The document discusses the course MM-532 Ceramic Engineering which covers topics related to crystal structures, physical properties, mechanical properties, processing, and characterization of ceramic materials. It focuses on crystal structures, imperfections, phase diagrams, stress-strain behavior, powder processing, sintering, and characterization of ceramic products such as alumina and nitrides. The course includes a sessional and final exam.

1. Dr. Fayaz Hussain

2. MM-532 Ceramic Engineering
• Crystal Structures and Origin of Ceramics, Physical and
Thermal properties of Ceramics, Structure of Ceramics,
Silicate Ceramics, Imperfections in Ceramics, Ceramic
phase Diagrams, Mechanical Properties of Ceramic
Materials. Stress-Strain behaviour, Miscellaneous
Mechanical Considerations, Processing of ceramic Powders,
Powder Characterization and data analysis, Sintering
Thermodynamics and Kinetics, Novel Sintering Techniques,
Characterization of Sintered Products, Study of Transition
Alumina and Transformation Toughening in Ceramics
Development Fabrication and Processing of Carbides and
Nitrides, Characterization of Carbide and Nitride Ceramics.
40 Marks: Sessional & 60 Marks: Final paper

3. Ceramic Science and
Engineering
When you hear the word “ceramics,” people usually think of an image
of pottery or space shuttle tiles. What many people don’t realize is that
ceramics and ceramic engineering play an important role almost
everywhere you look and sometimes where you can’t look.
Besides everyday objects, ceramics are helping computers and other
electronic devices operate, improving people’s health in various ways,
providing global telecommunications, and protecting soldiers during
combat.

4. In the most simple of terms, ceramics are inorganic, nonmetallic materials.
They are typically crystalline in nature (have an ordered structure) and are
compounds formed between metallic and nonmetallic elements such as
aluminum and oxygen (alumina, Al2O3), calcium and oxygen (CaO), and
silicon and nitrogen (silicon nitride, Si3N4). In broader terms, ceramics also
include glass (which has a non-crystalline or amorphous random structure),
enamel (a type of glassy coating), glass-ceramics (a glass containing
ceramic crystals), and inorganic cement-type materials (cement, plaster and
lime). However, as ceramic technology has developed over time, the
definition has expanded to include a much wider range of other compositions
used in a variety of applications.
The word “ceramic” is traced back to the Greek term keramos, meaning
potter’s clay or pottery. Keramos, in turn, is related to an older Sanskrit root,
meaning “to burn.” Ceramus or Keramos was also an ancient city on the
north coast of the Aegean Sea in what is present-day Turkey.

5. Structural Clay
Products Brick, sewer pipe, roofing tile, clay floor and wall tile
whitewares Dinnerware, floor and wall tile, electrical porcelain, decorative ceramics
Refractories Brick and monolithic products used in iron and steel, non-ferrous metals, glass,
cements, ceramics, energy conversion, petroleum, and chemicals industries, kiln
furniture
Glasses Flat glass (windows), container glass (bottles), pressed and blown glass (dinnerware),
glass fibers (home insulation)
Cements Concrete roads, bridges, buildings, dams, sidewalks, bricks/blocks
Abrasives Natural and Synthetic abrasives
Automotive cam rollers, fuel pump rollers, brakes, clutches, spark plugs, sensors, filters, windows,
thermal insulation, emissions control, heaters, igniters, glass fiber composites for door
chassis
Aerospace Thermal insulation, space shuttle tiles, wear components, combustor liners, turbine
blades/rotors, fire detection feedthrus, thermocouple housings, aircraft instrumentation
and control systems, satellite positioning equipment, ignition systems, instrument
displays and engine monitoring equipment, nose caps, nozzle jet vanes, engine flaps
Chemical Thermocouple protection tubes, tube sheet boiler ferrules, catalysts, catalyst supports,
pumping components, rotary seals
Areas of Specialization or
Branches of Ceramics
Boiler Tube Ferrules
There are two major categories of glasses and ceramics: traditional
and advanced

6. Coatings Engine components, cutting tools, industrial wear parts, biomedical implants, anti-
reflection, optical, self-cleaning coatings for building materials
Electrical/
Electronic
Capacitors, insulators, substrates, integrated circuit packages, piezoelectric, transistor
dielectrics, magnets, cathodes, superconductors, high voltage bushings, antennas,
sensors, accelerator tubes for electronic microscopes, substrates for hard disk drives
Environmental Solid oxide fuel cells, gas turbine components, measuring wheels/balls for check valves
(oilfields), nuclear fuel storage, hot gas filters (coal plants), solar cells, heat
exchangers, isolator flanges for nuclear fusion energy research, solar-hydrogen
technology, glass fiber reinforcement

7. Duties and
Responsibilities
Ceramic Engineers might be expected to
carry out the following…..
• Supervise or test chemical ,
physical, or electrical properties
on ceramic substances
• Analyze test results
• Seek information on firing,
processing, and forming new
ceramic products out of inorganic
and raw materials
• Figuring out different uses for the
ceramic materials
• Controlling or directing other
workers activities
• Rating information
• Taking accurate and precise
measurements
• Think logically
• Comparing different
characteristics of useable materials
• Demonstrate a variety of high
level mathematical skills
Responsibilities:
Duties:

8. Greatest Engineering Achievements of
the 20th Century
Achievement How Ceramics Contribute:
1. Electrification
Electrical insulators for power lines,
insulators for industrial/household
applications, glass light bulbs
2. Automobile
Engine sensors, catalytic converters, spark plugs,
windows, engine components, electrical devices
3. Airplane
Anti-fogging/freezing glass windows, jet engine components,
electronic components

