2023 20
Basically Ceramics can be divided into two categories as
 Traditional Ceramics
 Advanced Ceramics

(1) Traditional Ceramics

Traditional ceramics bear a close relationship to those
materials that have been developed since the earliest
civilization. They are Pottery, Porcelain, Tiles, Structural
clay products, Refractories, tableware, etc. However
traditional ceramics still represent a major part of the
ceramic industry.
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 Traditional Ceramics
 Traditional ceramics are comprised of three basic
components - clay, silica (quartz), and feldspar.

 Clay is one of the most common ceramic raw materials. It is

used widely because it is found in great quantities naturally
and it is easily formed.

 Clay is used in structural clay products (bricks, pipes, tiles)

and white wares (pottery, tableware, china, sanitary ware).
Clay makes up the majority of the ceramic body and is
primarily composed of hydrated aluminium silicates,
Al2O3.SiO2.H2O.

 Most clay products also contain an inexpensive filler, often

quartz, and a feldspar, or flux, that forms a glass to bind
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ceramic particles during heat treatment.
Traditional Ceramic Ware

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 Types of Traditional ceramic ware

• Clay based bodies are known as earthen ware. Ex.

Earthen ware Pots and pans.
–

• Bodies are white on firing. Ex. Crockery ware,

White ware
sanitary ware, wall tiles, floor tiles etc.

Porcelain
.
• has the special property of translucency

usually red in color, due to the presence of iron. Ex.

Heavy clay Bricks, roofing tiles etc.
products

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Raw materials used in Traditional Ceramic Industry
can be divided into two groups as;
Clay: kaolin, ball
clay
1. Plastic raw materials
Non clay plastic
raw materials
Talc, pyrophillite

2. Non plastic raw Feldspar, Dolomite,

materials Quartz or Silica sand

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Ceramic Manufacturing Processes

Ceramic floor tile

manufacturing process

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 Advanced Ceramics
Advanced ceramics include ceramics for electronic,
electrical and biological applications and ceramics for
structural applications at ambient as well as elevated
temperatures. Most of the advanced ceramic materials have
been developed during last fifty years.
 Electro Ceramics
 Advanced Structural Ceramics
 Ceramic Coatings
 Bio Ceramics
 Chemical Processing and Environmental
Ceramics MT2171/ SUA/2023 28
 Markets for Advanced Ceramics

Global advanced ceramics market value was USD 56.70 billion in 2015 and is
projected to reach USD 134.58 billion by 2024, growing at a CAGR of 10.2% from
2016 to 2024. MT2171/ SUA/2023 29
 Electro Ceramics
Ceramic industry interfaces directly with the electronics
industry through the use of ceramic components as an
integral part of electronic devices and packages

 Dielectrics and Insulators

 Piezoelectric materials
 Magnetic Ceramics and Magnetic storage
 Ceramic Semiconductors (PTCR materials)
 Ceramic Superconductors
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 ELECTRO CERAMICS

Electrical
Insulators Semiconductors Superconductors
Conductors
&< 10-12( Ωm) -1 Electrodes LaSrFeO3 YBa2Cu3O7-x
RuO2 - Thick
NTC Thermistors Mn3-xNuxO4 film
PTC Thermistors BaTiO3
ZnO Varistors
Si Chips
ZrO2 Oxygen Sensors

Low k’ High k’
Substrates Al2O3 Capacitors BaTiO3
Switch bases Actuators PbMbNbO3
High Voltage Porcelain Piezoelectric PZT
Low Frequency Porcelain Pyroelectric Ba1-xSrxTiO3
High Frequency Porcelain

Optical Ceramics
Magnetic Ceramics
Electro- Optics PLZT, Ba 1-x SrxTiO3(Night Vision)
Transformers MnZnFe2O4
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Window - Radar 31
Permanent Magnets BaFe12O19
Electroluminescent Ceramics
ELECTRO CERAMICS- Products and Uses:
 Computer chips
 CD players
 Satellite communication systems
 Automobile electronic ignition systems
 Programmable appliances
 Digital cameras and television
 Transistor radios
 Computer – controlled industrial machines
 Robots
 Microphone
 Loud speaker
 Hydrophone sonar
 Non – destructive inspection
 Ultrasonic cleaners
 Motors, transformers
 Quartz watches
 Buzzer, alarms
 Musical instruments
 Lighter and igniters MT2171/ SUA/2023 32
 The electronic market has undergone
significant changes in the past few decades

commercialization of
Miniaturization and new technologies such
Integration as mobile
communication,
personal computers and
Internet

Advanced Ceramics become more and

more important
The electronic industry would not exist without ceramics. Ceramics can be excellent
insulators, semiconductors, superconductors, and magnets. It's hard to imagine not
having mobile phones, computers, television, and other consumer electronic products.
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Miniaturizing capacitors
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 Piezoelectric Ceramics

Definition

“Electric polarization produced by mechanical strain in

crystals belongings to certain classes, the polarization being
proportional to the strain and changing sign with it.”
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 Piezoelectric Effects in Crystalline Materials ( Ceramics)

The piezoelectric effect is a linear, reversible

electromechanical interaction occurring in materials
possessing the proper symmetry properties.
The direct piezoelectric effect is the production of an
electric polarization by a strain; the converse piezoelectric
effect is the production of a stress by an electric field.

