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Introduction
Compared to the huge markets of metal
or plastic components technical ceram-
ics are a niche product. Accordingly, they
are rarely considered in the curriculum of
mechanical engineers. As a consequence,
the use of ceramics may simply fail in
the design of new products, because the
engineers involved are not familiar with
it. However, as indicated in Fig. 1, many
material properties of ceramics are clearly
superior to plastics and metals. Especially
the higher stiffness and hardness as well
as better corrosion and abrasion resistance
of ceramics are valuable advantages in its
use as engineering material. In addition,
its excellent high-temperature resistance
is crucial for many refractory applications.
The small coefficient of thermal expansion
of many ceramics is helpful in its use with Fig. 1
thermal loads or in precision mechanics. Comparison of ceramic, metallic and plastic material properties: upward arrow indicates
Compared to most metals, ceramics have larger, downward arrow smaller magnitude; width of arrow indicates order of effect;
colour of arrow indicates assessment: green means in general beneficial, orange means
a smaller density, making them superior in in general detrimental (according to [1])
lightweight design. Thermal and electrical
conductivity of ceramics can be selected
in a very wide range – depending on their ceramics. Compared to high-volume pro- to avoid any risk by using traditional ma-
composition and microstructure. Together duction of iron based metals and plastics, terial solutions – which is a serious barrier
with other properties, not mentioned in ceramic manufacturing is rather expen- for new ceramic applications.
Fig. 1, like electrical permittivity, dielectric sive resulting in higher prices of ceramic The complexity of material selection can
strength, piezoelectric coefficients, trans- products. Unlike most plastics and metals, be reduced using systematic methods.
parency, refractive index or biocompat- ceramics are inherently brittle. Brittle- Dissemination of these methods is help-
ibility ceramic properties can be exactly ness can lead to a risk of failure, which
matched to the requirements of a specific is not acceptable according to present-day
application. manufacturing standards. So the decision Friedrich Raether
Fraunhofer Institute for
Yet, in competition with plastics and metals in favour of ceramics is not easy in the Silicate Research
one has also to address disadvantages of design of new products. It becomes even Center for High Temperature Materials
more complex, because it depends on the and Design HTL
95448 Bayreuth
interplay of many factors beyond material Germany
Keywords
material selection, component reliability, properties as illustrated in Fig. 2. Due to
carbon foot print this difficulty, there is a strong motivation www.htl.fraunhofer.de
data bases available – many of them free ter strength? This requires a simple cal-
of charge on the internet. Yet, the major- culation. The weight M of the rod is given
ity of databases is restricted to a specific by:
material class: either metals or polymers
or ceramics. Comparing material data(1) (1) M = A A LL ρρ. . (1)
from different databases is difficult be-
cause listed properties differ by type and (1) To = A L fracture,
M avoid ρ. the tensile stresses σ
To avoid
To avoid fracture,
fracture,the
thetensile
tensilestresses σ within
stresses σ within
thethe
rodrod
haveh
measuring conditions. Examples for gen- (1) within
strength:
strength: M = the A Lrodρhave . to be smaller than the
eral cross-material databases are listed To avoid fracture,
tensile strength:the tensile stresses σ within the rod have to be s
in reference [2–4]. MATWEB [2] is a very strength:
F
large database containing 110 000 dataavoid
To (2) σ fracture,
= F < σ T the . tensile stresses σ within the rod h
(2)
strength: σ = F A < σ . (2)
records which is close to the estimated (2) σ = A< σ T . T
A
number of 130 000 materials commercial-
Combining
ly available [5]. However, it containsCombining
only Combining
both equations
both
F equations equations
gives:
gives:
the trade names and data sheets of the
Combining
(2) σ = both
both < σequations
. gives:gives:
ρ
(3) M>>F AF L MI; MI ρ= ρ.
T
=
(3) M > F L MI; MI σ T =σ T .
material producers making cross-material (3) M L MI; MI . (3)
MI σ
searches difficult. Reference [3] points to
Combining
Since
Since FFSince andLboth
and L areset, equations
set, the ratiogives: between
T density
ρ and tensileρ andstt
an ambitious Japanese database on inor- F are
and L are theset,
ratiotheMI ratiobetween
MI between density
density ρ and tensile strength σρ
Fig. 2 minimized
Since
ganic materials containing 82 000 crystal minimized F and totoL obtain
obtainare set, minimum
minimum the ratio
weight. weight.
