SI EDITION

MANUFACTURING
Engineering and Technology
Seventh Edition

CHAPTER
8
CERAMICS, GRAPHITE, DIAMOND AND NANOMATERIALS:

STRUCTURE, GENERAL PROPERTIES AND APPLICATIONS

Serope Kalpakjian
Steven R. Schmid ALWAYS LEARNING  Copyright © 2014 Pearson Education South Asia Pte Ltd
Chapter Outline
1. Introduction
2. The Structure of Ceramics
3. General Properties and Applications of
Ceramics
4. Glasses
5. Glass Ceramics
6. Graphite
7. Diamond
8. Nanomaterials

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Introduction
 Ceramics, glasses and glass ceramics have unique
properties
 Various forms of carbon include graphite,
diamond and carbon nanotube

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The Structure of Ceramics
 Ceramics are compounds of metallic and
nonmetallic elements
 Ceramics refers to the material and ceramic
product itself
 Divided into 2 categories:
1. Traditional ceramics
2. Industrial ceramics

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The Structure of Ceramics
 Ceramic crystals structure is the most complex
 Bonding between atoms is covalent or ionic,
stronger than metallic bonds
 Hardness, thermal and electrical resistance are
higher
 Ceramics are single-crystal or polycrystalline
 Grain size major influence the strength and
properties
 Finer the grain size, higher the strength and
toughness
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The Structure of Ceramics :
Raw Materials
 Clay is used as raw materials for making
ceramics
 Most common example is kaolinite, a white clay
consisting of silicate of aluminum
 Other major raw materials are flint and feldspar
 Porcelain is a white ceramic composed of kaolin,
quartz and feldspar

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The Structure of Ceramics :
Oxide Ceramics
 2 major types of oxide ceramics: alumina and
zirconia

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The Structure of Ceramics :
Oxide Ceramics

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The Structure of Ceramics :
Oxide Ceramics
Alumina
 Also called corundum or emery, most widely
used oxide ceramic
 High hardness and moderate strength
 Contains impurities and possesses non-uniform
properties
 Used for electrical and thermal insulation and in
cutting tools and abrasives

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The Structure of Ceramics :
Oxide Ceramics
Zirconia
 Has good toughness, good resistance to thermal
shock, wear, and corrosion, low thermal
conductivity and a low friction coefficient
 Partially stabilized zirconia (PSZ) has higher
strength and toughness and better reliability in
performance
 Used for dies for the hot extrusion of metals and
zirconia beads

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The Structure of Ceramics :
Oxide Ceramics
CASE STUDY 8.1
Ceramic Knives
 Made of zirconium oxide
 Advantages ceramic knives:
1. High hardness and wear resistance
2. Chemically inert, do not stain
3. Lightweight and are easier to use

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The Structure of Ceramics :
Other Ceramics
Carbides
 Made of tungsten, titanium and silicon
 Examples of carbides:
1. Tungsten carbide (WC)
2. Titanium carbide (TiC)
3. Silicon carbide (SiC)

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The Structure of Ceramics :
Other Ceramics
Nitrides
1. Cubic boron nitride (cBN)
2. Titanium nitride (TiN)
3. Silicon nitride

Sialon
 Consists of silicon nitride with aluminum oxide,
yttrium oxide, and titanium carbide
 Higher strength and thermal-shock resistance and
used as a cutting-tool material
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The Structure of Ceramics :
Other Ceramics
Cermets
 Ceramic phase bonded with a metallic phase
 Also called black ceramics or hot-pressed
ceramics
 For high-temperature applications, nozzles for jet
engines and brakes for aircraft

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The Structure of Ceramics :
Other Ceramics
Silica
 Silica is a polymorphic material, having different
crystal structures
 Most common is quartz, is a hard and abrasive
hexagonal crystal
 Silicates is the reaction of silica with oxides of
aluminum, magnesium, calcium, potassium,
sodium, and iron

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The Structure of Ceramics :
Other Ceramics
Nanoceramics and Composites
 Particle size in ceramics is reduced to improve the
ductility and manufacturing properties
 Nanoceramics or nanophase ceramics consist of
atomic clusters
 Exhibit ductility at low temperatures, stronger
and easier to fabricate
 Used in automotive industry, i.e. valves

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General Properties and Applications
of Ceramics
 Ceramics is brittle, has high strength and hardness
at elevated temperatures, but low thermal and
electrical conductivity
 They are sensitive to flaws, defects, and surface
or internal cracks

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General Properties and Applications of
Ceramics: Mechanical Properties

 Table shows mechanical properties of engineering

ceramics

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General Properties and Applications of
Ceramics: Mechanical Properties

 Tensile strength of polycrystalline ceramic

increases with decreasing grain size and porosity
 Relationship is represented by

 nP P = volume fraction of pores in the solid

UTS  UTS o e UTSo = tensile strength at zero porosity
n range from 4 and 7

 Modulus of elasticity of ceramics is


E  Eo 1  1.9P  0.9P 2  Eo = elastic modulus at zero porosity

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General Properties and Applications of
Ceramics: Mechanical Properties

