Traditional and engineering ceramics

Traditional and engineering ceramics

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Traditional ceramics Clay Silica Feldspar
+ +
2 3 2 2
2 3 2 2
6 . .
6 . .
SiO O Al O Na
SiO O Al O K
2
SiO O H SiO O Al
2 2 3 2
2 . 2 .
Structural clay products : bricks,
sewer pipe, roofing tile
EX: Triaxial bodies: Whiteware,
porcelain, chinaware, sanitary ware.
Reactions of a triaxial body
Traditional and engineering ceramics
Traditional and engineering ceramics
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Chapter 1
Traditional ceramics
Triaxial whiteware chemical composition
Traditional and engineering ceramics
Traditional and engineering ceramics
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Chapter 1
Traditional ceramics
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Chapter 1
Electron micrograph of an electrical
insulator porcelain (etched 10 s, 0
o
C,
40% HF, silica replica)
quartz
Mullite needles
High silica glass
Traditional and engineering ceramics
Traditional and engineering ceramics
Traditional ceramics
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Slip casting process
Master and plaster moulds
Fresh cast
Dry
Slip casting
Colour paint Fire
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http://www.lindawilsonceramics.co.za/3.html
Pottery
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Slip casting process Slip casting process Sanitaryware
Slip casting in plaster moulds and demoulding
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Slip preparation
in ball mill
O H O H CaSO O H CaSO
C
o
2 2
3
2 2
1
4
150
2 4
. 2 . +
Hemihydrate plaster produced from gymsum
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Engineering ceramics
Contain more of pure compounds of oxides,
carbides, nitrides.
Ex: Al
2
O
3
, Si
3
N
4
, SiC, ZrO
2
, refractory
oxides
Mechanical properties of engineering ceramics
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Engineering ceramics Alumina
Refractory tubing
High purity crucibles for high temp
High quality electrical applications
(low dielectric loss and high resistivity)
Spark plug insulator
Microstructure of sintered, powdered aluminium
oxide doped with magnesium oxide
Alumina tubes
www.sentrotech.com
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Engineering ceramics Silicon nitride (Si
3
N
4
)
Dissociate at T > 1800
o
C.
Cannot be directly sintered reaction bonding.
Silicon nitride for engineering applications
Silicon powder
N
2
flow
nitriding
Microporous Si
3
N
4
High strength
nonporous Si
3
N
4
Hot pressing with
1-5%MgO
www.defazio-rotary.com
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Engineering ceramics Silicon carbide (SiC)
Hard refractory carbide.
Form skin of SiO
2
at high temp.
Resistance to oxidation at high temp.
Can be sintered 2100
o
C with 0.5-1%B.
Fibrous reinforcement in ceramic-
matrix composite material.
SiC fibre reinforced Titanium matrix
www.stork.com
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Chapter 1
Traditional and engineering ceramics
Traditional and engineering ceramics
Engineering ceramics Zirconia (ZrO
2
)
Polymorphic: tetragonal monoclinic.
Mixed with CaO, MgO and Y
2
O
3
Partially stabilized zirconia (PSZ).
1170
o
C
Volume expansion
Heat treatment Cubic structure
www.azom.com
Zirconia
Mechanical properties of ceramics
Mechanical properties of ceramics
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Brittle
High strength (varying from 0.7 7000 MPa)
Better compressive strength than tensile (5-10 times)
refractory; porous ceramics; glasses <50
porcelains; steatite, cordierite; magnesia, polished
glasses;
50-100
impure and/or porous alumina; mullite; high-alumina
porcelains; reaction bonded silicon nitride and
carbide; glass ceramics
100-200
sintered pure alumina and SiC; tempered glass 200-600
Hot Pressed structural ceramics such as silicon
nitride, silicon carbide, alumina; sintered tetragonal
zirconia and sialon; cemented carbides
600-1000
polycrystalline long ceramic fibres (Al
2
O
3
, SiC): 1-2
GPa, single crystal short ceramic fibres (Al
2
O
3
, SiC
whiskers): 5-20 GPa,
> 1000
Materials Level of strength
(MPa)
Mechanical properties of ceramics
Mechanical properties of ceramics
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Deformation mechanisms
Lack of plasticity due to ionic and covalent bonding (directional).
Stressing of covalent crystal separation of electron-pair
bonds without subsequent reformation brittle
Deforming of ionic single crystal (MgO or NaCl) shows
considering amount of plastic deformation under compressive
force. However ionic polycrystals are brittle due to crack formation
at grain boundaries.
NaCl structure showing slip on
the (110) plane [110] direction
or AA and on the (100) plane
[010] direction BB
Mechanical properties of ceramics
Mechanical properties of ceramics
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Chapter 1
Factors affecting strength of ceramics
Depending on amount of defects
giving stress concentration
Surface cracks
Porosity
Inclusions
Excessive grain sizes
No plastic deformation during crack
propagation from defects very brittle.
Note:
Fabrication
Should control
chemical composition
microstructure
surface condition
temperature
environment
Mechanical properties of ceramics
Mechanical properties of ceramics
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Chapter 1
Toughness of ceramics
Low toughness due to covalent-ionic bonding.
Using hot pressing, reaction bonding to improve toughness.
Fibre-reinforced ceramic matrix composites.
Fracture toughness of ceramics
Mechanical properties of ceramics
Mechanical properties of ceramics
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Toughness of ceramics Example
A reaction-bonded silicon nitride has a strength of 300 MPa and a
fracture toughness of 3.6 MPa.m
1/2
, What is the largest-size internal
crack that this material can support without fracturing? Given Y = 1
( )
( )
m m a
MPa
m MPa K
a
a Y K
f
IC
f IC

