1

The Reliability Analysis of Selected Technical Ceramic Components of Varying Degree of Geometrical Complexity Made Processed by Different Techniques Syed Aun Zaidi (MSME-38) Supervisor: Dr. Hassan Bin Awais
2

PRESENTATION STEPS
Objectives Introduction 4th Semester Targets The Semester Output

Literature

Survey Experimental Work

Project Management & Timeline

3

Sequence

Objective 4th Semester Targets The Semester Output Conclusions

Objective

Advanced ceramics are the need of strategic commissions They offer attractive combinations of engineering properties But they are not REPRODUCABLE making them UN-RELIABLE The Project is to learn the Relaibility

4th Semester Targets

(supervisor assigned)

Literature Review Fundamental theory Choose systems of interest

Highlight need base State of the Art

Acquire Material Design Experimental Scheme Learn Equipment and Material Handling Clearly identify variables to study, based on recent research trends Preliminary Experimentation if Possible

Ceramics Vs Other Materials

Ashby M. Material selection in mechanical design. Third edition p.54. Pergamon press.

OBJECTIVES

Reliability of ceramics

Achieve higher Weibull

modulus
Describing these effects Comparison ofquantitatively conventional

and microwave sintering

9

INTRODUCTION
A

strong movement to use ceramics in new technological applications but the diverse properties of ceramics are not always appreciated. For structural functions, adequate mechanical properties are of prime

10

INTRODUCTION(cont..)
Unfortunately ceramics is brittle, that can lead to sudden failing in catastrophic manner Ceramics contain flaw of different sizes, apparently identical specie have different strength So we have to cope with the scatter in strength.

11

INTRODUCTION(cont..)

Scatter in strength by described by;

By mean and standard deviation

By Weibull statistics

12

INTRODUCTION(cont..)
Weibull distribution is used for the calculation of failure probability of the brittle materials. It has few advantages over Gaussian distribution. It is very flexible Useful even with inadequacies in data Works with small samples

13

Ceramics

Processing

Weibull modulus

Literature Survey

Mechanical properties

Applications

14

CERAMICS

We are well familiar with the word Ceramics Few properties quickly come in our minds which are High temperature resistant High corrosion resistant Highly brittle High melting point

15

CERAMICS APPLICATIONS
1) 2) 3)

In turbines In compressors In nozzles In Firefly, ceramics are used for major components such as the turbine, compressor and turbine inlet nozzle The demand for small-size energy sources with high power densities is increasing with the development of

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CERAMICS APPLICATIONS

Micro gas turbine engine Micro gas turbine engines can have higher power density per volume Higher power densities can also lead to redundant systems that have higher reliability than single engine systems

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CERAMICS APPLICATIONS

A fist-size miniature gas turbine engine with silicon nitride parts called Firefly is being developed at the Rapid Prototyping Laboratory (RPL). The ceramic turbine has been spin tested with room temperature air and it achieved a speed of 456,000 rpm.

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CERAMICS APPLICATIONS

In automobiles

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CERAMICS IN AUTOMOBILE

20

Processing of Ceramics

21

PROCESSING OF CERAMICS

Paraffin wax

Carnauba Wax

Polyethylene Wax

Powder

Binding

Molding

Sintering

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MOLDING OF CERAMICS

It is usually done in Plastic injection molding machine. Injection molding is a manufacturing process for producing parts by injecting material into a mold. Injection molding can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplastic and

23

PARTS OF INJECTION MOLDING MACHINE

24

CERAMIC INJECTION MOLDING

Powder Technology

Ceramic Injection Molding

Plastic Injection Molding

25

SINTERING
Conventional

Sintering Microwave Sintering

26

CONVENTIONAL SINTERING
Sintering is the means whereby the powder particles are welded together and a strong finished part produced The sintering of mechanical parts is usually done in a continuous belt furnace - in special cases a vacuum furnace is used.

27

CONVENTIONAL SINTERING

28

MICROWAVE SINTERING

The use of microwaves in ceramic processing is a relatively recent development. They can be applied effectively and efficiently to heat and sinter ceramic objects Metal in the form of powder will absorb microwaves at room temperature and will be heated very effectively and

29

TEMPERATURE PROFILE

Temperature profile within the sample a) conventional heating b) Microwave Heating c) microwave (Hybrid) heating

30

MICROWAVE SINTERING FURNACE

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MICROWAVE SINTERING Vs. CONVENTIONAL SINTERING

SEM micrograph of samples sintered at 980oC (a) Conventional Sintering (b) Microwave sintering
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MICROWAVE SINTERING Vs. CONVENTIONAL SINTERING

a) Comparison of density

b) Comparison of permeability

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MICROWAVE SINTERING Vs. CONVENTIONAL SINTERING

Heating profile and power consumption of microwave and conventionally sintered

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MECHANICAL TESTING

Three point bend testing

Flexural strength Modulus of elasticity Proof strength Rupture energy

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Weibull Distributions

Normal Distributions

Statistical approaches

Exponential Distributions

Gamma Distribution

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WEIBULL DISTRIBUTION

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WEIBULL MODULUS

The Weibull modulus is a dimensionless parameter of the Weibull distribution which is used to describe variability in measured material strength of brittle materials.

