Lesson1Apps

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Lesson 1 – August 22, 2011

History, Applications and Properties of Ceramics and Glasses

******************** The Structure/Processing/Properties Concept

Steve [email protected] [email protected] 847-870-1621

Illinois Institute of Technology, Dept. of Mechanical, Materials, and Aerospace Engineering

MMAE 468 – Introduction to Ceramic Materials

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Good Evening.

Key Concepts in Lesson 1! Ceramics and glass are not new. They

have been around a very long time.

! Ceramics are used across a broad range of low-tech and high-tech applications.

! Ceramics are different than metals and polymers in their composition, structure, processing, and properties.

! The Structure/Processing/Properties Conceptis the FUNDAMENTAL framework for materials engineering and design.

Carbon-Carbon Disc Brakes

Stone Arrowheads

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Objectives – Lesson 1

1. Define and discuss “what is a ceramic” and how is it different than a metal or polymer”

2. Review the development and timeline of ceramics in history.

3. Discuss the range of traditional and advanced applications for ceramics and glasses.

4. Introduce the Structure/Processing/Properties Concept as the framework for materials engineering and design.

5. Review the range of properties, structure, and processing methods for ceramics and glass.

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This Evening’s Amusement

• Your Dilbert Guide to Bureaucracy

The Knack

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Text Book References for Lesson 1 - Ceramic Applications

• Richerson, Modern Ceramic Engineering, Chapters 1, 2, 3

• Kingery, Introduction to Ceramics, Chapter 1

• ASM Engineered Materials Handbook, Vol. 4 Ceramics and Glasses -- Sections 1, 12, 13, 14, and 15.

• Carter and Norton, Ceramic Materials - Science and Engineering, Chapter 1 and 2

• Barsoum, Fundamentals of Ceramics, Chapter 1

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Ceramics in our Modern Economy

What do you think of, if I ask you --

• What is a ceramic?

• Where are ceramics used in your daily life?

• What is a high-tech advanced ceramic?

• How big is the $ market for ceramics in the US?

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What is a Ceramic?

• From the Greek “keramos– burnt material”– Refers to traditional pottery

• From Kingery– Ceramics is the art and science of making

and using solid articles which have as theiressential component, and are composed in large part of, inorganic nonmetallic materials

• From Barsoum– Solid compounds that are formed by the application of heat, and

sometimes heat and pressure, comprising at least two elements provided one of them is a non-metal and a nonmetallic elemental solid. [The other element(s) may be a metal(s) or another nonmetallic elemental solid(s)]

We can define ceramics in terms of properties, composition, structure, applications, and processing

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How is a ceramic different than a metals or polymer?

Corrosion and Oxidation Resistance

Crystal Structure

Composition

Density

Ceramics

Processing Temperatures

Thermal Properties – conductivity, thermal expansion, specific heat

Magnetic Properties

Optical Properties

Electrical Properties – conductivity, dielectric strength

Mechanical Properties -- Strength, Hardness, Stiffness, Toughness, Ductility

Melt/Softening Temperature

PolymersMetalsPX

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Typical Perception of Ceramic Properties

• Hard and Brittle

• High Melting Temperature

• Poor Thermal and Electrical Conductor

• Nonmagnetic

• Resistant to Corrosion

• Formed from powders or slurries; and then densifiedand strengthened by heat.

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Groups in the Ceramics Family

• Crystalline Ceramics– Composition – Metal Oxides, Carbides, Nitrides– Structure – Polycrystalline and Single Crystal– Processing

• Thermal Bonding - Sintering

• Glass Materials – Structure and Processing – Glass Ceramics

• Natural Ceramics (Minerals and Biological)– Stone and Obsidian– What mineral/ceramic do you eat?– What ceramic are your bones made of?

Ca10(PO4)6(OH)2

• Exceptions to the Rule!!– Elemental?– Cold Chemical Processing?

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History of Ceramics

• Man is the “Tool Maker.”– What were the first durable tools?? (35,000 BC)– What were the first ornaments and art??

