Material science

TI -107

Ceramics
Roland Silitonga
Introduction
Ceramics have a collection of highly
desirable properties:

Hard (but may be brittle)

Example: ceramic floor tiles break if dropped

High melting points

Example: often exceed 1500oC
Introduction
Ceramics have a collection of highly
desirable properties:

Low electrical conductivity

Example: often used as electrical insulators
as seen hooked to the electrical wires on
utility poles
Introduction
Ceramics have a collection of highly
desirable properties:

Low thermal conductivity

Example: often used as pot holders for hot
pans, or as heat shield for space shuttle or
exhaust blanket for aircraft engines, because
they do not conduct heat
Introduction
Ceramics have a collection of highly
desirable properties:

Good chemical and thermal stability

Example: glass bottles are used to store
highly corrosive chemicals without
undergoing any type of degradation
Introduction
Ceramics have a collection of highly
desirable properties:

High compressive strength

Example: concrete is used in the construction
of highways which support huge trucks
carrying massive cargos
Introduction
Ceramics are compound between
metallic and non-metallic materials.
Inter-atomic ion bonding.
The term Keramikos (Greek) means
burnt stuff
Introduction
This material have desirable properties
achieved through a high temperature
heat treatment called firing.
Traditional ceramics have primary
material such as clay.
Introduction
Ancient clay tablet with cuneiform on it
Old ceramic ancient. (Mesopotamia)

Ancient Clay Image of a

Deer Excavated from
Uzumasa Remains
(Japan).
Introduction
Ceramics of china

Blue & white Chinese floral

motif ceramic vase from
Jingdezhen, the porcelain
capital of China, producing
ceramics for over 1000 years
Introduction
Porcelain
Introduction
Bricks & tiles
Introduction
Glass
Introduction
Classification
Ceramic Structure
Ceramics are composed of at least two
elements.
The structure are more complex than
metals.
The atomic bonding are purely ionic to
totally covalent.
Ceramic Structure
The metallic ion, or CATIONS are
positively charged.
They give up the valence electron to the
non-metallic ion called ANIONS.
The anions are negatively charged.
Ceramic Structure
First:
The crystal must be electrically neutral.
That means : all the cation positive
charges must be balanced by an equal
number of anion negative charges.
Example:
Calcium Fluoride
(Ca2+ and 2F- create CaF2 )
Ceramic Structure
Second:
The size or ionic radius (of Cation &
Anion)
Ratio of cation & anion radius is rC / rA
Coordination Number is related to the
ratio.
Ceramic Structure
A stable ceramic crystal structure,
formed when those anions surrounding a
cation are all in contact with that cation.
Anion

stable stable Un-stable

Ceramic Structure
The Coordination Number is related to
the cation-anion radius ratio,
i.e., number of anion nearest neighbor
for a cation.
The common Coordination Number are:
2, 3, 4, 6 and 8.
Ceramic Structure
Coordination Number for various Cation-Anion
Radius Ratio, table 12.2
Coordination Cation-Anion Radius
Number Ratio
2 < 0.155
3 0.155 0.225
4 0.225 0.414
6 0.414 0.732
8 0.732 1.0
Ceramic Structure
The ionic radius for several cation and anions is
in Table 12.3
AX Type Crystal Structure
The number of Cation & Anion are same.
Referred to as AX Compound,
A denotes the cation,
X denotes the anion.
AX Type Crystal Structure
Rock Salt Structure.
Sodium Chloride (NaCl)
Coordination Number = 6
AX Type Crystal Structure
Cesium Chloride Structure.
Cesium Chloride (CsCl)
Coordination Number = 8
AX Type Crystal Structure
Zinc Blende Structure.
Zinc Sulfide (ZnS)
Coordination Number = 4
AmXp Type Crystal Structure
If the charges on the Cation and Anions
are not the same.
A chemical formula AmXp where
m and or p 1
Example :
Fluorite (CaF2)
Coordination number = 8
AmBnXp - Type Crystal Structure
Ceramic compound have more than one
of cation (represented by A & B).
Example :
Barium Titanate (BaTiO3).
both Ba2+ and Ti4+ cations.
Summary of Common Ceramic
Crystal Structure (table 12.4)
Table 12.4