MI This This
between
ratio
has to
ratio
is is
density
the the ρma
material a
ind
Criteria for material selection engineering
structures, 15 000 phase diagramsminimized (3)
engineering M >
task.F
task.
to obtain If L If MI;
instead
instead
to minimum
of MI
of
weight =
weight M T
weight. M
cost . cost
has to has
be
weight.This ratio is the
to be
minimized, min
is: is: σ T
and be minimized obtain minimum
index for forthe theexample
index
55 000 material property records.engineering
Yet, This ratio
example
task. is Ifabove
the
above
instead
material of weight
index related M to cost has to be
ρρp p
ful to support decision-making and to Since
polymers are listed in a separate database
index F and
the
(4) MI =σ ,
(4)forMI = L
specific
the are
example
, set,
engineering the
above ratio
task. is: MI
If between
instead of density ρ an
promote the use of new materials. Some and the material property records areminimized
not weight toMσρ obtain
T
Tpcost hasminimum
to be weight.
minimized, the This ratio is the
systematic methods for material selec- complete. engineering MI =task. ,Ifmaterial
(4) corresponding instead index
of for
weight the ex-
M cost has to be
with p = material σ price
T per kilogram. Using material indeces a ratio
tion are outlined in this paper. Some ex- Another approach is realized with theindex
CES
with
various ample
pfor
=material above
the example
material is:
price per
candidates above is:possible.
kilogram.
becomes Using material
If two independent indece
amples of successful substitutions of other selector database of Granta [4]. It con-various choice,ρcandidate
material material pcandidates materialsbecomes can bepossible.
plotted with If twoone materindep
materials by ceramics are given. General tains only 3500 material data records with (4)p =MI
asofy-axis.
material = a trade-off
material
choice,
Then ,price surface
candidate permaterials
kilogram.
can be can Using
(4)
be
constructed material
plotted showing with in
on
the
obstacles impeding a wider use of cer- metals, polymers and ceramics but thesevarious
the surface.material
This
σisT candidates
demonstrated becomes
in Fig. 3 for possible.
the light If
and two
cheap inc
as y-axis. Then a trade-off surface can be constructed show
amics as engineering material are given records enable a systematic materialmaterial
se-
best with
choice p
–
choice,=
if amaterial
low price
candidate priceis per
very
the surface. This is demonstrated in Fig. 3 for the light and kilogram.
important
materials Using
can– andbe a unidirectiona
plotted with
polymer ifmaterial
p =materialweight is price
more relevant. All other materials are located
and an outlook regarding global trends is lection. With 60 properties per material,
with
as
best y-axis.
choice – ifindices
Then aalow a price
trade-offrational ranking
perissurface
kilogram. between
very important
Fig. 3 compared to the trade-off surface. Ceramics are inferior by a
canUsing – material
be constructed
and a unidir ins
provided. numerical as well as categorical data,various
thethis
polymer various
surface. material material
This candidates
isis on candidates
demonstrated becomes becomes
in
AllFig. possible.
3 for If- being
the two
light in
Note, thatifa weight
constraint moremaximum relevant. service other
temperature materials areab
database is rather complete. An advantage
material
Fig.
best
changes possible.
3 compared
choicethe – ifIfato
choice,
competition. two
lowtheindependent
candidate trade-off
price
Now materials
is very
ceramics indices
surface. are
can
important
become be
the plotted
Ceramics best– and are with
choice ainfe
un
–
Material selection of the CES selector database is the as con-
Note,y-axis.
trade-off
polymer required
that aweight
ifThen
surface for
constraint atrade-off
ina Fig. ismaterial
3.on
moreMany choice,
maximum
surface
examples
relevant. candidate
service
can be
of material
All temperature
other indices are-sb
constructed
materials
Before a systematic decision for a specific sistency checking of data excluding rough covering materials
also can
thermal be and plotted with
electrical one
materialmaterialuse [5]. Additional
changes
the surface. the competition.
This is Now
demonstrated
Fig. 3 compared to the trade-off surface. Ceramics ceramics in Fig. become3 for the
the best areex
light c
material can be started, a careful analysis mistakes. However, as with other data the nextindex
trade-off section. as x- in
surface andFig. the 3.otherMany as y-axis.
examples Then of material indi
best
Note, choice
that a –constraint
if a low price on maximum is very important service temperatur – and a un
of the customer requirements is neces- bases the quality of the data is not covering
suf- a trade-off
also thermal surface andcan be constructed
electrical material usematerials
[5].the Addit
polymer
changes Ceramic if
the weight
competition.
success is more
stories relevant.
