Yrd. Doç. Dr. Ayşe KALEMTAŞ
MME391 CeramicMaterials
Asst. Prof. Dr. Ayşe KALEMTAŞ
Bursa Technical University, Metallurgical and Materials Engineering Department
Office Hours:[email protected], [email protected]
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Content of the Lecture Introduction to ceramic materials, description of ceramic materials properties,
properties- microstructure-sintering process, brief history of ceramic materials,classification of ceramic materials.
Ceramic crystal structures, bonds in ceramic materials Crystal structures, crystal directions and planes, ceramic crystal chemistry, ceramic
crystal structures Phase equilibria and phase equilibrium diagrams in ceramics, phase rule, binary phase
rule, one component, two component and three component systems, solid solutions,important phase diagrams
Properties of ceramic materials, physical properties of ceramics, thermal properties ofceramics, mechanical properties of ceramics, toughening mechanisms.
Electrical properties of ceramics, dielectrical, magnetic and optical properties Powder processing, ceramic raw materials; traditional ceramic raw materials; ceramic
clays, kaolin, quartz, feldspar, wollastonite, talc, advanced ceramic raw materials;aluminum oxide, zirconium oxide
Raw materials selection criteria, purity, particle size and reactivity, powder preparationand sizing, mechanical sizing, chemical sizing, mixing, reconsolidation, additives, spraydrying, composition calculation
Shape forming processes, pressing, step in pressing, selection of additives, uniaxialpressing, ısostatic pressing, application of pressing, casting, slip casting, extrusion,injection molding
Densification, theory of sintering, sintering stages, sintering mechanism Control of conventional sintering, sintering atmosphere, time/temperature cycle, design
of the furnace, sintering problems, hot pressing, hot ısostatic pressing, spark plazmasintering
Yrd. Doç. Dr. Ayşe KALEMTAŞ
References
1) Reed, J. S., ”Principles of Ceramic Processing” John Wiley&Sons, NewYork (1995).
2) Ring, T. A., "Fundamentals of Ceramic Powder Processing andSynthesis", Academic Press, San Diego (1996).
3) Hunter, R., “Introduction to Modern Colloid Science”, OxfordUniversity Press (1993).
4) Rahaman, M. N., "Ceramic Processing and Sintering", Marcel DekkerInc. (1995).
5) Hiemenz, P. C. and Rajagopalan, R., "Principles of Colloid and SurfaceChemistry", Marcel Dekker Inc. (1997).
6) W.D. Kingery, H.K. Bowen, and D.R. Uhlmann, “Introduction ToCeramics”, John Wiley and Sons, 1976.
7) D. W. Richerson, "Modern Ceramic Engineering," Second Edition,Marcel Dekker Inc., (1992).
Yrd. Doç. Dr. Ayşe KALEMTAŞ
GRADING
1. Mid Term Exam: 20 %
2. Mid Term Exam: 30 %
FINAL EXAM : 50 %
Yrd. Doç. Dr. Ayşe KALEMTAŞ
CLASSIFICATION OF MATERIALS
Materials
Metals Polymers Ceramics Composites
Ceramic Materials
GlassesClay
ProductsRefractories Abrasives Cements
Advanced
Ceramics
Yrd. Doç. 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
Yrd. Doç. 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.
Yrd. Doç. Dr. Ayşe KALEMTAŞ
What is "ceramic"?
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.
Yrd. Doç. Dr. Ayşe KALEMTAŞ
What is "ceramic"?
Bonding: Mostly ionic, some covalent. % ionic character increases with difference electronegativity.
CaF2
SiC
Yrd. Doç. Dr. Ayşe KALEMTAŞ
What is "ceramic"?
Ceramic materials brittle fracture !!!
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Examples of ceramic materials ranging from household to high performance combustion engines which utilize both metals and ceramics.
MET
ALS High density
Medium to highmelting point
Medium to highelastic modulus
Reactive
Ductile
CER
AM
ICS Low density
High meltingpoint
Very high elasticmodulus
Unreactive
Brittle
PO
LYM
ERS Very low density
Low meltingpoint
Low elasticmodulus
Very reactive
Ductile andbrittle types
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
A comparison of the properties of ceramics, metals, and polymers
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Introduction to Ceramic Materials
Ceramic materials have now become the cornerstone of such advanced technologies
as energy transformation, storage and supply, information technology, transportation systems, medical
technology, and manufacturing technology
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Future of Materials Science
Design of materials having specific desired characteristics directly from ourknowledge of atomic structure.
• Miniaturization: “Nanostructured" materials, with microstructure that has lengthscales between 1 and 100 nanometers with unusual properties. Electroniccomponents, materials for quantum computing.
• Smart materials: airplane wings that deice themselves, buildings that stabilizethemselves in earthquakes…
• Environment-friendly materials: biodegradable or photodegradable plastics,advances in nuclear waste processing, etc.