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WEIBULL MODULUS

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WEIBULL MODULUS

In order to understand weibull modulus , an example is given, which will help us in better understanding.

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WEIBULL MODULUS
Sr. (MPa) S=n/N+ ln Ln ln n 1 (1/S) o. 1 985 0.1 20.708 0.8340 3 2 949 0.2 20.671 0.4758 8 3 945 0.3 20.667 0.1856 3
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WEIBULL MODULUS
ln ln (1/S) Vs ln
1 0.5 0 20.708 ln ln(1/S) -0.5 -1 -1.5 -2 -2.5 20.671 20.667 20.641 20.57 20.474 20.463 20.411 20.297

ln

Weibull modulus , m=7

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B-ALLOWABLE STRENGTH

Weibull modulus , m=7

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Plastic Injection Molding

Experimental Work

Sintering

Mechanical Testing

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EXPERIMENTAL WORK

Material under consideration is UPC 518 Al2O3 Properties of UPC 518 Al2O3

14% Binder 14% Binder consist of the following material: 86% Ceramic powder

Binders

Paraffin Wax Polyethylene

Wt. % 78 12

Melting Point 49-52 80-90

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EXPERIMENTAL WORK

Experimental work is started which includes few prerequisites on PIM Machine.

Changing setup of plastic molding to ceramic molding in PIM

Sampling

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Conclusions

The 4th semester targets are satisfactorily achieved

Literature Review Material Selection Equipment Handling Material Acquisition Preliminary Experimentation

The 5th semester would be reserved extensively for experimentation

5th Semester Time-line

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PROPOSED TIMELINE
Mar Apr Ma Jun Jul Au Se Oc c y e y g p t h t Literature Survey Experimen tation

Samplin

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50

Learning the machine operation and its variables

Operation mode
Manual

Injection control
Injection pressure (0 129) MPa

Ejection control
Ejection force 14 kN

Temperature control
Temperature ragne (0 450) C

Semi-automatic

Injection speed (0 - 65) mm/sec

Ejection stroke 100 mm

Automatic

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Continue

Clamping system

Clamping system
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IM with easily flowing material

(a) Telephonic box

(c) Tensile specimen

(b) Telephonic box

Current temperature of barrel zone sample # Material Shape Injection pressure (MPa) Injection speed (g/sec) Hold pressure time (sec)

(d) gear

Injection/ screw position

(a)

LDPE

Tel box

148

158

158

150

45

50

15

40

(b)

PP

Tel box

163

185

183

159

60

45

15

40

(c)

LDPE

Tensile specimen

155

162

156

155

80

45

15

48.4

(d)

LDPE

Gear

152

161

158

156

80

50

16

90.3

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IM of the dies with complexity of shape

(i) Single crucible

(h) 4-piece cylinder

Current temperature of zone sample # Material Shape Injection pressure (MPa) Injection speed (g/sec)

(j) Single cylinder

Hold pressure time (sec)

Injection/ screw position

(h)

LDPE

4- small cylinders

152

161

161

155

75

55

15

95

(i)

LDPE

Single crucible

148

162

165

160

75

55

20

115

(j)

LDPE

Single cylender

148

161

165

160

75

55

16

92

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Continue

(e) Flat plate

(g) 4-small crucibles

(f) 8-point bend test

sample # Material Shape Current temperature of barrel zone Injection pressure (MPa) Injection speed (g/sec) Hold pressure time (sec) Injection/ screw position

(e)

LDPE

Flat plate

148

162

156

152

80

65

15

130

(f)

LDPE

8-point bend test

152

160

165

150

70

50

10

30

(g)

LDPE

4-small crucibles

155

159

161

155

75

55

20

115

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Powder & Binder Characterization

Shape

Particle size & distribution

Uni & bimodal

Cumulative %

Alumina: A-11

Particle size(m)

Powder
Laser particle pycnometer
Cumulative %

Alumina: A-14

Alumina 12 m (nippon) 9 m (nippon) 3 m (alfa aeser) 1 m (logitech) 0.05 m (logitech) 0.3 m (alfa aeser) silica