Now ceramics All other
become be
sary. Usually several material properties ficient to replace careful investigationsthe onnext showing
section. the best materials lined up at the
affect the performance for the planned Fig.
trade-off
material properties of selected candidates.
3 compared
surface
surface. Thisin to the trade-off
Fig. 3. Many
is demonstrated surface.
examples
in Fig. 3 for Ceramics
of material i are
Usually
Note,
covering thatceramics
a are
constraint superior on to metals
maximum and materialiftemperatur
plastics
service additional
[5]. Ad
use. They can interact in a complex man- Also few high temperature data are avail- thealso
Ceramic thermal
lightsuccess
and cheap and electrical
connecting
stories rod. Steel use
construction
changes the properties,
competition. are to be fulfilled – e.g. thermal, electrical
ner. E.g., if a light-weight construction is the
able. On the other hand, the CES selector nextis section.
first example the heat
best choicefor
sinks if aNow
– micro- loworpriceceramics
power is very become the be
electronics are discuss
required, material stiffness and density enables material selection via materialtrade-off
in-
by the electronics
Usually surface
important
ceramicsisare – in
and Fig.a
dissipated
superior3. Many
unidirectional
to heat
to metals examples
carbon
and theand of to
heatplastics
has material
beiftransf
addi
are strongly correlated in reducing weight. dices, which is a powerful tool to reduce
coveringCeramic
medium
construction fiber reinforced
also
to prevent thermal
success
properties, polymer
overheating and
stories
are to if weight
electrical
of bethefulfilledis more
material
electronics. use
Therefore
– e.g. thermal, [5].
electrAel
In addition, there are constraints, e.g. di- the number of dimensions in the decision
the
firstnext
mounted relevant.
examplesection.
on All
substrates other materials
separating are
e.g.
heat sinks for micro- or power electronics are located
chips from in the cooling liquid
mensional limitations from the construc- space. Usually the
be electrically upper
ceramics
by the electronics right
isolating
isaresection
- excluding
superior
dissipated of Fig.to 3 heat
metals
to compared
metalsfor this purpose. They r
and and the heatplastics has toif ba
tion, and optimization items, e.g. price re- Material indices combine material proper- conductivityto the λtrade-off
and lowsurface. thickness to maximize heat flow. On the ot
medium Ceramic
construction to success
prevent
duringproperties,
integrityCeramics assembly
stories
overheating
and are toofbe of the electronics.
fulfilled –require Therefor
e.g. therma
are infer ior use anthe heat sinks a minim
duction. This leads to a multidimensional ties with optimization targets of the con-
mounted
first example
substrates on substrates
dependingheat sinks
on forbymicro-
separating
materials strength
order
e.g. orchips
σ
of from
power
. The the
electronics
material coolin
index
decision space where each material is struction. Their use can be illustrated be magnitude.
in aelectrically Note, that
isolating - a constraint
excluding metals
B
on for this purpose
Usually
by the
requirements ceramics
electronicsis: are
is superior totometals
dissipated heat and andthe plastics
heat hasif a
represented by a point. In more than two simple example: consider a rod designed maximum service temperature – being
conductivity
construction
medium to λ
prevent and low
properties, thickness
are
overheating to be to
of maximize
fulfilled
the –
electronics. heat therma
e.g. flow.Ther O
dimensions often spider graphs are used for the transmission of tensile forces. The above 1000 1 assembly°C – completely changes
integrity
first example during heat
=competition. sinks and
for use
micro- of the
or heat
power sinks require
electronics
for this purpose and materials are repre- weight of the rod shall be minimized.mounted
The (5) the MIon substrates .