• Learning from Nature: shells and biological hard tissue can be as strong as themost advanced laboratory-produced ceramics, mollusces produce biocompatibleadhesives that we do not know how to reproduce…
• Materials for lightweight batteries with high storage densities, for turbine bladesthat can operate at 2500°C, room-temperature superconductors? chemical sensors(artificial nose) of extremely high sensitivity, cotton shirts that never requireironing…
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Application Base Classification
Ceramic Materials
Advanced Ceramics
Structural Ceramics
Bioceramics
Ceramics used in
automotive industry
Nuclear ceramics
Wear resistant
ceramics (tribological)
Functional Ceramics
Electronic substrate,
package ceramicsCapasitor dielectric,
piezoelectric ceramics
Magnetic ceramics
Optical ceramics
Conductive ceramics
Traditional Ceramics
Whitewares
Cement
Abrasives
Refractories
Brick and tile
Structural clay
products
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Earthenware, Stoneware, China, Porcelain, are all distinguished
by their firing temperature and glass forming temperature
Tiles are made from similar composition material
Structural bricks are made from cheaper mixtures -often a
single clay (“Fletton Brick”)
Refractory bricks have special compositions to withstand high
temperatures or corrosive environments
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Clay pipes are sustainableproducts and last longer thanother materials
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Insulating brick
Refractory Brick
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
Heat resistantglass lidHeat resistant glassware
(microwave safe)Tempered GlassCutting Board
http://www.wolfard.com
Classic Wolfard Oil Lamp
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
www.tripadvisor.comGlass sink cabinets in the bathroom
www.aarticommercial.com/products.php
Laminated Windscreen Glass
http://freshome.comhttp://www.ifjk.org
Tempered glass table
Heat resistantglass door
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Applications
www.toxel.comGlass Bathtub
http://www.wickedreport.comHirom Glass Violin is a product of Hario Glass Co. Ltd., Japan. And also, The world’s first hand made
glass violin.
www.whitersstreetglass.com.auGlass splashbacks
http://worlds-interior-design.blogspot.comWall-to-wall glass windows
http://freshome.comSuperdurable tempered glass
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Special Glass Products
bullet proof
burglar-proof
showcase
counter
aquarium
skylight
long corridor
sidelite, etc.
Laminated glass is widely
used for
http://www.livingetc.comGlass staircase
www.aarticommercial.comLaminated Windscreen Glass
If the laminated glass is made from “ordinary” float glass, it isstill workable (cutting and drilling is possible) and the PVBhelps the fractured glass to stay put inside the construction.
Laminated Glass
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Special Glass ProductsLaminated Glass
BULLETPROOF GLASS
Bulletproof glass is made of laminated
glasses and films which have special
shielding capability towards bullets.
The different levels of bullet proof glasses
are able to shield the bullets from
penetration and prevent the broken
parts from injuring people. They are
widely applied in bank, counters of
jewelry and gold shops, cash trucks and
other regions requiring special safety
prevention.
www.bmw-security-vehicles.com22-millimetre glass/plastic laminate with apolycarbonate coating on the inside to preventflying splinters. The 22-millimetre glassprotects against:
• Blunt instruments.44 Magnum with full-jacket flat-nosebullets .357 Magnum with coned bullets 9-millimetre Luger with round-nose bullets
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: ApplicationsCEMENT AND CONCRETE MANUFACTURING
Lime
Clay
Iron
Kiln
Gypsum
Clinker
Additions
Mill
Gravel
Cement
Admixtures
Sand
Water
Mixer
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Application
Cutting tools
Bearing, liners, seals
Agricultural
machineryEngine 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
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
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
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Ceramic filter Foam ceramic molten metal filter
Ceramic Knife Ceramic Fiber Boards As The Heat Insulation
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Ceramic Fiber Products
Ceramic fittings
Ceramic faucet valves withsuperior wear resistance andsealing performance.
Ceramics are used in various textilemachines as guide parts, threadprocessing nozzles, oiling nozzles,rollers and twister parts. Cutting and wear-resistant parts Alumina Ceramic Pipe Lining
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
http://aluminatechnologies.com/products.php
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Ceramic seal rings, axial bearings and radial bearings ensure highly reliable operation and longservice life wherever fluids are pumped or gas is compressed.
Ball Heads Cup Inserts. For insertinginto the acetabular cup
Knee Joint Components.Improved quality of life,reduce wear and minimizethe risk of allergies.
High temperature wearresistance industrial zirconiaadvanced ceramic insulatorproducts
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
With its extensive material range and continuously growing productionexpertise in the field of ceramic components for textile processing,
Biocompatible ceramic partsfor drug-delivery systems.
Sheer VeneersZrO2-metal free
restorations
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Bearing Rollers made from Silicon Nitride
In engine design or exhaust systems, in liquid orgas circuits – automotive industry demands onseal rings, bearings and sealing technology areespecially high. Technical ceramics ensure wearresistance, temperature resistance and stability inthese aggressive environments.
Ceramic gas nozzles made of silicon nitride
Ceramic rollers
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Inserts from CeramTec's latest generation ofceramic cutting materials. Designed specificallyfor high-performance machining of cast ironmaterials.
The proven performance standard forefficient machining with indexable insertsmade of ceramic cutting materials.
CBN indexable inserts (polycrystalline cubic boron nitride)for efficient machining of cast iron materials and sinteredsteels 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 orfoundry technology
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Traditional Ceramics: Processing
Minerals
Chemical
processing
PowderPowder
processing
Green body
SinteringDense/Porous
Compact
Final Product
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Key Steps
Powder synthesis
Powder handling
Green body formation
Sintering of green body
Final machining and assembly
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Design Objectives
PerformanceLife Cycle
Considerations
Manufacturin
g TechniquesCost
Yrd. Doç. Dr. Ayşe KALEMTAŞ
Advanced Ceramics: Applications
Material science is the investigation of the relationship among processing, structure, properties and performance of materials.
Structure Properties
Processing
Performance
Yrd. Doç. Dr. Ayşe KALEMTAŞ
QUESTIONS