CERAMICS

BY GROUP 2
CERAMICS
From Greek word Keramos (clay)

Compounds of metallic and non-metallic
elements

Most frequently oxides, nitrides, carbides
and silicates


2 Classes of Ceramics
TRADITIONAL CERAMICS
Ceramic materials that are derived from common,
naturally occurring raw materials such as clay
minerals and quartz sand.

A type of ceramic used in traditional applications
such as construction, earthenware, and glassware.

ADVANCED CERAMICS

A type of ceramic exhibiting a high degree of
industrial efficiency.
A type of ceramic used in specialized, recently
developed applications.
Advanced ceramics are ideally suited for industrial
applications that provide a physical interface
between different components due to their ability to
withstand high temperatures, vibration and
mechanical shock.




4 CLASSIFICATION OF
CERAMICS
AMORPHOUS CERAMICS

Lacking a definite repeating form, shape or
structure

Glasses
CRYSTALLINE CERAMICS
- atoms (or ions) are arranged in a regularly repeating pattern in three
dimensions (i.e., they have long-range order)
- Crystalline ceramics are the Engineering ceramics
High melting points
Strong
Hard
Brittle
Good corrosion resistance


EXAMPLE OF CRYSTAL
STRUCTURE
Rock salt structure(AX)(NaCl ) Spinel structure(AB2X4)(MgAl2O4)


BONDED CERAMICS
Individual crystals are bonded together by a glassy
matrix, as with most clay - derived products

CEMENTS
some are crystalline, while others contain both
crystalline and amorphous phases
STRUCTURES OF CERAMICS
SIMPLE CRYSTAL STRUCTURES
Containing ionic or covalent bonds, or a mixture of
two.

COMPLEX SILICATE STRUCTURES
The majority of ceramic materials, in particular
those derived from clay, sand, or cement, contain
the element silicon in the from of silicates.
CLAY
Al
2
Si
2
O
5
(OH)
4
.
TRICALCIUM SILICATE
Ca
3
SiO
5


ALUMINA
Al
2
O
3


TYPES OF CERAMIC PRODUCTS
STRUCTURAL
A common traditional ceramic used in the
construction industry. Structural ceramics include
brick, clay pipes, and concrete.

REFRACTORIES
A type of ceramic that can withstand extremely
high temperatures. Refractories are used in
industrial furnaces.








WHITEWARES
A traditional ceramic used to make pottery and
porcelain. Whiteware ceramics often have a glassy
structure.

GLASSES
A type of ceramic material characterized by its
noncrystalline structure. Glasses do not solidify at
a specific temperature. Instead, they gradually
solidify as the temperature decreases.



ABRASIVES
type of ceramic material that is very hard and wear
resistant. Abrasives also refer to tools used to
wear away and remove material.

SYNTHETIC
Type of ceramic material that is made from
chemicals or artificial substances rather than from
natural ones.


CEMENT
Bind other materials together. Used for roads, bridges,
buildings, dams, etc.

ADVANCED CERAMICS
Advanced or Technical Ceramics are parts made from oxide
ceramics, non-oxide ceramics, or composites; each providing
unique material properties of the finished piece. The majority
of these products are manufactured with high density and low
porosity and are used in high performance applications.


APPLICATION OF ADVANCED
CERAMICS


STRUCTURAL
ELECTRICAL
COATINGS
CHEMICAL AND ENVIRONMENTAL

3 CLASSIFICATION OF
TECHNICAL CERAMICS
OXIDES
Oxidation resistant
chemically inert
electrically insulating
generally low thermal conductivity
slightly complex manufacturing
low cost for alumina
more complex manufacturing
higher cost for zirconia.

NON-OXIDES
Low oxidation resistance
extreme hardness
chemically inert
high thermal conductivity
electrically conducting
difficult energy dependent manufacturing and high cost.
CERAMIC BASED COMPOSITE
Toughness
low and high oxidation resistance (type related)
variable thermal and electrical conductivity
complex manufacturing processes
high cost.


PROPERTIES OF CERAMICS
MECHANICAL
Mechanical properties are important in structural
and building materials as well as textile fabrics.
They include the many properties used to
describe the strength of materials such as:
elasticity / plasticity, tensile strength,
compressive strength, shear strength, fracture
toughness & ductility (low in brittle materials),
and indentation hardness.

ELECTRICAL
Insulating properties
In contrast to Metals Ceramics have very low electrical
conductivity due to Ionic-Covalent Bonding which does
not form free electrons.

Electrical conductivity
Electrical conductivity is ability of material to conduct
electric current.
Most of ceramic materials are dielectric (materials,
having very low electric conductivity, but supporting
electrostatic field).

Dielectric Strength
ability of a material to prevent electron
conductivity at high voltage. Dielectric strength is
determined as value of electric field strength
(expressed in v/m) at which electron conductivity
breakdown occurs.
Dielectric Constant
relative (to vacuum) ability of a material to carry
alternating current (dielectric constant of vacuum
equals to 1).

Semi-conducting properties
used for manufacturing varistors (resistors
with non-linear current-voltage
characteristic, which are used for over-
voltage protection) and Positive
Temperature Coefficient (PTC) Resistors.