9. 4. Safe water supply and treatment Filters/membranes
5. Electronics
Substrates and IC packages,
capacitors, piezoelectrics, insulators, magnets, superconductors
6. Radio and television
Glass tubes (CRTs), glass
faceplate, phosphor coatings,
electrical components, magnets
7. Agricultural mechanization
Refractories for melting and
forming of ferrous and non-ferrous metal components
8. Computers
Electrical components, magnetic
storage, glass for computer monitors

10. 9. Telephone Electrical components, glass optical fibers
10. Air conditioning and refrigeration
Glass fiber insulation, ceramic
magnets
11. Interstate highways
Cement for roads and bridges, glass microspheres
used to produce reflective paints for signs and road lines.
12. Space exploration
Space shuttle tile, high-temperature
resistant components, ceramic ablation
materials, electromagnetic and
transparent windows, electrical
components, telescope lenses

11. 13. Internet
Electronic components, magnetic storage,
computer monitor glass
14. Imaging: X-rays to
film
Piezoceramic transducers for
ultrasound diagnostics, sonar
detection, ocean floor mapping and
more, ceramic scintillator for X-ray
computed tomography (CT scans),
telescope lenses, glass monitors, phosphor coatings for radar and sonar screens
15. Household
appliances
Porcelain enamel coatings for major appliances,
glass fiber insulation for stoves and refrigerators,
electrical components, glass-ceramic stove tops,
spiral resistance heaters for toasters, ovens and ranges
16. Health
technologies
Replacement joints, heart valves, bone
substitutes, hearing aids, pacemakers,
teeth replacements/braces, transducers
for ultrasound diagnostics, scintillators for X-ray computed tomography (CT scans),
cancer treatments

12. 17. Petroleum and
natural gas
technologies
Ceramic catalysts, refractories, packing media for
petroleum and gas refinement, cement and drill bits for well drilling
18. Lasers and fiber
optics
Glass optical fibers, fiber amplifiers, laser materials, electronic components
19. Nuclear
technologies
Fuel pellets, control rods, high-
reliability seats and valves, nuclear
waste containment
20. High-performance
materials
Including advanced ceramics for their excellent wear, corrosion and high
temperature resistance; high stiffness; high melting point; high compressive
strength and hardness; and wide range of electrical, magnetic, and optical
properties

14. Table 14-1 (Continued)

15. Structure and Properties of Ceramics
Ceramics usually have a
combination of stronger
bonds called ionic
(occurs between a metal
and nonmetal and
involves the attraction of
opposite charges when
electrons are transferred
from the metal to the
nonmetal);
• The strength of an ionic bond depends on the size of the charge on
each ion and on the radius of each ion.
• The greater the number of electrons being shared, is the greater the
force of attraction, or the stronger the covalent bond.
• These types of bonds result in high elastic modulus and hardness,
high melting points, low thermal expansion, and good chemical
resistance. On the other hand, ceramics are also hard and often brittle
(unless the material is toughened by reinforcements or other means),
which leads to fracture.

24. Oxide nickel-zinc ferrite
representation, with
stoichiometry
Ni0.5Zn0.5Fe2O4 with
structure type inverse
spinel.

35. AX crystal structure

40. Property Ceramic Metal Polymer
Hardness Very High Low Very Low
Elastic modulus Very High High Low
High temperature
strength
Thermal expansion High Low Very Low
Ductility Low High High
Corrosion resistance High Low Low
Wear resistance High Low Low
Electrical conductivity Depends on material High Low
Density Low High Very Low
Thermal conductivity Depends on material High Low
Magnetic Depends on material High Very Low
General Comparison of Materials

41. Properties of Ceramics

43.  Zirconium dioxide is one of the most studied ceramic materials. Pure ZrO2 has
a monoclinic crystal structure at room temperature and transitions
totetragonal and cubic at increasing temperatures. The volume expansion
caused by the cubic to tetragonal to monoclinic transformation induces very
large stresses, and will cause pure ZrO2 to crack upon cooling from high
temperatures. Several different oxides are added to zirconia to stabilize the
tetragonal and/or cubic phases: magnesium oxide (MgO), yttrium oxide,
(Y2O3), calcium oxide (CaO), and cerium(III) oxide (Ce2O3), amongst others.
 Zirconia is very useful in its 'stabilized' state. In some cases, the tetragonal
phase can be metastable. If sufficient quantities of the metastable tetragonal
phase is present, then an applied stress, magnified by the stress
concentration at a crack tip, can cause the tetragonal phase to convert to
monoclinic, with the associated volume expansion. This phase transformation
can then put the crack into compression, retarding its growth, and enhancing
the fracture toughness. This mechanism is known as transformation
toughening, and significantly extends the reliability and lifetime of products
made with stabilized zirconia.

45. Fully Stabilized Zirconia
 Generally, addition of more than 16 mol% of CaO (7.9 wt%),
16 mol% MgO (5.86 wt%), or 8 mol% of Y2O3 (13.75 wt%), into
zirconia structure is needed to form a fully stabilized zirconia.
Its structure becomes cubic solid solution.
 Its structure becomes cubic solid solution, which has no
phase transformation from room temperature up to 2,500 ° C.
As a good ceramic ion conducting materials, fully yttria
stabilized Zirconia (YSZ) has been used in oxygen sensor and
solid oxide full cell (SOFC) applications.
 The SOFC applications have recently been attracting more
worldwide attention, due to their high energy transfer
efficient and environment concerns.