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What Are Ceramics?

comes from the Greece word keramos, which


stands for Clay and clay products
broadly classed as inorganic, non-metallic
materials
Usually a compound, or a combination of
compounds,
between metallic and nonmetallic elements
(mainly, O, N, C, B)
always composed of more than one element
(Al2O3, SiO2, SiC, etc.)
bonds are either totally ionic, or combination of
ionic
and covalent

Typical Characteristics of Ceramic Materials


Brittle
Light in weight
High melting points
Hard, wear-resistant, electrically and
thermally insulating, refractory, chemically
stable, durable, non-magnetic.
BUT
These properties are not common to ALL
ceramics !!

Classification of Ceramics
very traditional (clay-based and silica-based
ceramics
(used for construction and other applications)
but also new HIGH-TECH ceramics and uses
1. optical (transparency) (opto-electronics)
2. electronic (piezoelectric, sensor,
superconductor)
3. thermo-mechanical (engine material)
4. wear-resisting (cutting tool)

Classification
Based on their specific applications, ceramics
are classified as:
-Glasses
-Clay products
-Refractories
-Abrasives
-Cements
-Advanced ceramics for special applications

Classification based on COMPOSITION


Silicate Ceramics: presence of glassy phase in
a porous structure
clay ceramics (with mullite 3Al2O3.2SiO2)
silica ceramics (with cordierite 2MgO 2Al O
2SiO )
Oxide Ceramics: dominant crystalline phase,
with small glassy phase
single oxide (Al2O3),
modified oxide (zirconia toughened alumina)
mixed oxide (mullite, BaTiO3)

Classification based on COMPOSITION


Non-oxide Ceramics:
carbon, SiC, BN, TiB2, sialon
Glass-ceramics: partially crystallised glass
SiO2-Li2O, LAS, MAS

Bonding in Ceramics
The properties of the materials depend upon the:
The type of atoms present
The types of bonding b/w the atoms
The way the atoms are packed

Type of bonding in ceramics


How the bonding influences the properties of ceramics
Properties of any material dictate the processing
techniques of that material

Bonding in Ceramics
Two types of bonding exist in ceramics, Ionic and
Covalent bonding
Ionic and Covalent bonds are considered stronger
bonds as compared to metallic bonding.
Ceramics Cant be deformed plastically

Eventually, this bonding will influence our choice of


Processing technique.

Bonding in Ceramics
Type of bonding in Ceramics leads to:
High melting point
Low thermal expansion
High hardness
Good chemical resistance
Brittle

Processing of Ceramics
Traditional and technical ceramics are manufactured
by compacting powders or particles into shapes
which are then heated to a high temperature to bond
the particles together
Basic steps in the processing of ceramics are:
Material Preparation
Forming or Casting
Thermal treatment

Processing of Ceramics
Material Preparation

Most ceramics products are made by agglomeration


of particles.
Raw materials may vary
Wet or dry mixing and grinding

Processing of Ceramics
Forming or Casting

Means ways of forming ceramic shapes; from tea pot to


engineering ceramics such as computer parts.
Commonly used ceramic forming methods are:
a) Pressing

Ceramic particulate raw materials can be pressed in the dry,


plastic or wet condition into a die to form shaped products.

Dry pressing is used for electronic ceramic components.

Hot pressing: Ceramic parts of high density and improved


mechanical properties are produced by combining the pressing
and firing operations

Processing of Ceramics
Forming or Casting

Commonly used ceramic forming methods are:


Slip casting
a) A stable suspension called slip is prepared.
b) Slip is poured into a mould and liquid portion of the slip
is partially absorbed.
c) The material in the mold is allowed to dry to provide
adequate strength for handling.
d) Removed from mold and fired to attain the required
microstructure and properties.

Processing of Ceramics
Slip casting

Processing of Ceramics
Forming or Casting

Extrusion
Hollow shape ceramic materials can
be produced by extrusion method.
Used to produce refractory bricks,
sewer pipes, hollow tiles, technical
ceramics and electrical insulators.

Processing of Ceramics
Thermal treatment

Essential step in the manufacturing of most ceramic


products
Thermal treatment includes:
a) Drying and binder removal
b) Sintering
In sintering, atomic diffusion takes place between the
contacting surfaces of the particles so that they become
chemically bonded together.

Processing of Ceramics
Thermal treatment

a) Drying and binder removal


b) Sintering
c) Vitrification
During the firing of ceramic materials, vitrification takes
place, where by the glass phase liquifies and fills the pore
spaces in the material. This liquid glass phase may also react
with some of the remaining solid refractory material upon
cooling.
The liquid phase solidifies to form a vitreous or glassy matrix
that bonds the unmelted particles together.

Strength of Ceramics
Before pursuing to processing of ceramics, some
general understandings:
Smaller the particle size, the higher is the strength of
ceramics
An increased toughness leads to enhancement in resistance
to fracture
High particle aspect ratio may be useful in enhancing
toughness

Ceramics toughness
Ceramics have inherently low toughness
It limits the applications of ceramics
Processes such as hot pressing, ceramics with additives and
reaction bonding, engineering ceramics with improved
toughness have been produced
Phase transformation in zirconia combined with some
refractory oxide (CaO, MgO) produce ceramic materials
with exceptionally high fracture toughness.

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