Structure Structure Anion Cation Anion Example

Name Type Packing
Rock Salt AX FCC 6 6 NaCl,
MgO, FeO
Cesium AX Simple 8 8 CsCl
Chloride Cubic
Zinc AX FCC 4 4 ZnS, SiC
Blende
Fluorite AX2 Simple 8 4 CaF2, UO2,
Cubic ThO2
Perovskite ABX3 FCC 12 (6) 6 BaTiO3

Spinel AB2X4 FCC 4 (6) 4 MgAl2O4

Silicate Ceramics
Silicates are materials composed
primarily of silicon and oxygen.
The two most abundant element in the
earths crust.
Example: Soils, Rocks, Clays.
The structure are combination of unit cell
SiO44- tetrahedron.
Silicate Ceramics
Silica
Silicon Dioxide (SiO2)
Three primary polymorphic crystalline
forms:
Quarts
Cristobalite
Tridymite
Silicate Ceramics
Silica Glasses
Silica can be made to exist as a non-
crystalline solid or glass.
Called : Fused Silica or Vitreous Silica.
Silicate Ceramics
The Silicates
The various silicate minerals have more
complex structure:
SiO44- tetrahedron
Si2O76-
Si3O96-
Simple Silicates
the most simple structure involve
isolated tetrahedra.
Forsterite (Mg2SiO4) has the equivalent
of two Mg2+ ion and SiO44-
Akermanite (Ca2MgSi2O7)
Layered Silicates
One of the most common clay minerals
kaolite, has a relatively simple two layer
silicate sheet structure.
Kaolite Clay (Al2(SiO5)(OH)4
Carbon
It is an element that exist in various
polymorphic forms.
Diamonds
Graphite
Diamonds
The diamonds is polycrystalline and may
consist of very small and or relatively
large grain.
Large diamond single crystal are used as
gem stone.
Diamonds
Industrially, diamonds are utilized to
grind or cut other softer materials.
Graphite
It has a crystal structure distinctly different from that
of diamond.
It is also stable than diamond.
Graphite
It has desirable properties:
High strength and
Good chemical stability at elevated
temperature.
Non-oxidation atmosphere.
High thermal conductivity
High adsorption of gasses.
Good machine-ability.
Graphite
Used as:
Electrodes for arc welding.
Electrodes in batteries.
Electrical brushes and resistors.
High temperature refractory and
insulations.
Heating elements for electric furnace.
Air purification devices.
Imperfections in Ceramics
Atomic Point Defects.
Atomic defects involving host atoms may
exist in ceramic compounds.
Both vacancies and interstitial are possible.
Example :
Sodium Chloride (NaCl).
Iron Oxide (FeO).
Imperfections in Ceramics
Impurities in Ceramics
Impurities atoms can form solid solution in
ceramic materials much as they do in metals.
For example: in sodium chloride, impurities
Ca2+ and O2- ion would most likely
substitute for Na+ and Cl- ions.
Imperfections in Ceramics
Diffusion in ionic materials.
Diffusion in these material usually occurs by
a vacancy mechanism.
Ceramic Phase Diagrams
The Aluminum Oxide - Chromium Oxide.
Al2O3 - Cr2O3 System.
Fig 12.24
Ceramic Phase Diagrams
The Magnesium Oxide - Aluminum Oxide.
MgO - Al2O3 System.
Fig 12.25
Ceramic Phase Diagrams
Zirconium Oxide (Zirconia) and Calcium
Oxide (Calcia) ZrO2 CaO System.
Fig 12.26
Ceramic Phase Diagrams
The Silica - Aluminium System.
SiO2 - Al2O3 System.
Fig 12.27
Mechanical Properties
Brittle fracture of Ceramics
At room temperature, both crystalline
and non-crystalline ceramics almost
always fracture before any plastic
deformation.
It can occur in response to an applied
tensile load.
Mechanical Properties
Stress Strain Behavior
It is not a Tensile-Test, while :
1. Difficult to prepare the specimen.
2. Difficult to grip the specimen.
3. Ceramic fail after only about 0.1%
strain.
Mechanical Properties
Stress Strain Behavior
The stress at fracture using this flexure
test as flexural strength.
Mechanical Properties
Flexural Strength & Modulus Elasticity
Table 12.5
Mechanical Properties
Elastic Behavior
The elastic stress-strain behavior for
ceramic material using Flexural test is
similar to the Tensile Test Result of
metal.
Mechanical Properties
Elastic Behavior
Fig 12.30
A linear relationship
Mechanism of Plastic Deformation
Most Ceramic material are fracture
before the plastic deformation.
Plastic deformation is different for
crystalline and non-crystalline.
Mechanism of Plastic Deformation
Crystalline Ceramics
Plastic deformation occurs, as metal,
by motion of dislocation.
Non crystalline Ceramics
Plastic deformation does not occur.
Mechanical Properties
Hardness
One beneficial mechanical property of
ceramics is their hardness.
See Table 12.6
Mechanical Properties
Creep
Often ceramics material experience creep
deformation as a result of exposure to stress
(usually compressive) at elevated
temperature.
Types & Application of
Ceramics
 Classification
Ceramics Materials

