Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
MATERIALS IN
PRACTICE
Asst. Prof. Dr. Ayşe KALEMTAŞ
Office Hours: Friday, 16:30-17:30
[email protected], [email protected]
Phone: +90 – 252 211 19 17
Metallurgical and Materials Engineering Department
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
OBJECTIVE
To provide a basic understanding of ceramic
materials.
To understand
processing,
properties,
characterisation and
design
of ceramic materials.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
REFERENCES
D. W. Richerson, "Modern Ceramic Engineering," Second
Edition, Marcel Dekker Inc., (1992).
W.D. Kingery, H.K. Bowen, and D.R. Uhlmann,
“Introduction to Ceramics”, John Wiley and Sons, 1976.
Reed, J. S., ”Principles of Ceramic Processing” John
Wiley&Sons, New York (1995).
Ring, T. A., "Fundamentals of Ceramic Powder Processing
and Synthesis", Academic Press, San Diego (1996).
Rahaman, M. N., "Ceramic Processing and Sintering",
Marcel Dekker Inc. (1995).
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
ISSUES TO ADDRESS
What is ceramic?
Classification of ceramic materials
Processing of ceramic materials
Properties of ceramic materials
Typical applications of ceramic materials
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Classifications of Materials
Materials
Metals
Polymers
Ceramics
Composites
With technological
progress, natural
materials become
insufficient to meet
increasing demands
on product
capabilities and
functions.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
What is "ceramic"?
• from Greek meaning: "burnt earth"
• non-metal, inorganic
• Ceramic materials are inorganic compounds consisting of metallic and nonmetallic elements which are held together with ionic and/or covalent bonds.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Ceramics are
inorganic, nonmetallic, solids, crystalline,
amorphous (e.g. glass), hard, brittle, stable
to high temperatures, less dense than
metals, more elastic than metals, and very
high melting.
Ceramics can be covalent network and/or ionic
bonded.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Ductile versus Brittle Fracture
Fracture Behavior: Very Ductile Modulate Ductile Brittle
Ductile Fracture is
Desirable
Ductile warning
before fracture
Brittle no warning
before fracture
% RA or %EL: Large Moderate Small
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Bonding:
Mostly ionic, some covalent.
% ionic character increases with difference electronegativity.
CaF2
SiC
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction
A comparison of the properties of ceramics, metals, and polymers
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Introduction
A comparison of the properties of ceramics, metals, and polymers
MET
ALS
High density
Medium to high melting point
Medium to high elastic modulus
Reactive
Ductile
CER
AM
ICS Low density
High melting point
Very high elastic modulus
Unreactive
Brittle
PO
LYM
ERS Very low density
Low melting point
Low elastic modulus
Very reactive
Ductile and brittle types
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Historical Perspective
Stone Age: 2.5 million years ago
Pottery Age: 4000 B.C.E
Copper Age: 4000 B.C.E – 3000 B.C.E.
Bronze Age: 2000 B.C.E – 1000 B.C.E.
Foundation of metallurgy- Alloys of copper and tin
Iron Age: 1000 B.C.E – 1B.C.E.
Plastics Age: late 20th Century to current time
Semiconductor Age: late 20th Century to current time
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramics Materials
Ceramic Materials
Naturally occurring minerals Synthetic materials
their origin
locations in which they can be found
their relative abundance
Naturally occurring minerals require extraction,
which is often a regional industry located close to
abundant quantities of the natural deposit.
Most minerals need to go through some form of
physical or chemical processing before use. The
collective term for these processes is beneficiation.
When you understand how oxides are
manufactured, it will be clear why they are often
impure and why Si, Na, Ca are the major impurities.
borides (TiB2, BN, etc.)
carbides (SiC, B4C, TiC, etc.)
nitrides (AlN, Si3N4, TiN, etc.)
oxides (TiO2, Al2O3, etc.)
These ceramics are becoming more common,
but are generally expensive and desire special
processing environments.
For many nonoxides the main impurities are
often components of the starting material which
was not reacted, e.g., Al in AlN or Si in Si3N4.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramics Materials
Non-uniform, crude materials from natural
deposits clays. (Montmorillonite, illite, etc.)
NATURAL RAW MATERIALS
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Classification of Ceramics
Ceramic Materials
Advanced Ceramics Traditional Ceramics
Advanced ceramics
Made from artificial or chemically modified raw
materials.