• Clay & Fire -- formed synthetic stone– Containers, Tablets, Tiles, Sculpture (oldest = 24,000 BC)– Forming, Decorating. Glazing

• Plaster, Mortar, Cement, and Bricks for Structures (7000 BC)

• Glass Technology (1500 BC)– plastic forming and decorating– Casting" coring " blowing

• Earthenware and Whiteware from China (1000BC)

Ceramic Technology Leads to Metal Technology

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Ceramics In Your life??? PX

How and where are ceramics and glass used --In your house?

In your car?

In your computer, phone, and television?

In medicine and health?

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Ceramics in Terms of Applications Areas

“TRADITIONAL” APPLICATIONS– Whitewares --Structural Clay Products– Glass --Refractories in Industrial Processing– Concrete & Cement -- Abrasives

“ADVANCED CERAMICS” APPLICATIONS– Electronics -- Structural Ceramics– Electrochemical -- Environmental and Chemical– Medical and Bioengineering -- Coatings– Optical -- Nuclear– Cements and Sealing -- Thermal Management– Composites

How big is the US market for ceramics and glass?

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Ceramic and Glass Markets in the US Today

“Traditional” Ceramics– Glass– Whitewares– Structural Clay Products– Refractories– Concrete & Cement– Abrasives

“Advanced” Ceramics– C & G for Electronics– Structural Ceramics– Optical– Electrochemical– Thermal Management– Medical

$145BConcreteWhitewaresGlassBrickAbrasiveRefractories

Advanced Ceramics and Glass ($B)

9.8

2.8

1.8

1.7

1.7

1.1 1.1

Traditional Ceramics ($B)

110

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1046 3

$20BGlass -ElecElectronicOthersElectricalGlass-OptIndustrialTransport.

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“TRADITIONAL” APPLICATIONSWhitewares

• Tableware, pottery, decorative ceramics• Sanitary ware • Floor and wall tile • Porcelain coatings on metals • Electrical porcelain

Structural Clay Products• Brick, • Sewer pipe, • roofing tile, industrial tile, flue linings

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“TRADITIONAL” APPLICATIONSConcrete and Cement

• Concrete for roads, bridges, buildings, dams, etc.

Refractories• Monolithic, fibrous, and castable

insulation products for high temperature industrial processes

• iron and steel, non-ferrous metals, casting, glass, cements, ceramics, energy conversion, petroleum, and chemicals industries

• Thermocouple tubes

Abrasives• Natural (garnet, diamond, etc.) and synthetic (silicon carbide,

diamond, fused alumina, etc.) abrasives • Used for grinding, cutting, polishing, lapping, or pressure blasting of

materials

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“TRADITIONAL” APPLICATIONSGlass Products

» Architectural/Building glass (windows), » Vehicular glass » Container glass (bottles), » Pressed and blown glass (tableware)» Optical Glass (lenses, mirrors)» Glass for Lighting» Glass fibers (insulation and composites)

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Advanced Ceramic ApplicationsThe Future of Advanced Ceramics –http://www.youtube.com/watch?v=69Y0VuOYqkU

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Electrical Devices (Conductors, Semiconductors, Insulators)– Capacitors, insulators/resistors, varistors, filters and gates– Ceramic Substrates, integrated circuit packages– Glass-epoxy substrates– Ferromagnetic devices – permanent magnetics,

data storage, transformers, – Piezo Electric Energy Conversion

• Sensors, actuators, converters– Thermo-electric Energy Conversion

• Sensors, actuators, converters– High Temperature Superconductors– Low Signature Military Applications (EMF management)

Discrete Components, Thin Film, and Thick Film

Advanced Ceramic Applications

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Electrochemical Devices and Sensors(Ionic Conductors -- chemical energy ⇒ electricity)

• Solid Oxide Fuel cells –• Chemical sensors –

oxygen, humidity, gas sensors

Optical • Optical Fiber• Electro-optical devices

– Solid-state lasers– Optical gates and switches

• Electronic display glass for televisions and flat panels.• Tailored transmittance windows/radomes• Precision Mirrors (low CTE high modulus structures)• Optical Coatings (wavelength reflective, transmissive)• Photochromic Glasses


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Structural • Wear parts -- bearings, seals, valves, dies, nozzles• Cutting tools • Ballistic Armor plate• Reciprocating Engine parts

– turborotors, valves, rollers, • Turbine Engine parts

–combustion liners, exhaust components,rotors, and stators.