8 . 45 10 58 . 4
300
. 6 . 3
5
2
2
2
2
= =
= =
=

Therefore the largest internal crack 2a = 91.6 m

Mechanical properties of ceramics
Mechanical properties of ceramics
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Transformation toughening of Partially Stabilized Zirconia (PSZ)
Zirconia
+ (CaO, MgO or Y
2
O
3
)
PSZ (metal stable)
Sintering at 1800
o
C+rapid cooling to RT+
reheating at 1400
o
C to give fine precipitates
Suranaree University of Technology October 2007
Tetragonal monoclinic
under stressing
Volume expansion
Mechanical properties of ceramics
Mechanical properties of ceramics
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Fatigue failure of ceramics
Fatigue failure in ceramics is rare due to lack of
plastic deformation during cyclic loading.
Fatigue cracking of polycrystalline alumina under cyclic loading
Mechanical properties of ceramics
Mechanical properties of ceramics
Suranaree University of Technology October 2007
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Abrasive property of ceramics
Hard and brittle
Used as cutting, grinding and polishing tools.
www.moldmakingtechnology.com
Ceramic grinding wheels
Ceramic cutting tools
Aluminium oxide
Silicon carbide
Titanium nitride
Tungsten carbide
Boron nitride
Thermal properties of ceramics
Thermal properties of ceramics
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Low thermal conductivity
due to ionic-covalent
bonding insulator.
Also used as refractories
in metal, chemical and
glass industries.
Thermal conductivity of
ceramic materials
Thermal properties of ceramics
Thermal properties of ceramics
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Ceramic refractory materials
A mixture of ceramic compounds
Low-high temperature strength
Low bulk density (2.1-3.3 g.cm
-3
)
Porosity insulating
Refractory bricks (60% Al
2
O
3
)
for hot blast furnace
img.alibaba.com
Basic refractory
Acidic refractory
Mainly based on SiO
2
and Al
2
O
3
Mainly based on magnesia (MgO),
lime (CaO) and Cr
2
O
3
Thermal properties of ceramics
Thermal properties of ceramics
Suranaree University of Technology October 2007
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Chapter 1
Thermal properties of ceramics
Thermal properties of ceramics
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Acidic refractory Basic refractory
Silica refractory has high
refractoriness, high mechanical
strength and rigidity at high
temperature.
Fireclays (fine plastic clays +
flint + coarse clay or grog)
High alumina refractories
contains 50-99% alumina,
giving higher fusion temperature
(more expensive than fireclay).
Basic refractory consists of
mixtures of MgO, CaO and Cr
2
O
3
.
High bulk density
High melting point
Good resistance to chemical
attack (basic slag, oxides)
Ex 92-95% MgO used for lining
in basic-oxygen steelmaking
process
Thermal properties of ceramics
Thermal properties of ceramics
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Ceramic tile insulation for the space shuttle orbiter
Suranaree University of Technology October 2007
About 24,000 ceramic tiles (70%) of silica-fibre compound are
used for insulating external surface of space shuttle.
Thermal properties of ceramics
Thermal properties of ceramics
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Ceramic tile insulation for the space shuttle orbiter
Suranaree University of Technology October 2007
Microstructure of LI900 high-temperature
reusable surface insulation (HTRS)
High temperature reusable surface
(HTRS) made from 90% silica fibres
and 10% empty space.
Density = 0.144 g.cm
-3
Temp ~ 1260
o
C
media.nasaexplores.com
upload.wikimedia.org
Borosilicate coating
Glass
Glass
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Transparency
Hardness and strength
Corrosion/chemical resistance
Vacuumtight enclosure
Insulator
Properties of glass
Blown glass
www.geocities.com
Tinted or heat-absorbed glass
www.arch.tu.ac.th
Definition of glass
An inorganic and noncrystalline
material which maintains its
amorphous microstructure below its
glass transition temperature.
Glass
Glass
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Glass transition temperature (T
g
)
Unlike solidified metal, a glass
liquid does not crystallize but
follow an AD path.
Viscous Plastic Glassy
Temp (decrease)
The faster cooling rate,
the higher values of T
g
.
Solidification of crystalline and amorphous
materials showing a change in specific volume
Glass
Glass
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Structure of glass
Glass forming oxide - SiO
2
Si-O tetrahedron Ideal crystalline silica
(crystobalite)
Simple silica glass with
no-long range order
Glass
Glass
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Structure of glass
Glass modifying oxides - Na
2
O, K
2
O, CaO, MgO
Oxygen from Na
2
O breaks up
silica network, leaving oxygen
atoms with an unshared electron.
Na
+
or K
+
ions fits into interstices
of network.
Network modified glass (soda-lime glass)
Glass
Glass
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Chapter 1
Structure of glass
Intermediate oxides in glass - Al
2
O
3
, Pb
2
O
3
Oxides such as Al
2
O
3
or Pb
2
O
3
cannot form glass network but
join into an existing network.
Aluminosilicate glass
provides higher temperature than
common glass.
Glass
Glass
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Glass composition
Silica glass
Soda-lime glass
Borosilicate glass
(Pyrex glass)
Lead glass
No radiation damage
Reduced T
m
~ 730
o
C
Low thermal expansion
Shielding from high
energy radiation
Glass
Glass
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Chapter 1
Viscous deformation of glasses
Glass remains its viscous
(supercooled) liquid above T
g
.
Temp > T
g
Viscosity
RT Q
o
e
+
=
= viscosity of the glass