Traditional ceramics
Mainly made from natural raw materials such as kaolinite (clay mineral), quartz and
feldspar.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Classification of Ceramics
Ceramic Materials
Advanced Ceramics
Structural Ceramics
Bioceramics
Ceramics used in automotive industry
Nuclear ceramics
Wear resistant ceramics (tribological)
Functional Ceramics
Electronic substrate, package ceramics
Capasitor dielectric, piezoelectric ceramics
Magnetic ceramics
Optical ceramics
Conductive ceramics
Traditional Ceramics
Whitewares
Cement
Abrasives
Refractories
Brick and tile
Structural clay products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramic Products
Whitewares:
• Dinnerware
• Floor and wall tile
• Electrical porcelain
• Decorative ceramics
Cement:
• Concrete roads, bridges, buildings, dams, sidewalks, bricks/blocks
Abrasives:
• Natural and synthetic abrasives
Refractories:
• Brick and monolithic products used in iron and steel, non-ferrous metals, glass, cements, ceramics, energy conversion, petroleum, and chemicals industries, kiln furniture
Glasses:
• Flat glass (windows), container glass (bottles), pressed and blown glass (dinnerware), glass fibers (home insulation)
Structural clay products:
• Brick, sewer pipe, roofing tile
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramic Products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramic Products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramic Products
Clay pipes are sustainable
products and last longer than
other materials
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramic Products
Insulating brick
Refractory Brick
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of Traditional Ceramics
Minerals
Chemical processing
Powder Powder
processing
Green body
Sintering Dense/Porous
Compact
Final Product
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Materials Tetrahedron
Microstructures Properties
Processing
Performance
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramics
Clay products – Main Components
Clay
Silica Feldspar
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Traditional Ceramics
Clay products – Main Components
When mixed with water the crystals can easily slide over each other (like a pack of cards), and this phenomenon
gives rise to the plasticity of clays.
Provides plasticity, when mixed with water
Hardens upon drying and firing (without losing
the shape)
Adding water to clay
-- allows material to shear easily along weak
van der Waals bonds
-- enables extrusion
-- enables slip casting
Silica, SiO2, is mixed with clay to reduce shrinkage
of the ware while it is being fired, and thus
prevent cracking, and to increase the rigidity of the ware so that it will
not collapse at the high temperatures required for firing. Silica is useful for this purpose becasue
it is hard, chemically stable, has a high
melting point and can readily be obtained in a pure state in the form of
quartz.
Feldspars are used as a flux in the firing of
ceramic ware. When a body is fired, the
feldspar melts at a lower temperature than clay or
silica, due to the presence of Na+, K+ or Ca2+ ions, and forms a
molten glass which causes solid particles of
clay to cling together: when the glass solidifies
it gives strength and hardness to the body.
Clay
Silica
Feldspar
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Cement and Concrete Manufacturing
Lime
Clay
Iron
Kiln
Gypsum
Clinker
Additions
Mill
Gravel
Cement
Admixtures
Sand
Water
Mixer
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Classification of Ceramics
Ceramic Materials
Advanced Ceramics
Structural Ceramics
Bioceramics
Ceramics used in automotive industry
Nuclear ceramics
Wear resistant ceramics (tribological)
Functional Ceramics
Electronic substrate, package ceramics
Capasitor dielectric, piezoelectric ceramics
Magnetic ceramics
Optical ceramics
Conductive ceramics
Traditional Ceramics
Whitewares
Cement
Abrasives
Refractories
Brick and tile
Structural clay products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Materials
The technology of ceramics is a rapidly developing applied science in
today’s world. Technological advances result from unexpected material
discoveries. On the other hand, the new technology can drive the
development of new ceramics.
Currently many new classes of materials have been devised to satisfy
various new applications. Advanced ceramics offer numerous
enhancements in performance, durability, reliability, hardness, high
mechanical strength at high temperature, stiffness, low density, optical
conductivity, electrical insulation and conductivity, thermal insulation
and conductivity, radiation resistance, and so on.
Ceramic technologies have been widely used for aircraft and
aerospace applications, wear-resistant parts, bio-ceramics, cutting
tools, advanced optics, superconductivity, nuclear reactors, etc.
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Materials
OXIDES
The raw materials used for oxide ceramics
are almost entirely produced by chemical
processes to achieve a high chemical purity
and to obtain the most suitable powders for
component fabrication.
