TEKNOLOGI DAN DESAIN KERAMIK

Kimia Pilihan:
Kelompok Kimia Keramik
Dr.rer.nat. I Wayan Karyasa, S.Pd., M.Sc/
PENDAHULUAN
REVIEW KULIAH SEBELUMNYA

What a ceramic is ?
From Greek word “keramos” (pottery, potter’s clay)
Inorganic nonmetallic materials obtained by the action of heat and
subsequent cooling.
Polycrystalline materials, single phase or multiphase (composites),
sometimes with an amorphous component (glass).
PENDAHULUAN
Ceramic body armour
REVIEW KULIAH SEBELUMNYA Two Kyocera ceramic
knives (Y:ZrO2)
plates (Al2O3, SiC)

Traditional ceramics
• Whitewares: tableware, cookware, sanitary ware, etc.
• Refractories (kiln and furnace linings for steel and glass
industry)
• Structural clay products (floor & roof tiles, bricks, etc.)
Fabricated from clay, quartz, feldspar (earthenware) and kaolin
Ceramic Si3N4 bearing parts
(porcelain)

Technical/advanced ceramics
• Structural ceramics (mechanical properties: strength,
toughness, hardness, creep resistance)
• Functional ceramics (electric, magnetic, optical properties)
The Porsche Carrera GT's
silicon carbide disk brake
Functional ceramics
Functionality Material Applications

Resistors SiC, MoSi2, LaCrO3 Heating elements for high temperature

furnaces
Thermistors Spinels Temperature sensors, self-regulating
(NTCR & PTCR) BaTiO3 heating elements
Dielectrics with very low Al2O3, AlN, Substrates for electronic circuits and
losses (r = 3 -10) cordierite chip packaging
Dielectrics for microwave BaTi4O9, MW resonators, filters and antennas for
applications (r = 30-80) Zr(Ti,Sn)O4, mobile communications and GPS
BaMg1/3Ta2/3O3, devices, tunable MW devices
(Ba,Sr)TiO3,
Temperature stable dielectrics CaTiO3, BaO- Capacitors with temperature-
(r  100) Nd2O3-TiO2 independent capacitance
Dielectrics with very high BaTiO3 Multilayer ceramic capacitors
dielectric constant (r  3000)
Piezoelectric ceramics Pb(Zr,Ti)O3 (PZT) Transducers, actuators and resonators

Pyroelectric ceramics Pb(Zr,Ti)O3 IR radiation detection and imaging

Functional ceramics
Functionality Material Applications

Ferroelectric Pb(Zr,Ti)O3 Ferroelectric memories (FeRAMs)

ceramics SrBi2Ta2O9
Electrostrictive PbMg1/3Nb2/3O3 -PbTiO3 Actuators
ceramics (PMN-PT)
Magnetic ceramics Spinels (Ni,Zn)Fe2O4 Inductors
BaFe12O19 Permanent magnets
Y3Fe5O12 (YIG) Microwave devices (radars)
Ionic conductors Y:ZrO2 (YSZ) Electrolytes for solid-oxide fuel cells
Gd:CeO2 (SOFCs), oxygen sensors
β-alumina Na-Batteries
Superconductors YBa2Cu3O7-x (YBCO) Superconducting cables for magnets
MgB2
Transparent Al2O3, MgAl2O4, Y3Al5O12 Phosphors, optical materials for lenses
ceramics (YAG) and laser systems, nose cones for heat-
seeking missiles, high-pressure sodium
street lamps
Optoelectronic LiNbO3 Waveguides, frequency doublers,
materials PLZT voltage-controlled optical switches,
modulators
 Thick (left) and thin (right) substrates (alumina)

Pressed and extruded parts (alumina, mullite, zirconia)

Ferrites cores Microwave dielectric components

 Low Temperature Co-fired Ceramics Pyroelectric Infrared sensor (PZT)
(LTCC) Ceramic Multilayer Substrates

Monolithic Multilayer Ceramic Capacitors SAW filter (SIO2, LiNbO3, LiTaO3)

(modified BaTiO3)

Ceramic resonators (SiO2, PZT, BaMg1/3Ta2/3O3)

Thermistors (NTCR: spinels; PTCR:

modified BaTiO3)

Ceramic filters (BaMg1/3Ta2/3O3, Zr(Sn,Ti)O4)

Cheap ferrite beads Multilayer piezoelectric ceramic

(hexaferrites BaFe12O19) actuators for diesel injection system
(PZT – PbZrxTi1-xO3)

Multilayer technology used for higher performances and device miniaturization

TEKNOLOGI DAN DESAIN
KERAMIK
TEKNOLOGI KERAMIK
• TEKNOLOGI BAHAN
• TEKNOLOGI PROSES/MANUFAKTUR
• TEKNOLOGI TESTING KUALITAS