o
= pre-exponential constant
Q = molar activation energy for
viscous flow
R = gas constant
T = absolute temperature
Glass
Glass
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Viscosity reference points
Working point
Softening point
Annealing point
Strain point
Viscosity = 10
4
poise (10
3
Pa.s) fabrication
Viscosity = 10
8
poise glass flows at an appreciate
rate under its own weight (and surface tension).
Viscosity = 10
13
poise relieving internal stresses
Viscosity = 10
14.5
poise glass is rigid with slow
rate of stress relaxation.
Note: glass are usually melt at temp relating to viscosity = 10
2
poise
Glass
Glass
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Example
A 96 % silica glass has a viscosity of 10
13
P at its annealing point of
940
o
C and a viscosity of 10
8
P at its softening point of 1470
o
C.
Calculate the activation energy in kJ/mol for the viscous flow of this
glass in this temperature range.
T
anneal
= 940+273 = 1213 K,
ap
=10
13
P
T
softening
= 1470+273 = 1743 K,
ap
=10
8
P
RT Q
o
e
+
=
5
8
13
10
10
10 1 1
exp = =
(
(

|
|

\
|
=
sp ap sp
ap
T T R
Q

mol kJ Q
K K
Q
/ 382
1743
1
1213
1
314 . 8
exp 10
5
=
(

\
|
=
Glass
Glass
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Chapter 1
Fabrications of glass
Forming sheet and plate glass
Blowing, pressing and casting of glass
Float glass process molten glass ribbon moves on the top of
molten tin in a reducing atmosphere.
Remove glass sheet when the glass surface is hard enough
then pass to annealing furnace called lehr to remove residual
stresses.
For deep, hallow shapes like bottles, jars, light bulbs envelops.
Blowing air to force molten glass into moulds.
Pressing a plunger into a mold containing molten glass.
Casting into open moulds.
Glass
Glass
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Float glass process
Glass
Glass
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a) Reheat , b) final blow stage of a glass blowing machine process
Glass
Glass
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Pyrex glass
Borosilicate glass
Low thermal expansion
Inert to almost all materials with the exception of
hydrofluoric acid, hot phosphoric acid and hot alkalies.
2.0% Al
2
O
3
13.0% B
2
O
3
0.5 K
2
O
4.0% Na
2
O
81% SiO
2
Approximate composition
Glass
Glass
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b) after centre has cooled. a) After surface has cooled from high
temperature near glass-softening temperature.
The surface cools first (by rapid air cooling) and contract while
the interior is warm, developing compressive on the surface and
tensile in the middle.
Tempered glass
Glass
Glass
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Distribution of residual stresses across the
sections of glass thermally tempered and
chemically strengthend
Tempered glass
Tempering effect increases
the strength (4 x stronger than
annealed glass.
Has higher impact resistance
than annealed glass.
Ex: Auto side window, safety
glass for doors.
Glass
Glass
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Chapter 1
Laminated glass
Plastic interlayer (PVB-poly vinyle butyral)
is sandwiched with floated/annealed glass.
Safety glass: Breaking like a spider web.
Laminated glass
www.dupont.com
Spider web breaking pattern
http://en.wikipedia.org/
Glass
Glass
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Laminated glass
www.goodandquickglass.com
Suranaree University of Technology October 2007
Glass
Glass
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Chemical strengthened glass
Suranaree University of Technology October 2007
Submerging sodium aluminosilicate glass in a bath containing a
potassium salt at T~ 450-500
o
C for 6-10 h.
Replacing Na ions with
larger K ions on the glass
surface.
Producing thin
compressive stresses at
the surface and tensile
stresses in the centre.
Distribution of residual stresses across the section of glass
thermally tempered and chemically strengthened.
Used in supersonic aircraft glazing,
ophthalmic lenses.