• Heat resistant tools and molds for casting of refractory metals.

Coatings • For thermal protection, wear, corrosion, and friction control.• For cutting tools, engine components, and industrial wear parts• Release coats in high temperature molds.• (Thick and thin coatings)

Advanced Ceramic Applications Handout

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Environmental and Chemical -• Filters and separation membranes

– Controlled porosity • Corrosion resistant furnace melt components • Catalysts and catalyst supports

for industrial chemical production• Catalyst supports for automotive

converters

Medical and Bioengineering -• Dental Materials• Bone Replacement• Bone Scaffolding

Cements and Sealing Materials• For high temperature bonding

Advanced Ceramic Applications Handout

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Nuclear Power• Fuel, fuel rods, neutron control, radiation barriers • Hot structures in reactors• Waste encapsulation in glass.

Thermal Engineering• Resistance heaters• Engineered thermal insulation

http://www.youtube.com/watch?v=kHnen2nSmDY&feature=related

• Heat exchangers and recuperators• Burner and combustion plates• High Thermal Conductivity Substrates for Electronics

Friction Materials• High Performance Brakes – Light Weight, Long Life

• Compared to metal and carbon-carbon• Clutch Plates


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Where is aluminum oxide commonly used?

Where is covalent 3-D crystalline carbon commonly found?

How is titanium dioxide commonly used?

Where is graphite commonly used?

Where are alumino silicates commonly used?

What is the largest use of silicon dioxide?

How is cubic boron carbide commonly used?

PX

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The Structure/Processing/Properties Concept

To engineer and control the final properties in the end product you have to –– Understand and control the composition and structure.– Understand and control the manufacturing process.

Corollary –You also have to know, understand, and manage what happens to structure, composition, and properties in the service environment.

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The Structure/Processing/Properties Concept

To produce the taste and texture in the meal you have to –– Understand and control the ingredients and ratios.– Understand and control the mixing and cooking process.

Cooks uses the same principles in the kitchen !!

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The Structure/Processing/Properties Concept in the Design Process

What does this mean to the materials engineer?You have the primary responsibility to --

– Know and understand (in detail) the capabilities, limitations, applications, and costs in your area of materials expertise.

– Identify, define, and recommend the material/s and processing methods that will meet the design requirements for performance, reliability, cost.

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The Structure/Processing/Properties Concept in the Design Process

What does this mean to the design engineer?

You have the responsibility to --– Provide the materials engineer a

clear and complete understanding of what your performance requirements and design targets are.

– Have a basic understanding of how structure, processing, and properties work together for your materials of interest in production and in use.

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How are Ceramics Studied and Organized?

By Composition and Atomic Structure

By Micro and Macro Structure

By Engineering Properties

By Fabrication Method

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Ceramics in Terms of Composition and Structure

– Oxide Ceramics • Single Oxide• Mixed Oxides

– Carbon-Graphite– Carbide Ceramics– Nitride Ceramics– Boride Ceramics– Other Compositions

• Sulfides, Phosphides, Silicides, – Stoichiometery

– Atomic Structure• Crystalline• Amorphous/Glassy

– Phase Composition• Single Phase• Multiphase

– Crystal Defects

Grain Structure – Size, Shape, Size Distribution, AnisotropyGrain Boundaries – Composition, Crystallinity, Morphology, Volume FractionVolume defects -- Pores, Cracks, inclusions, agglomeratesSurface Condition and Defects – roughness, scratches, pits, chips, cracksResidual Stresses -- Processing and microstructure differences

Chemical Composition Crystallinity and Phases

Microstructure Features

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Ceramics in Terms of Macrostructure

Monolithic Dense Ceramic Components– Plates, Bars, Discs, Spheres,– Thin Sheets (Electronic Substrates) – Complex Shapes