Glasses Refractory Abrasive Advance

Clay Ceramics
Products
Cements

Glasses Glass Fireclay Basic

Ceramics Silica Special
Structural White-
Clay wares
Products
Clay Product
Tanah Liat (?)
In-expensive.
Found naturally in the earth.
Clay product may be formed in wet
condition (mixed by water).
Some of the require high-temperature
firing.
Clay Product
Classification:
Structural Clay Product:
Building bricks.
Tiles.
Sewer pipes.
White wares:
Porcelain, pottery, tableware,
Plumbing (sanitary) ware.
Refractory
It has capacity to withstand high
temperature without melting or
decomposing.
Un-reactive and inert when exposed to
severe environment.
Ability to provide thermal insulation.
Refractory
They are marketed in a variety of form.
Brick form is most common.
The classification:
Fireclay,
Silica,
Basic,
Special refractory.
Refractory
Compositions, see Table 13.2
Refractory
Fireclay refractory
Withstand high temp, below 1587oC.
In brick shape for furnace lining.
Thermally insulate structural member.
The strength is not important.
Refractory
Refractory
Silica Refractory.
Withstand high temp, below 1650oC.
Resist to slags that are rich in silica for
vessel.
Refractory
Basic Refractory
Contain Magnesia (MgO) are termed
Basic.
Resistant to attack by slag
Extensive use in some steel-making
open heart furnace.
Refractory
Basic Refractory
The furnace
Refractory
Special Refractory
Silicon Carbide (SiC) is used for
electrical resistance heating elements.
Abrasive
To wear, grind or cut away other
material.
Abrasive material are:
Diamond (natural & synthetic).
Silicon Carbides,
Tungsten Carbides (WC),
Aluminum Oxide,
Silica Sand.
Abrasive
Grinding wheel,
Abrasive paper,
Polishing.
 Cements
As inorganic Cements:
Such as : cements, plaster of paris and lime
Portland cements:
It is produced by grinding and mixing clay and lime mineral
and then heating to about 1400oC.
Portland cement is termed a hydraulic cements. The hardness
develops by chemical reaction with water.
Cements
The setting & hardening result from
relatively complicated hydration reaction
Between cement and water
For example:
2CaO SiO2 + x H2O = 2CaO SiO x H2O
The reaction begin just soon the water
added
Advance Ceramics
It is used in the :
Optical fiber communication systems.
Micro-electro mechanical systems.
Ceramic ball bearing.
Fabrication & Processing
Glass properties.
Glassy or non-crystalline material,
become more and more viscous in
decreasing temperature.
There is no definite temperature at
which the liquid transfer to a solid.
Fabrication & Processing
However, glassy material, the volume
decrease continuously with temperature
reduction.
The graphics is called Glass Transition
Temperature.
See fig 13.5
Fabrication & Processing
In glass forming operation, the
characteristic of glass is depend on
viscosity and temperature.
Some specific point in glass processing
are:
1. Melting Point.
2. Working Point.
3. Softening Point.
4. Annealing Point.
5. Strain Point.
Fabrication & Processing
See fig 13.6

1. Melting Point.
the glass is fluid enough to be
considered a liquid.
Fabrication & Processing
2. Working Point.
The glass is easily deformed at this
viscosity.

