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Processing of Ceramics
ISSUES TO ADDRESS...
• How do we classify ceramics?
Chapter 13 - 1
13.1- 13.8 Taxonomy of Ceramics
Glasses Clay Refractories Abrasives Cements Advanced
products ceramics
-optical -whiteware -bricks for -sandpaper -composites engine
-composite -bricks high T -cutting -structural -rotors
reinforce (furnaces) -polishing -valves
-containers/ Adapted from Fig. 13.1 and discussion in
-bearings
household Section 13.2-6, Callister 7e.
-sensors
• Properties:
-- Tm for glass is moderate, but large for other ceramics.
-- Small toughness, ductility; large moduli & creep resist.
• Applications:
-- e.g. Thermally shock and chemically resistance-lab ware, ovenware
. High index of refraction – optical lenses
• Fabrication
-- some glasses can be easily formed
-- other ceramics can not be formed or cast.
Chapter 13 - 2
Glass-ceramics
100% crystallization
100% glass
Chapter 13 -
Application: Refractories
• Need a material to use in high temperature furnaces.
• Consider the Silica (SiO2) - Alumina (Al2O3) system.
• Phase diagram shows:
mullite, alumina, and crystobalite as candidate refractories.
2200 3Al2O3-2SiO2
T(°C)
mullite
2000 Liquid
(L) alumina + L
Adapted from Fig. 12.27,
1800 Callister 7e. (Fig. 12.27
mullite is adapted from F.J. Klug
crystobalite alumina and R.H. Doremus,
+L +L + "Alumina Silica Phase
1600 mullite Diagram in the Mullite
Region", J. American
mullite Ceramic Society 70(10),
+ crystobalite p. 758, 1987.)
1400
0 20 40 60 80 100
Silica Composition (wt% alumina)
Chapter 13 - 4
• 20wt%Al2O3-80wt%SiO2 and 25wt%Al2O3-75wt%SiO2
Which is more desirable for refractory?
2200 3Al2O3-2SiO2
T(°C)
mullite
2000 Liquid
(L) alumina + L
1800
crystobalite mullite alumina
+L +L +
1600 mullite
mullite
+ crystobalite
1400
0 20 40 60 80 100
Composition (wt% alumina)
Chapter 13 - 5
Application: Die Blanks
• Die surface:
-- 4 mm polycrystalline diamond
particles that are sintered onto a
cemented tungsten carbide Courtesy Martin Deakins, GE
substrate. Superabrasives, Worthington,
OH. Used with permission.
-- polycrystalline diamond helps control
fracture and gives uniform hardness
in all directions.
Chapter 13 - 6
Application: Cutting Tools
• Tools:
-- for grinding glass, tungsten,
carbide, ceramics
-- for cutting Si wafers
-- for oil drilling
• Operation:
sensor
-- voltage difference
gas with an reference
produced when unknown, higher gas at fixed
O2- ions diffuse oxygen content O2-
oxygen content
diffusion
from the external
surface of the sensor
to the reference gas. + -
Parison
mold
Compressed
• Blowing: air wind up
Glass • Glasses:
(amorphous solid)
-- do not crystallize
Crystalline -- change in slope in spec. vol. curve at
(i.e., ordered) solid
glass transition temperature, Tg
Tg Tm T -- transparent
- no crystals to scatter light
Chapter 13 - 10
Glass Viscosity vs. T and Impurities
• soda-lime glass: 70% SiO2
• Viscosity decreases with T balance Na2O (soda) & CaO (lime)
• Impurities lower Tdeform • borosilicate (Pyrex):
13% B2O3, 3.5% Na2O, 2.5% Al2O3
• Vycor: 96% SiO2, 4% B2O3
• fused silica: > 99.5 wt% SiO2
Viscosity [Pa s]
Fracture
14
10 strain point
Release stress in 15 min
annealing range
10 10
Hold shape
6
10 Tdeform : soft enough
to deform
Easilyor “work”
deformed
10 2
Tmelt Adapted from Fig. 13.7, Callister, 7e.
Liquid
(Fig. 13.7 is from E.B. Shand, Engineering
1 Glass, Modern Materials, Vol. 6, Academic
200 600 1000 1400 1800 T(°C) Press, New York, 1968, p. 262.)
Chapter 13 - 11
Heat Treating Glass
• Annealing:
--removes internal stress caused by uneven cooling.
• Tempering:
--puts surface of glass part into compression
--suppresses growth of cracks from surface scratches.
--sequence:
before cooling surface cooling further cooled
cooler compression
hot hot tension
cooler compression
Chapter 13 - 12
13.10 Ceramic Fabrication Methods-IIA
(50%) 1. Clay
(25%) 2. Filler – e.g. quartz (finely ground)
(25%) 3. Fluxing agent (Feldspar)
binds it together
Chapter 13 - 14
Features of a Slip
Shear
• Clay is inexpensive
• Adding water to clay Al2(OH)42+ layer
-- allows material to shear easily charge
along weak van der Waals bonds neutral
-- enables extrusion Si2O52- layer
-- enables slip casting
weak van
der Waals
• Structure of bonding
4+
Kaolinite Clay: charge Si
3+
Adapted from Fig. 12.14, Callister 7e. neutral Al
(Fig. 12.14 is adapted from W.E. Hauth, -
"Crystal Chemistry of Ceramics", American
OH
2-
Ceramic Society Bulletin, Vol. 30 (4), 1951, O
p. 140.)
Shear Chapter 13 - 15
Drying and Firing
• Drying: layer size and spacing decrease. Adapted from Fig.
13.13, Callister 7e.
(Fig. 13.13 is from
W.D. Kingery,
Introduction to
Ceramics, John
Wiley and Sons,
Inc., 1960.)
70mm Chapter 13 - 16
13.11 Ceramic Fabrication Methods-IIB
15 mm Chapter 13 - 17
Powder Pressing
Sintering - powder touches - forms neck & gradually neck thickens
– add processing aids to help form neck
– little or no plastic deformation
Uniaxial compression - compacted in single direction
Isostatic (hydrostatic) compression - pressure applied by
fluid - powder in rubber envelope
Chapter 13 - 18
Powder Pressing
Chapter 13 - 22