NONOXIDES
Most of the important nonoxide ceramics
do not occur naturally and therefore must
be synthesized. The synthesis route is
usually one of the following:
Combine the metal directly with the
nonmetal at high temperatures.
Reduce the oxide with carbon at high
temperature (carbothermal reduction) and
subsequently react it with the nonmetal.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Application
Cutting tools
Bearing, liners, seals
Agricultural machinery
Engine and turbine parts
Shielding, armour
Hig performance windows
Artificial bones, teeth
Property
Hardness, toughness
Wear resistance
Wear resistance
Heat, wear resistance
Hardness, toughness
Translucence, strenght
Wear resistance, strenght
Material
Alumina, SiAlON
Alumina, zirconia
Alumina, zirconia
SiC, Alumina, Si3N4
Alumina, B4C
Alumina, Magnesia
Zirconia, Alumina
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of Ceramics
* : Ceramic Materials: Science and Engineering, by C. Barry
Carter and M. Grant Norton, Springer, 2007, page 6.
A comparison of different
aspects of traditional and
advanced ceramics.*
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Raw Material Selection Criterias
Raw material cost
Market factors
Technical process parameters
Performance of the desired product
Market price of the product
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Design Objectives
Performance: Strength, Temperature
Manufacturing Techniques
Life Cycle Considerations
Cost
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Other Ceramic Materials
Cements - Ceramic raw materials are joined using a binder that does
not require firing or sintering in a process called cementation.
Coatings - Ceramics are often used to provide protective coatings to
other materials.
Thin Films and Single Crystals - Thin films of many complex and
multi-component ceramics are produced using different techniques
such as sputtering, sol-gel, and chemical-vapor deposition (CVD).
Fibers - Fibers are produced from ceramic materials for several uses:
as a reinforcement in composite materials, for weaving into fabrics, or
for use in fiber-optic systems.
Joining and Assembly of Ceramic Components - Ceramics are
often made as monolithic components rather than assemblies of
numerous components.
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Materials
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Materials
Advanced
ceramic
application
tree
Limitations due to
- High cost
- Low toughness
- Low reliability M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing
Technology 175 (2006) 364–375
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Ceramic filter Foam ceramic molten metal filter
Ceramic Knife Ceramic Fiber Boards As The Heat Insulation
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Ceramic Fiber Products
Ceramic fittings
Ceramic faucet valves with superior
wear resistance and sealing
performance.
Ceramics are used in various textile
machines as guide parts, thread
processing nozzles, oiling nozzles,
rollers and twister parts. Cutting and wear-resistant parts Alumina Ceramic Pipe Lining
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
http://aluminatechnologies.com/products.php
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Ceramic seal rings, axial bearings and radial bearings ensure highly reliable operation and long service life
wherever fluids are pumped or gas is compressed.
Ball Heads Cup Inserts. For inserting
into the acetabular cup
Knee Joint Components.
Improved quality of life,
reduce wear and minimize the
risk of allergies.
High temperature wear
resistance industrial zirconia
advanced ceramic insulator
products
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
With its extensive material range and continuously growing production
expertise in the field of ceramic components for textile processing,
Biocompatible ceramic parts for
drug-delivery systems.
Sheer Veneers ZrO2-metal free
restorations
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Bearing Rollers made from Silicon Nitride
In engine design or exhaust systems, in liquid or gas
circuits – automotive industry demands on seal
rings, bearings and sealing technology are especially
high. Technical ceramics ensure wear resistance,
temperature resistance and stability in these
aggressive environments.
Ceramic gas nozzles made of silicon nitride
Ceramic rollers
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Advanced Ceramic Products
Inserts from CeramTec's latest generation of
ceramic cutting materials. Designed specifically
for high-performance machining of cast iron
materials.
The proven performance standard for
efficient machining with indexable inserts
made of ceramic cutting materials.
CBN indexable inserts (polycrystalline cubic boron nitride) for
efficient machining of cast iron materials and sintered steels for
turning, milling, boring and grooving.
Whether filtration, galvanization, water heating or soil analysis; fields of
application such as the chemicals industry, laboratories, electronics and
electrical engineering, environmental technology or foundry technology
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Thanks for your kind
attention
THE END
Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ Materials in Practice Asst. Prof. Dr. Ayşe KALEMTAŞ
Any
Questions