3. Softening Point.
the maximum temperature at which a
glass piece may be handled without
causing significant dimension alteration.
Fabrication & Processing
4. Annealing Point.
at this temperature, atomic diffusion is
sufficiently rapid that any residual stress
may be removed within about 15 minutes

5. Strain Point.
The glass transition temperature will be
above the strain point.
Fabrication & Processing
The temperature at which each of these
points occurs depends on glass
composition.
Softening Soda Lime and 96% Silica glass
are about 700 and 1550oC. See fig.13.6
Fabrication & Processing
Glass Forming
Glass Forming
It is produced by heating the raw
material to an elevated temperature
above which melting occurs.
Glass Forming
Glass Forming
It is essential that the glass product be
homogenous and pore free.
Transparency
Glass Forming
Glass Forming
It is produced by heating the raw
material to an elevated temperature
above which melting occurs.
Glass Forming
Four different forming methods:
Pressing.
Blowing.
Drawing.
Fiber forming.
Fabrication & Processing
Glass forming & blowing
Gob Parison Blow

Pressing
operation
Glass Forming
Glass Forming
Glass Forming
Glass Forming
Glass Forming
Glass Blowing
Glass Blowing
Heat Treating Glasses
Annealing
When a ceramic material is cooled, internal
stresses may be introduced.
It called thermal stress.
To solve is by cooling at slow rate.
Heat Treating Glasses
Glass Tempering
The glassware is heated to a temperature
below softening point.
It is then cooled to room temperature in a
jet of air or oil bath.
The residual stress arise from difference
cooling rate for surface and interior region.
Heat Treating Glasses
Glass Tempering
Automobile windshield.
Eyeglass lenses.
Large glass window and doors.
Fabrication of Clay Product
Clay Characteristic
The clay minerals play two important role
in ceramic bodies:
1. When water is added, they become
very plastic. This condition called
hydro-plasticity.
Fabrication of Clay Product
Clay Characteristic
The clay minerals play two important role
in ceramic bodies:
2. Clay fuses or melts over a range of
temperature. A dense and strong
ceramic piece may be produced during
firing without complete melting.
Fabrication of Clay Product
Clay are aluminosilicates are composed of
Alumina (Al2O3) and Silica (SiO2) that
contain chemically bound water.
Fabrication of Clay Product
Composition of Clay.
The combination of Clay may consist of
Quartz
Fledspar
Fabrication of Clay Product
Fabrication Techniques.
1. Hydroplastic Forming.
Clay mineral + Water poured into the mold.
Fabrication of Clay Product
2. Slip casting
Fabrication of Clay Product
Drying & Firing
A clay that has been formed and dried but
not fired is termed Green.
Drying may be done below 50oC
Firing done between 900 to 1400oC.
Fabrication of Clay Product
Powder Metallurgy.
Fabrication of Clay Product
Powder Metallurgy
Fig 13.13
Fig 13.14
See the presentation of powder metallurgy
Typical iron and copper based P/M parts
Automotive industry is leading with more than 75% of
the share. American cars contain more than 16 kg of
P/M parts while European cars have 7 kg and Japan
cars have 5 kg P/M parts.
Shock absorbers, pistons, break shoe and other parts relevant.
Transmission gears Business machines
Connection rods, typewriter parts and copy
machine parts.
The Basic Process
Consists of 4 basic steps:

1. Powder Manufacture
2. Mixing or Blending
3. Compacting
4. Sintering