DESAIN KERAMIK
• BENTUK/SHAPE
• FUNGSI
• ARTS
TEKNOLOGI BAHAN
• Metals
- Ferrous: Steel (iron-carbon, 0,02% - 2,11% C)
Cast iron (iron + 2% - 4% C + silicon)
- Nonferrous: copper, aluminium, nickel, alloys
• Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti)
• Polymers
- Thermoplastic polymers: PE, PP, PS, PVC
- Thermosetting polymers: phenolics, epoxies
- Elastomers: rubber, neoprene, silicone, PU
• Composites: more phases, particles/fibres + matrix
glass reinforced plastic, Kevlar, WC in cobalt
TEKNOLOGI BAHAN
TEKNOLOGI PROSES
Manufacturing capability
• Technological Processing capability
- Available processes and machines
- Outsourcing of some operations (casting, heat
treatment, etc.)
• Physical product limitations
- Size, weight
- Machine dimensions, handling
• Production capacity (Plant capacity)
- Production quantity in a given time, output
Classification of
Manufacturing processes
 Processing operations
1) Shaping operations
- Solidification processes  casting of metals,
moulding of plastics
- Particulate processing  powder metallurgy
- Deformation processes  forging, extrusion
- Material removal processes  machining, non-
traditional, grinding
2) Property enhancing processes
- Heat treatments, sintering
3) Surface processing
- Cleaning, coating, plating, deposion
Casting and moulding processes

Pouring of the Solidification

liquid or melt
Particulate processing
Deformation processes

Forging Extrusion
 Shaping processes
 General aim: Minimize waste and scrap.
- Net shape processes  no subsequent machining
- Near net shape processes  minimum machining

Turning Drilling Milling

Manufacturing processes
1) Processing operations
2) Assembly operations
- Permanent joining: welding, brazing, adhesives
- Mechanical assembly: bolts, screws, rivets, etc.
3) Production machines and tooling
- Machine tools: lathe, milling machine, etc.
- Presses, forge hamers, rolling mills
- Welding machines and equipment
- General and special purpose equipment
- Tooling
Production systems
• Consist of people, equipment and procedures
• Production facilities: factory, production equipment
material handling equipment
 Plant layout + Manufacturing systems
 Influence of production quantity (low, medium,
high)
• Manufacturing support systems
- Manufacturing engineering  process planning
- Production planning and control  logistics,
ordering materials and parts, scheduling
- Quality control
 Plant layouts

Fixed-position layout Process layout

Cellular layout Product layout

Production System
Mutual relationships
Manufacturing Process Selection
Aspects:
• Batch size: Single product, medium size or mass
production
• Geometric requirements: Shape and tolerances
• Manufacturing phase: Primary or secondary
• Tools: General purpose or product specific
• Assembly: Pay attention to assembly aspects
during process selection for part manu-
facturing
• Minimize costs: Costs per product + Costs per
batch + Once-only costs
TEKNOLOGI TESTING

• PRODUCT ATRIBUTES TESTING

• NATIONAL AND INTERNATIONAL STANDARDS TESTING
 Product attributes
• Mechanical properties, e.g. tensile strength
• Physical properties, e.g. thermal expansion
• Dimensions, e.g. mm
•Tolerances: bilateral, unilateral tolerances
limit dimensions
• Geometric attributes: angularity, circularity,
concentricity, cylindricity, flatness, parallellism,
perpendicularity, roundness, squareness and
straightness
• Surface quality, e.g. roughness
 Specification of tolerances

Bilatertal tolerance Unilateral tolerance Limit dimensions

Geometric
tolerances
a. Flatness
b. Circularity
c. Cylindricity
d. Perpendicularity
e. Concentricity
 Surfaces
• Importance of surface quality
- Aesthetic reasons
- Safety aspects
- Influence on friction and wear
- Influence on mechanical and physical properties
- Important for assembly
- Better electrical contact
• Surface technology is concerned with
- Surface texture
- Surface integrity
- Relationship with manufacturing processes
Characteristics of surfaces
 A microscopic view shows:
 - Substrate  bulk material
 - Altered layer  different structure
 - Surface texture  exterior part with roughness
 - In addition: Mostly an oxide film
Surface texture
 Surface texture  Deviations from the surface
- Roughness: small deviations
- Waveness: deviations with much larger spacing
- Lay: predominant direction or pattern of the surface
- Flaws: irregularities like cracks, inclusions, etc.
Possible lays
Surface roughness (1)
Definition of (average) surface roughness
Arithmetic average (AA) of the vertical
deviations from the normal surface
over a specified surface length.
Surface roughness (2)
• Approximation form:

n
yi
Ra  
i 1 n
• Units for Ra: μm (10 -6 m)
• Cutoff length  Filter to separate the waviness from
 the roughness deviations
 Usually: Cutoff length = 0,8 mm = 1/5.Lm
• Surface finish = surface roughness denoting good
 quality and smoothness

Symbols for surface texture

Symbols on engineering drawings

Tolerance limits
Surface roughness values