σ B λ 2 is dissipated Nowseparating
ceramics e.g. become chips from the co
substrates depending on materials strength σBthe. The materia
sented by polygons. In any case, a ranking tensile force F and the length of thebybe rodthe electronics
electrically
the best choice isolating – as -indicated
excluding toby heat
ametals
sec- and for heat
this has
purp
requirements is:
of materials – in order to make the best L are preset whereas its cross section medium A
conductivity ond λ andsurface
to trade-off
prevent overheating
low in Fig. 3.of
thickness tothe
Many electronics.
ex-
maximize heatTher flow
choice – becomes very difficult, because mounted
is variable. It is clear that a low material ampleson substrates
of material separating
indices
integrity during1assembly and use of the heat sinks requ are e.g.
given chips
in from the co
the trade-off between different axes is density ρ and a high tensile strength be σ the
electrically =
book
T (5) MIdepending
substrates of Ashby
isolating covering also
. on materials strength σB. The mat
- excluding thermal
metals for this purp
are favourable to fulfil the requirements. σ Band
λ
and electrical λ 2 low thickness
complex. conductivity
requirements is: material use [5]. Additional
to maximize heat flow
The second challenge is to obtain the re- But how to evaluate materials if oneintegrity
has examples will
during assembly and use be presented in the of next
the heat sinks requ
quired data. There are numerous material the better density and the other the bet- section.
substrates depending
1 on materials strength σB. The mat
(5) MI = is: 2 .
requirements σB λ
58 CERAMICAPPLICATIONS 4 (2016) [1]
1
(5) MI = .
σB λ2
COMPONENTS TECHNOLOGY INSIGHTS
(1) M = A L ρ .
To avoid fracture, the tensile stresses σ within the rod have to be smaller than the tensile
strength:
F
(2) σ = < σT .
A
Fig. 6 Fig. 7
Glass ceramics with adaptable translucency and colour Dental implant of zirconia produced within dimensional
for aesthetic dental restorations tolerances of ±20 µm without finishing
(Source: BCE Special Ceramics GmbH)
tion (Fig. 8). It is used in layered compos- There are numerous further successful plastics or metals. This is a barrier for a
ites together with transparent polymers for applications of technical ceramics. All of wider use of ceramic components, which
bullet proof windowpanes. Manufacturing them are based on specific material prop- cannot be underestimated. It creates a
transparent ceramics requires very pure erties not attainable with metals or poly- driving force for circumventing use of cer-
raw materials and expensive hot isostatic mers. But a more comprehensive descrip- amics by searching for other solutions,
pressing processes. A decrease of produc- tion is far beyond the scope of the present e.g. by changing the construction or by
tion cost opens up many new applica- article. Instead some challenges are ad- combining different materials. The cus-
tions. E.g. superior abrasion and corrosion dressed in the next chapter. tomers view provides a strong reason to
resistance as well as high temperature improve reliability of ceramic components.
stability of transparent ceramics allows its Technical challenges and future trends Much progress has been obtained in this
use as inspection glasses in harsh envir- From the viewpoint of construction en- field during the last two decades. So many
onments (Fig. 9). gineers ceramics are not as reliable as construction engineers meanwhile ac-
cept the necessity of using special design
rules compatible to ceramic properties.
Automation level in ceramic production
has been significantly increased leading
to better reproducibility of critical process
steps. Also process monitoring and qual-
ity control have been drastically improved.
Note that special ceramic products have
Fig. 8 Fig. 9
Inverse strength versus inverse Young’s modulus Inspection glasses of transparent spinel ceram-
of transparent ceramics, glasses and polymers ics for high temperature application
(material data from [4]) (Source: CeramTec-ETEC GmbH)
References
[1] http://www.keramverband.de/brevier_dt/ their electrical, thermal and elastic prop- [9] Raether, F.: Parameters for inherently
brevier.htm erties. Comp. Mater. Science 81 (2014) homogeneous sintering processes. Adv.
[2] http://www.matweb.com 205–211 Engin. Mater. 17 (2015) 1374–1382
[3] http://www.crystdb.nims.go.jp [7] Raether, F. (ed.): Energieeffizienz bei der [10] Nachum, S.; Vogt, J.; Raether, F.: Addi-
[4] www.grantadesign.com Keramikherstellung. Frankfurt 2013 tive Manufacturing of Ceramics: Stereo-
[5] Ashby, M.F.: Material selection in me- [8] Raether, F.: Ceramic Matrix Composites lithography Versus Binder Jetting. cfi/
chanical design. New York 2009 – an Alternative for Challenging Con- Ber. DKG 93 (2016), in print
[6] Müller, T.M.; Raether, F.: 3D modelling struction Tasks. Ceramic Applications 1
of ceramic composites and simulation of (2013) 45–49