Pycnometer density: Alumina A-11= 4.053 g/cm3

Cumulative %

Particle size(m)

Alumina: 0.05m
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Particle size(m)

Continue
Polymer based Wax based

Thermogravemetric analysis, heating rate 10 0C/min

100

80

Paraffin wax paraffin

weight %

Carnauba wax carnauba

60

40

20

carnauba wax paraffin wax

0 100 200 300 400 500 600 700

temperature C
120

Binder
Pycnometer tga
weight %

100

80

golden river wax Golden river wax

60

40

Paraffin wax Carnauba wax Super pink Golden river wax Polyethylene Polypropylene Microcrystalline wax

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Pycnometer density:
Carnauba wax= 0.997 g/cm3
weight %

0 100 200 300 400 500 600 700

temperature (c)
100

80

microcrystalline wax Microcrystalline wax

60

Paraffin wax= 0.9021 g/cm3

40

20

0 100 200 300 400 500 600

57
700

temperature (c)

Feedstock preparation
Feed stock is prepared by manually stirring Heating bath is used to provide heat to the beaker
Sample # Powder Particle size(m) Binder system Wt of binder system (g) Stearic acid Wt% Wt of powder added (g) Wt % solid loading Vol % solid loading

Paraffin Wt%

Carnauba Wt%

(1)

Alumina

12

85

10

9.03

64.4

28.9

(2)

Alumina

12

95

10

19.31

65.9

30.1

(3)

Alumina

12

85

10

100

195.43

66.15

30.6

(4)

Alumina

85

10

50

94.41

65.4

29.83

(5)

Alumina

0.05

85

10

100

224.78

69.2

34

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Sample preparation
Hydraulic press is used to produce the samples

Sr #

Feedstock sample #

Shape of sample

Load applied (tons)

Time to apply load (sec)

Weight of sample (g)

a b c d e f g h i

(3) (3) (3) (4) (3) (3) (3) (4) (4)

Small disk Medium disk Large disk Gear Medium disk Tensile Tensile Gear Gear

3 3 3 3 3 3 3 3 3

20 20 15 17 15 20 20 16 16

0.835 2.704 4.497 17.10 3.462 22.27 20.65 12.46 20.09

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Debinding

Debinding is done using wicking method

With wicking
Sample # Stage Heating rate (oC/min)

Without wicking
Debinding temperature (0C) Debinding Hold time (min)

3&4

1 2 Furnace cooling

2 10

500 1000

30 30

60

Continued

Samples debinded at 1000 0C were too fragile that even paint brush cause surface roughness Browning was then done at 1400 0C Strength developed Samples cleaned easily
Sample # Stage Heating rate (oC/min) Debinding temperature (0C) Debinding Hold time (min)

3&4

1 2 3 Furnace cooling

5 5 10

350 550 1000

30 120 30

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Sintering
Powder having particle size greater than 3 m is difficult to sinter without any sintering aid

Experiment 1:
Sample # Stage Heating rate (oC/mi n) Sintering temperatur e (0C) Sintering Hold time (hrs)

3&4

1 2 3

3 10 10

1600 1700 1000 30

Sintering temperature (0C)

11.30 0.15 0 0
Sintering Hold time (hrs)

4 3 2: Experiment
Sample # Stage Heating rate (oC/min)

3&4

1 2 3 4

3 10 10 3

1600 1700 1000 30

13.45 2 0 0

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Density calculation

Sr #

Sample

Shape

1
2 3 4

A
B C E

Small disk
Medium disk Large disk Medium disk

Sintered geometri cal density (g/cm3) 1.31 1.34 1.39 1.22

% of theoreti cal density

32.31%
33.06% 34.29% 30.09%

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Shape Complexity
The shape complexity index is obtained by using a feature based classification system which enables the important design issues. Classification of different shape complexity:A Part envelop is largely a solid of revolution.

B C

Part envelope is largely a prismatic solid. Flat or thin wall section component.

Sub classifications of categories A,B,C is on the basis of

Basic features Secondary features Multi axis Non-uniform Single axis Through features

Shape Complexity Definitions

1.

Basic Features

Straight forward processing where the operation can be carried out without a change of setting or the need of complex tooling. Parts are usually uniform in cross section.

2.Secondary features
Same as basic features but where additional processing is necessary or more complex tooling is required.

3.Multi-axis Features
Parts require to be processed in more than a single axis/set-up.

4.Non-uniform Features
Parts require the development of more complex processing techniques.

5.Complex Forms
Parts need dedicated tooling and the development of specialized processing techniques.