• Hollow tubes and cylinders• Curved and complex forms

Ceramics with Engineered Porosity– Honeycombs and Channels– Open cell foams– Closed cell foams– Fibrous mats– Micro and nano-porous membranes and film

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Ceramic Fibers– Long fibers

• Macro diameter (>25 microns)• Micro diameter (0.5 -- 25 microns)

– Short Filaments and Whiskers• < 1 micron diameter

– Woven 2-D and 3-D fabrics

Ceramic Coatings– Thin Film for Electronics (<0.5 microns)– Thick Film for Electronics (10-25 microns)– Thin Coatings (<20 microns) for Wear – Thin coatings (<5 microns) for Optics– Thick Coatings (>20 microns) for Thermal Barriers and Corrosion

Resistance

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Composite Ceramics– Fiber Reinforced

• Filament Wound, 2-D Weave, 3-D Weave and Braid

– Particulate and whisker reinforced– Laminated/Layered Ceramics

For Structural Applications, fiber-reinforced ceramic composites

• Eliminate brittle failure by providing toughness and damage tolerance.

• Enable tailored directional and localized properties

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Fiber Reinforced Ceramic Composites

For Structural Applications, fiber-reinforced ceramic composites

• Eliminate brittle failure by providing toughness and damage tolerance.

• Enable tailored directional and localized properties

Monolithic Silicon Carbide --http://www.youtube.com/watch?v=WgQNDcJrhDc&feature=related

Fiber Reinforced Silicon Carbide --http://www.youtube.com/watch?v=nTZtHhqo7zU

Ceramic Matrix Composites http://www.youtube.com/watch?v=XlIkWlh1nYQ

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Ceramics in Terms of Engineering Properties

Fundamental Engineering Properties

• Physical Properties

• Mechanical Properties

• Thermal Properties

Young’s Modulus, Shear Modulus,Poisson’s Ratio, Tensile Strength, Compressive Strength, Hardness,Flexure Strength, Impact Strength, Fracture Toughness

Density, Melt Temperature, Service Temperature

Specific Heat, Thermal Conductivity,Coef. Of Thermal Expansion, Thermal Diffusivity

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Fundamental Engineering Properties

– Electrical Properties

– Optical Properties

– Magnetic Properties

Index of Refraction, Transmission, Absorption, Reflection, Color, Phosphorescence, High Temperature Emissivity

Volume resistivity, dielectric strengthDielectric constant, loss tangent, loss factor, Te

Permeability, Permitivity, Saturation flux densityHysteresis, Coercive Force,

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• Mechanical Durability and Reliability– Cyclic Fatigue, Creep, – Crack Growth (Temperature and Environment)– Thermal Stresses and Thermal Shock– Residual Stresses from Fabrication– Wear, Abrasion, Erosion, Impact

• Environmental Durability– Thermal, Corrosion, Biologic, Radiation, Electrical Environments– Changes in Chemistry, Phases, Microstructure, Defects

• Friction Properties – Coef. of Friction, Wear and Abrasion Rates

• Variations in Properties (Mechanical-Thermal-Electric-Magnetic-Optical) with changes in Performance Conditions

• Component Interactions in Composites and Coatings

Application-Specific Performance Properties

Handout!!

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Ceramics in Terms of Fabrication Methods

Ceramic Forming– Start with Powders

• Grind, Size, Clean• Blend

– Green Shape• Dry Press• Isostatic Press• Slip Cast• Tape Cast• Extrude• Injection Mold• Green Machine

– Densify/Sinter• Furnace Heat

– Finish• Machine, Polish• Coat

– Inspect

Non Traditional Processes– Hot Press– Hot Isostatic Press– Flame/Plasma Spray

Deposition– Chemical Vapor

Deposition– Sol-Gel Fabrication– Polymer-Derived

Ceramics– Self-Propagating

Synthesis– Reaction Forming– Directed Metal

Oxidation– Rapid Prototyping

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Ceramics in Terms of Fabrication Methods