Superconducting properties
near-to-zero electric resistivity
THERMAL
Thermal Conductivity ()
amount of heat passing in unit time
through unit surface in a direction normal
to this surface when this transfer is driven
by unite temperature gradient under
steady state conditions.
Thermal Expansion (Coefficient
of Thermal Expansion)
is relative increase in length per unite
temperature rise

Heat Capacity is amount of heat required to
raise material temperature by one unit.
Specific Heat Capacity is amount of heat
required to raise temperature of unit mass of
material by one unit

Thermal Shock Resistance
ability of material to withstand sharp
changes in temperature.
Maximum Service Temperature
Ceramic materials retain
their properties at elevated temperatures
due to the strong ionic-covalent bonding.
MAGNETIC
Isotropic ceramic magnet - equal
magnetic properties in all directions
Anisotropic ceramic magnets -
magnetic properties in the direction of
pressing.
OPTICAL

REFRACTION

+ Light that is transmitted from one medium into another,
undergoes refraction.


+ Refractive index, (n) of a material is the ratio of the speed of light
in a vacuum (c = 3 x 108 m/s) to the speed of light in that
material.

+ n = c/v

CHEMICAL
Ceramics usually have a combination of
stronger bonds called ionic (occurs between a
metal and nonmetal and involves the
attraction of opposite charges when electrons
are transferred from the metal to the
nonmetal); and covalent (occurs between two
nonmetals and involves sharing of atoms).
GENERAL COMPARISON OF
MATERIALS
Property Ceramic Metal Polymer

Hardness Very High Low Very Low

Elastic modulus Very High High Low

Thermal expansion High Low Very Low

Wear resistance High Low Low

Corrosion resistance High Low Low

GENERAL COMPARISON OF
MATERIALS
Property Ceramic Metal Polymer

Ductility Low High High

Density Low High Very Low

Electrical conductivity Depends High Low
on material

Thermal conductivity Depends High Low
on material

Magnetic Depends High Very Low
on material
CERAMIC PROCESSING STEPS
O MILLING - Milling is the process by which materials
are reduced from a large size to a smaller size.

It involves the ff:
breaking up cemented material
pulverization
attrition
compression
impact
Crushing & Grinding (to get
ready ceramic powder for
shaping)

Ball Milling
OBATCHING The process of weighing oxides
according to recipes, and preparing them for mixing and
drying.
OMIXING - occurs after batching and is performed with
various machines, such as dry mixing ribbon mixers.
OFORMING - making the mixed material into shapes
FORMING involves the ff:
EXTRUSION - a process used to create objects of a
fixed cross-sectional profile
Pressing to make shaped parts
Slip casting

ODRYING is removing the water or binder from
the formed material.

O FIRING is where the dried parts pass through
a controlled heating process, and the oxides
are chemically changed to cause sintering
and bonding.
RIBBON MIXERS
SLIP CASTING

DRYING PROCESS
APPLICATIONS OF CERAMICS
Aerospace: space shuttle tiles, thermal
barriers, high temperature glass
windows, fuel cells
Consumer Uses: glassware, windows,
pottery, Corning ware, magnets,
dinnerware, ceramic tiles, lenses, home
electronics, microwave transducers
Automotive: catalytic converters, ceramic filters,
airbag sensors, ceramic rotors, valves, spark
plugs, pressure sensors, thermistors, vibration
sensors, oxygen sensors, safety glass
windshields, piston rings
Medical (Bioceramics): orthopedic joint
replacement, prosthesis, dental restoration,
bone implants
Military: structural components for ground, air
and naval vehicles, missiles, sensors

Computers: insulators, resistors,
superconductors, capacitors, ferroelectric
components, microelectronic packaging
Other Industries: bricks, cement,
membranes and filters, lab equipment
Communications: fiber optic/laser
communications, TV and radio
components, microphones
EXAMPLES OF CERAMICS
Barium titanate widely used in
electromechanical transducers, ceramic
capacitors, and data storage elements.
Bismuth strontium calcium copper oxide a high-
temperature superconductor
Boron nitride a graphite-like one used as a
lubricant, and a diamond-like one used as an
abrasive.
Ferrite is used in the magnetic cores of electrical
transformers and magnetic core memory.

Lead zirconate titanate (PZT) PZT is used as an
ultrasonic transducer, as its piezoelectric properties
greatly exceed those of Rochelle salt.
Magnesium diboride (MgB2) is an unconventional
superconductor.
Porcelain is used for a wide range of household and
industrial products.
Sialon (Silicon Aluminium Oxynitride) has high strength;
high thermal, shock, chemical and wear resistance, and
low density. These ceramics are used in non-ferrous
molten metal handling, weld pins and the chemical
industry.
Silicon carbide (SiC) is used as a susceptor in
microwave furnaces, a commonly used abrasive, and as
a refractory material.
Silicon nitride (Si3N4) is used as an abrasive powder.
Steatite (magnesium silicates) is used as an electrical insulator.
Titanium carbide Used in space shuttle re-entry shields and
scratchproof watches.
Uranium oxide (UO2), used as fuel in nuclear reactors.
Yttrium barium copper oxide (YBa2Cu3O7-x), another high
temperature superconductor.
Zinc oxide (ZnO), which is a semiconductor, and used in the
construction of varistors.
Zirconium dioxide (zirconia), Its high oxygen ion conductivity
recommends it for use in fuel cells and automotive oxygen sensors.
Most ceramic knife blades are made of this material.
Partially stabilised zirconia (PSZ) is much less brittle than other
ceramics and is used for metal forming tools, valves and liners,
abrasive slurries, kitchen knives and bearings subject to severe
abrasion.



END