The direct piezoelectric effect The converse piezoelectric effect

(a) A piezoelectric crystal with no applied (c) An applied field causes the crystal to
stress or field. become strained. In this case the field
(b) The crystal is strained by an applied force compresses the crystal.
that induces polarization in the crystal (d) The strain changes direction with the
and generates surface charges. applied field and now the crystal is
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extended.
 Smart electronic
automobile shock
absorber. The
multilayer piezoelectric
ceramic stack senses
road vibrations.

Important Piezoelectric Ceramics

 PZT (Lead Zirconate Titanate)
 PLZT (Lead Lanthanum Zirconate Titanate)
 PT (Lead Titanate)
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 BT (Barium Titanate)
 Pb

Zr/Ti

O
Lead Zirconate Titanate Ceramics
Pb(ZrxTi1-x)O3 Structure

Piezoelectric
Strain
Actuator
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 Ceramic Capacitor Dielectrics

Dielectric Ceramics – Barium Titanate

Barium Strontium titanate
Capacitors
 Disc & tube capacitors
 Multilayer ceramic (MLC) capacitors
 Dynamic Random Access Memory (DRAM) Capacitors
Designation Temperature Range Dielectric BaTiO3 content
0C Constants %
Up to
BX , X7R -55 to 125 3000 90 to 98

High K 10 to 85 8000 80 to 94

Z5V 10 to 85 18000 80 to 94

NPO -55 to 125 75 10 to 50

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The capacitance can be increased by stacking capacitors on
top of each other without increasing the area occupied. i.e.
the capacitance of multilayer device (with n number of
capacitors) is n2 times that of a single layer capacitor of the
same size and shape.
The multilayer capacitor (MLC) consists of thin layers of ceramic
interleaved with interdigital electrodes.

(Size of a MLC can be smaller as 0.001

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x 0.002 inchs)
 Semiconductor Ceramics - Thermally sensitive resistors
• Positive coefficient of resistance (PTCR)
• Negative coefficient of resistance (NTCR)
Positive Temperature Coefficient of Resistors (PTCR)

PTCR refers to the non-linear increase of resistance with

temperature in a certain temperature range. The PTCR effect
differs from the ordinary resistor materials which show a
normal change of resistance with temperature.

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 Magnetic Ceramics

Soft Ferrites
e.g Fe3O4 ,, MnFe2O4
NiOFe2O3
Hard Ferrites e.g. Isotropic
barium ferrite

Magnetic Ceramic
Components

Magnetic storage
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Ferrite magnetic ceramics are well established in the electronic
and electrical industry as a widely used magnetic material. From
the view point of electrical properties, Ferrites are semiconductors
or insulators. Due to the high resistivity of ferrites the eddy
currents produced by alternating magnetic fields are limited. This
phenomenon is very important in high frequency inductor and
transformer cores. Therefore Ferrites dominate the microwave
applications. Ferrites have also firmly established as the hard
magnet materials used for speakers and small electric motors.

The research into ferrites was started by Hilpert in 1909. The

work of Snoek of the Philips laboratories in 1930s initiate their
development into useful materials.
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 Bio-Ceramics
Ceramics used for repair and
reconstruction of diseased or damaged
parts of the musculo-skeletal system
termed as bioceramics.

Medical–grade Al2O3 used in total hip replacement: (Left) Al2O3 acertabular

cups mated with Al2O3 femoral balls; (center) Al2O3 balls ; (right) metallic
stem designs for morphological or cement fixation.
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 Structural Ceramics
Structural ceramics possess special properties such as Ability
to withstand high temperature, High strength and hardness,
Wear and corrosion resistance,Better toughness, Better creep
resistance, Optical properties.These ceramics are used for
structural applications under extreme conditions.
e.g. high temperature applications, Cutting tools, etc.

Structural Ceramics
 Silicon Carbide (SiC)
 Silicon Nitride (Si3N4)
 Zirconia (ZrO2)
 Alumuna (Al2O3) MT2171/ SUA/2023 47
 Refractories
Refractory materials must be chemically and physically stable at high
temperatures. Depending on the operating environment, they must be
resistant to thermal shock, be chemically inert, and/or have specific
ranges of thermal conductivity and of the coefficient of thermal
expansion.

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Advanced Ceramics Manufacturing Technologies
The engineering properties of a polycrystalline
ceramics are controlled by the microstructure ,
which in turn depends on the processing method
used to fabricate the body. Therefore, the fabrication
processes govern the production of microstructures
with the desired properties.
The development of advanced ceramics relies on
Processing microstructure property performance
interrelationships

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 CERAMIC PROCESSING SEQUENCE

Traditional Ceramics Advanced Cearmics

Chemical
Mining Synthesis
Calcinations
Powder Ball milling
communication preparation Spray drying
Dry pressing
Casting
Forming
Extrusion
Injection Molding Sintering
Forming
Densification HIP
Gas Pressure
Sintering
Densification Finishing Hot Pressing
operations

Finished
product Finished
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Advanced Ceramics require close control of processing steps

Fabrication of Multilayer Capacitors

Starting powders:
mixed-oxide or wet chemical
routes Burn out binder

Mix starting powders and Sinter

binders

Terminate
Cast tape Preheat and
evacuate

Screen print electrodes Inject electrodes

Stack printed electrodes Attach leads

Dice Encapsulate

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Physical and Chemical coating methods for thin and thick films.

Physical Methods
 Pulsed laser deposition (PLD)
 Sputtering
 Molecular beam epitaxy (MBE)

Chemical Methods
 Sol-gel techniques e.g. spin coating, screen printing, spraying
 Metal organic chemical vapour deposition (MOCVD)
 Electrophoretic deposition
Chemical solution growth techniques e.g. doctor blade
methods, dip coating, spary coating, etc.
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