Glass Forming– Start with Powders– Melt and control

viscosity– Form/Cast/Mold

• Blow Mold• Press Mold• Draw• Cast• Extrude• Spray• Spin

– Finish• Anneal / Temper• Grind/Polish• Coat/Decorate

– Inspect

Ceramic Coatings– Start with Powders– Initial Coat

• Slurry/Dip Coat• Spray Coat• Spread Coat

– Density by Heat– Non-traditional Coatings

• Thin Film by PVD and CVD• Thin Film by photolithography• Flame-Plasma Spray• Chemical Vapor Deposition• Lamination

– Inspect

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Major Ceramic Technical Landmarks

In the 20th CenturyFrom Carter and Norton -- Ceramic Materials – Science and Engineering

• Uranium Dioxide Nuclear Fuel

• The Float-glass process

• Pore free ceramics

• Nitride ceramics

• Magnetic ferrites

• Ferroelectric titanates( capacitors, transducers, thermistors)

• Optical fibers

• Glass ceramics

• Tough Ceramics

• Bioceramics

• Solid Oxide Fuel cells

• High Temp superconductivity

In the 19th CenturyThe Erie Canal

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Homework Lesson 1

• Homework assignment #1 is posted on the IIT Black Board. – Read Chapter 1,2, and 3 in Richerson

and review the lecture notes.

• Work the homework this week. Makea copy for yourself and turn the original in(paper, email ([email protected]), digital dropbox) before or in class next week. (NLT 7 PM by electrons)I will RSVP e-mails.

• Self-correct your homework.Answers will be posted on the IIT Blackboard after next Monday’s class.Questions in the next class.

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Closing Question

• What are the 3 most important things you learned in this lesson today??

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Key Concepts in Lesson 1! Ceramics and glass are not new.

They have been around a very long time.! But there are some very new ceramic applications!!

! Ceramics are used across a broad range of low-tech and high tech applications.

! Ceramics are different than metals and polymers in their composition, structure, processing, and properties.

! Ceramics can be classified by Composition and Atomic Structure, Micro and Macro Structure, Engineering Properties, and Fabrication Method

! The Structure/Processing/Properties Conceptis the FUNDAMENTAL framework for materials engineering and design.

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Don’t ForgetThe engineering properties of ceramics (and all materials)

are composition, structure, and process dependent.• Strength & Fracture toughness• Wear Resistance• Thermal Conductivity• Thermal Expansion• Corrosion Resistance• Electrical Properties• Optical Properties

If you don’t understand and control the composition, structure, and processing,

you can’t control the engineering properties!!

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Where are we headed over the next 3½ Months?

1. Aug 29– Atomic Bonding and Crystal Structure2. Sep 5– Labor Day – No Class3. Sep 12 – Crystal Chemistry and Defects4. Sep 19 – Phase Diagrams5. Sep 26 – Ceramic Design and the

Structure-Processing-Properties Paradigm6. Oct 3– Processing and Fabrication #17. Oct 10 – Fall Break8. Oct 17 -- Sintering and Densification9. Oct 26 – Mid Term Exam10. Oct 31 -- Ceramic Processing and Fabrication #211. Nov 7 – Mechanical Properties – Fast Fracture12. Nov 14– Mechanical Properties – Durability13. Nov 21 -- Electronic Properties, 14. Nov 28– Piezoelectric, Dielectric and Magnetic Properties 15. Dec 5- Final Exam

Lesson Structure1. Basic Principles,

Terms, Theories Mechanisms

2. Controlling Factors and Relative Effects

3. Practical Applications and Considerations

4. Testing and Measurement Methods

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Next Class

Atomic Bonding and Crystal Structure in Ceramics and Glasses (Aug 29)

Electronic Configuration of Atoms

Bonding Principles and Types of Bonds in CeramicsIonic BondingCovalent BondingVan der Waals Bonding

Bonding, Crystal Structure, and Stability in Ceramics

Glass/Non-Crystalline Structures

Read Ahead -- Richerson, Chapter 4

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Good Night

Thank You for your Attention this Evening

Have a Good Week..

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