6. Single Axis
This is usually the axis along the components largest dimension, however in the case of cylindrical or disc shaped components it is more convenient to consider the axis of revolution as the primary axis.

7. Through Features
Features which run along across or through a component from one end or side to the other

8. Important
If the component falls into more than one category, always choose the one that gives highest value of complexity.

Basic Rotational features

Regular Secondary features

A1

A2

Category includes Rotationally symmetrical/groove holes along the primary axis

Internal/external threads around primary axis.

Secondary Axis
Interna Internal or external features

Complex forms
Irregular or complex forms

A3

A4

A5

Holes/threads counterbores and other internal features not on primary axis

Projections, complex features.

Complex contoured surfaces

Single Axis/Plane
Basic features only Regular secondary repetitive features

B1

B2

Through steps, threads on single axis

Regular through features

Single Axis
Basic features only

Secondary/Repetitive
Uniform thickness

C1

C2

Blanks, washers, simple bends etc

Plain cogs/gears

Regular forms
cup., cone and box-type parts

Complex forms
Non-uniform forms

C4

C5

Components may involve changes in section thickness

Complex or irregular features

Tensile Strength : Comparison

Metals/ Alloys 5000 Graphite/ Ceramics/ Semicond Polymers Composites/ fibers
C fibers Aramid fib E-glass fib Steel (4140) qt Diamond W (pure) Ti (5Al-2.5Sn) a a Steel (4140) Si nitride Cu (71500) cw Cu (71500) hr Al oxide Steel (1020) ag Al (6061) a Ti (pure) Ta (pure) Al (6061) a Si crystal
<100>

Tensile strength, TS (MPa)

3000 2000 1000

A FRE(|| fiber) GFRE(|| fiber) CFRE(|| fiber)

300 200 100

Room Temp. values

Nylon 6,6 PC PET PVC PP HDPE wood(|| fiber) GFRE( fiber) CFRE( fiber) A FRE( fiber)

40 30
20 10

Glass-soda Concrete Graphite

LDPE

wood (

fiber)

Based on data in Table B4, Callister 7e. a = annealed hr = hot rolled ag = aged cd = cold drawn cw = cold worked qt = quenched & tempered AFRE, GFRE, & CFRE = aramid, glass, & carbon fiber-reinforced epoxy composites, with 60 vol% fibers.
76

Yield Strength : Comparison

Metals/ Alloys Graphite/ Ceramics/ Semicond Polymers Composites/ fibers 20 00
Steel (4140) qt

Yield strength, sy (MPa)

10 00
700 600 500 400 300 200

since in tension, fracture usually occurs before yield.

in ceramic matrix and epoxy matrix composites, since in tension, fracture usually occurs before yield.

Ti (5Al-2.5Sn) a W (pure) Cu (71500) cw Mo (pure) Steel (4140) a Steel (1020) cd

Hard to measure ,

Al (6061) ag Steel (1020) hr Ti (pure) a Ta (pure) Cu (71500) hr

Hard to measure,

Room T values
Based on data in Table B4, Callister 7e. a = annealed hr = hot rolled ag = aged cd = cold drawn cw = cold worked qt = quenched & tempered

100 70 60 50 40 30 20
Tin (pure) Al (6061) a

dry

PC Nylon 6,6 PET PVC humid PP HDPE

LDPE

10

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Fracture Toughness Graphite/

Metals/ Alloys Ceramics/ Semicond Polymers 100 70 60 50 40
Steels

Composites/ fibers
C-C (|| fibers) 1

Ti alloys
Al alloys Mg alloys Al/Al oxide(sf) 2 Y2 O 3 /ZrO 2 (p) 4 C/C( fibers) 1 Al oxid/SiC(w) 3 Si nitr/SiC(w) 5 Al oxid/ZrO 2 (p) 4 Glass/SiC(w) 6

K Ic (MPa m0.5 )

30 20

Based on data in Table B5, Callister 7e.

Composite reinforcement geometry is: f = fibers; sf = short fibers; w = whiskers; p = particles. Addition data as noted (vol. fraction of reinforcement):
1. (55vol%) ASM Handbook, Vol. 21, ASM Int., Materials Park, OH (2001) p. 606. 2. (55 vol%) Courtesy J. Cornie, MMC, Inc., Waltham, MA. 3. (30 vol%) P.F. Becher et al., Fracture Mechanics of Ceramics, Vol. 7, Plenum Press (1986). pp. 61-73. 4. Courtesy CoorsTek, Golden, CO. 5. (30 vol%) S.T. Buljan et al., "Development of Ceramic Matrix Composites for Application in Technology for Advanced Engines Program", ORNL/Sub/85-22011/2, ORNL, 1992. 6. (20vol%) F.D. Gace et al., Ceram. Eng. Sci. Proc., Vol. 7 (1986) pp. 978-82.