 Ceramics lack impact toughness and thermal-

shock resistance due to lack of ductility
 When undergoing fatigue failure under cyclic
loading, ceramics exhibit static fatigue
 When subjected to a static tensile load over time,
these materials suddenly may fail
 Ceramic components subjected to tensile stresses
may be prestressed

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General Properties and Applications of
Ceramics: Physical Properties

 Ceramics have low specific gravity and high

melting temperatures
 Thermal conductivity k is related to porosity by

k  ko 1  P  ko = thermal conductivity at zero porosity

P = porosity as a fraction of the total volume

 Oxide ceramics shows anisotropy of thermal

expansion, where thermal expansion varies in
different directions in the ceramic
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General Properties and Applications of
Ceramics: Applications

 Ceramics have high electrical resistivity and

dielectric strength
 It is used for automotive gas-turbine engine
components (rotors)
 They have low density and high elastic modulus,
enable the inertial forces generated by moving
parts to be lower

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General Properties and Applications of
Ceramics: Applications

CASE STUDY 8.2

Ceramic Gun Barrels
 Wear resistance and low density of ceramics
 Zirconia chosen due to high toughness, flexural
strength, specific heat, operating temperature, and
very low thermal conductivity
 Barrel is wrapped with a carbon fiber / polymer-
matrix composite to improve tensile stresses
developed during firing

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General Properties and Applications of
Ceramics: Applications

CASE STUDY 8.3

Ceramic Ball and Roller Bearings
 Used when high temperature, high speed, or
marginally lubricated conditions occur

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Glasses

 Glass is an amorphous solid with the structure of

a liquid
 It is cooled at a rate too high to allow crystals to
form (supercooled)
 Glass is defined as an inorganic product of fusion
that has cooled to a rigid condition without
crystallizing
 All glasses contain at
least 50% silica, known
as a glass former
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Glasses: Types of Glasses

 Commercial glasses are categorized by:

1. Soda-lime glass
2. Lead-alkali glass
3. Borosilicate glass
4. Aluminosilicate glass
5. 96%-silica glass
6. Fused silica glass

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Glasses: Types of Glasses

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Glasses: Mechanical Properties

 Behaviour of glass is regarded as perfectly elastic

and brittle
 Defects reduce the strength of glass by two to
three orders of magnitude
 Strength of glass is measured by bending it
 Glass surface is abraded to ensure that the test
gives a reliable strength level
 Phenomenon of static fatigue is exhibited by
glasses

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Glasses: Physical Properties

 Low thermal conductivity and high electrical

resistivity and dielectric strength
 Thermal expansion coefficients are lower than
metals and plastics
 Optical properties of glasses can be modified by
varying their composition and treatment

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Glass Ceramics

 Glass ceramics have a high crystalline

component to their microstructure
 Contain large proportions of several oxides
 Properties are a combination of glass and
ceramics
 As glass ceramics have a near-zero coefficient of
thermal expansion, they have high thermal-shock
resistance

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Graphite

 Graphite is a crystalline form of carbon having a

layered structure with close-packed carbon atoms
 It is weak when sheared along the layers
 Low frictional properties as a solid lubricant
 Strength and stiffness of graphite increase with
temperature
 It is brittle, has high electrical and thermal
conductivity and good resistance to thermal shock

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Graphite

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Graphite

Graphite Fibers
 fibers in reinforced plastics
Carbon and Graphite Foams
 Have high service temperatures, chemical
inertness, low thermal expansion, and thermal and
electrical properties
 Carbon foams are available in either graphitic or
nongraphitic structures. Graphitic foams have low
density, high thermal and electrical conductivity,
but lower mechanical strength
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Graphite: Fullerenes

 Carbon molecules (typically C60) are now

produced in the shape of soccer balls, called
fullerenes or buckyballs
 These chemically–inert spherical molecules are
produced from soot, and act much like solid
lubricant particles
 When mixed with metals, fullerenes can become
superconductors at low temperatures (around 40
K).

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Graphite: Nanotubes
 Carbon nanotubes is tubular forms of graphite to
implement in nanoscale devices
 Have high strength, to make into a reinforcing fiber
for composite materials
 They have very
high electrical
current carrying
capability, which
can be made as
semiconductors
or conductors
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Diamond
 Diamond is a principal form of carbon with a
covalently bonded structure
 Hardest substance known
 It is brittle and decompose in air at about 700°C
 Has numerous important applications:
1. Cutting-tool materials
2. Abrasives in grinding wheels
3. Dressing of grinding wheels
4. Dies for drawing wire
5. Coatings for cutting tools and dies
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Nanomaterials

 They have high strength, hardness, ductility,

toughness, wear resistance and corrosion
resistance
 Suitable for structural (load bearing) and
nonstructural applications
 Composition an be any combination of chemical
elements
 Nanometal– polymer hybrid nanomaterials are
developed for very lightweight components

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