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Metals vs Ceramics
Metals
Ceramics
What is a CERAMIC
Inorganic materials that consist of metallic and
non metallic (or two nonmetallic) elements
Bonded by ionic and/or covalent bonds
ZrO2 has 72% ionic and 27% covalent character
Properties
Good electrical and thermal insulators
Hard and brittle (low toughness and ductility)
Tensile strength 0.69-200 MPa (7000 MPa for Al2O3
whiskers)
Ceramic
Materials
Ceramic Materials
Glasses
Clay
(Amorphous, Products
silica based)
Glass
Ceramics
(poly cry stalline,
eg. Py roceram)
Refractories
Abrasives
Alumina, Silica
Diamond
high purity oxides SiC
Graphite
Silica Sand
Alumina
Cements
Calcium
Silicon
Advanced
Ceramics
Si N
3 4
SiC, BC, WC
ZrO
2
Ceramic-Matr ix
Composites
(f ibre and whisker
reinf ored)
Advanced Ceramics
Electroceramics, Capacitor, Resistor, Piezoelectric
Have been developed over the past half century
Thermal barrier coatings to protect metal structures,
wearing surfaces, etc.
Engine applications made from silicon nitride (Si3N4),
silicon carbide (SiC), Zirconia (ZrO2) and Alumina
(Al2O3)
Heat resistance and other desirable properties have
lead to the development of methods to toughen the
material by reinforcement with fibers and whiskers
opening up more applications for ceramics
COMPOSITES
Engine Components
Rotor (Alumina)
Gears (Alumina)
Turbocharger Comparison
g/cm3
MPa
GPa
(1000C)
Crystalline or Amorphous
The strong dependency of the bonding
on crystallographic direction for covalent
compounds result in a barrier to the
formation of a crystal structure.
Strictly periodic arrangements cannot be
established during solidification, and only
chain molecules are firmed.
GLASS?
An inorganic product high
temperature treatment
(fusion) that has been
cooled to a rigid condition
without crystallization.
Silica Polymorphs
Glass Compositions
Blow Molding
Softened
glass
Tempered Glass
The strength of glass can
be enhanced by inducing
compressive residual
stresses at the surface.
Two methods are used:
Thermal Tempering
Chemical Hardening
The surface stays in
compression - closing
small scratches and
cracks.
Small Scratches
Hardening Processes
Tempering:
Glass heated above Tg but below the softening
point
Cooled to room temp in air or oil
Surface cools to below Tg before interior
when interior cools and contracts it draws the
exterior into compression.
Chemical Hardening:
Cations with large ionic radius are diffused into the
surface
This strains the lattice inducing compressive
strains and stresses.
Method (Naming)
Product
Films, monoliths
Monoliths
Monoliths
Monoliths
Films, fibers
Fibers, films
Monoliths
Monoliths, films
Ceramic Processing
Slip Casting
Sinter
and
Serve
Filling
Mould
Compaction
Green part
ejected - then
sintered
Sintering/Firing Process
Pressed Ceramic
Particles
Sintered for
a short time
Sintered for
a long time
Glass Ceramics
These are primarily silicates containing oxides
such as Alumina (AL2O3), TiO2, LiO2, and
others.
In amorphous form, the glasses are transparent.
Most glasses can be made to transform into a
polycrystalline state by a suitable heat-treatment
process, called devitrification.
An initiator, such as TiO2, is added to begin the
nucleation of ceramic crystals. The product is
called a glass ceramic.
Desirable properties include: high strength and
thermal conductivity, low thermal expansion,
resistant to thermal shock, ease of fabrication.
using conventional methods.
Refractories
Used to provide thermal protection of other
materials in very high temperature applications,
such as steel making (Tm=1500C), metal
foundry operations, etc.
They are usually composed of alumina
(Tm=2050C) and silica along with other oxides:
MgO (Tm=2850C), Fe2O3, TiO2, etc., and have
intrinsic porosity typically greater than 10% by
volume.
Specialized refractories, (those already
mentioned) and BeO, ZrO2, mullite, SiC, and
graphite with low porosity are also used.