10 7 6 5 4 3 2
PC Diamond Si carbide Al oxide Si nitride PET PP PVC

1 0.7 0.6 0.5

Si crystal <111> Glass -soda Concrete

<100>

PS Polyester

Glass 6
78

Measuring Elastic Modulus Room T behavior is usually elastic, with brittle failure.
3-Point Bend Testing often used.
--tensile tests are difficult for brittle materials. F
cross section

L/2

L/2

d b
rect.

Adapted from Fig. 12.32, Callister 7e.

R
circ. d = midpoint deflection

Determine elastic modulus according to:

F
x
slope =

E= F d

L3

d 4bd 3
rect. cross section

L3

d 12 p R4
circ. cross section

linear-elastic behavior

Measuring Strength 3-point bend test to measure room T strength.

cross section

L/2

L/2

d
b
rect.

R
circ.
location of max tension

Adapted from Fig. 12.32, Callister 7e.

d = midpoint deflection

Flexural strength:

Typ. values:

s fs =
Ff

1.5Ff L
rect.

Ff L
pR3

Material

bd 2

x
dfs

sfs (MPa) E(GPa) Si nitride 250-1000 304 Si carbide 100-820 345 Al oxide 275-700 393 glass (soda) 69 69

Data from Table 12.5, Callister 7e.

 Elevated Temperature Tensile Test (T > 0.4 Tm).

creep test

Measuring Elevated T Response

s

x
slope = ess = steady-state creep rate

s
time

Thermal Expansion: Comparison a(10-6/K) Material

Polymers Polypropylene Polyethylene Polystyrene Teflon

at room T
145-180 106-198 90-150 126-216

Polymers have smaller a because of weak secondary bonds

Metals Aluminum Steel Tungsten Gold Ceramics Magnesia (MgO) Alumina (Al2O3) Soda-lime glass Silica (cryst. SiO2)

23.6 12 4.5 14.2

13.5 7.6 9 0.4

Q: Why does a generally decrease with increasing bond energy?

Selected values from Table 19.1, Callister 7e.

Thermal Conductivity: Comparison

Metals

Material

k (W/m-K)
247 52 178 315 38 39 1.7 1.4

Energy Transfer
By vibration of atoms and motion of electrons By vibration of atoms

Aluminum Steel Tungsten Gold

increasing k

Ceramics
Magnesia (MgO) Alumina (Al2O3) Soda-lime glass Silica (cryst. SiO2)

Polymers
Polypropylene Polyethylene Polystyrene Teflon

By vibration/ 0.12 0.46-0.50 rotation of chain molecules 0.13 0.25

Selected values from Table 19.1, Callister 7e.

Comparison Of Strength And Specific Strength Of Aluminum With Other Alloys

TaALAT Lecture 1501 Prepared By Ron Cobden, Alcan,banbury.2009

84

The following are examples of engineering problems solved with Weibull analysis:

A project engineer reports three failures of a component in service operations during a three-month period. The Program Manager asks, "How many failures will we have in the next quarter, six months, and year?" What will it cost? What is the best corrective action to reduce the risk and losses? To order spare parts and schedule maintenance labor, how many units will be returned to depot for overhaul for each failure mode month-by-month next year? The program manager wants to be 95% confident that he will have enough spare parts and labor available to support the overall program.

A state Air Resources Board requires a fleet recall when any part in the emissions system exceeds a 4% failure rate during the warranty period. Based on the warranty data, which parts will exceed the 4% rate and on what date?
After an engineering change, how many units must be tested for how long, without any failures, to verify that the old failure mode is eliminated, or significantly improved with 90% confidence? An electric utility is plagued with outages from superheater tube failures. Based on inspection data forecast the life of the boiler based on plugging failed tubes. The boiler is replaced when 10% of the tubes have been plugged due to failure. The cost of an unplanned failure for a component, subject to a wear out failure mode, is twenty times the cost of a planned replacement. What is the optimal replacement interval?

Scope: Weibull analysis includes

Plotting the data and interpreting the plot Failure forecasting and prediction Evaluating corrective action plans Test substantiation for new designs with minimum cost Maintenance planning and cost effective replacement strategies Spare parts forecasting

Warranty analysis and support cost predictions Controlling production processes Calibration of complex design systems, i.e., CAD\CAM, finite analysis, etc. Recommendations to management in response to service problems