1. 1
Lesson 1 – August 22, 2011
History, Applications and Properties
of Ceramics and Glasses
********************
The Structure/Processing/Properties Concept
Steve Gonczy
sgpnczy@iit.edu gatewaymt@aol.com 847-870-1621
Illinois Institute of Technology,
Dept. of Mechanical, Materials, and Aerospace Engineering
MMAE 468 – Introduction to Ceramic Materials
2. 2
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
Concept
is the FUNDAMENTAL framework for
materials engineering and design.
Carbon-Carbon Disc Brakes
Stone Arrowheads
3. 3
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.
5. 5
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
6. 6
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?
7. 7
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 their
essential 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
8. 8
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
PolymersMetals
PX
9. 9
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 densified
and strengthened by heat.
10. 10
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?
11. 11
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
12. 12
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?
13. 13
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?
14. 14
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
$145B
Concrete
Whitewares
Glass
Brick
Abrasive
Refractories
Advanced Ceramics and Glass ($B)
9.8
2.8
1.8
1.7
1.7
1.1
1.1
Traditional Ceramics ($B)
110
11
10
46 3
$20B
Glass -Elec
Electronic
Others
Electrical
Glass-Opt
Industrial
Transport.
15. 15
Ceramics in Terms of Applications Areas
“TRADITIONAL” APPLICATIONS
Whitewares
• 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
16. 16
Ceramics in Terms of Applications Areas
“TRADITIONAL” APPLICATIONS
Concrete 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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Ceramics in Terms of Applications Areas
“TRADITIONAL” APPLICATIONS
Glass 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)
18. 18
Ceramics in Terms of Applications Areas
Advanced Ceramic Applications
The Future of Advanced Ceramics –
http://www.youtube.com/watch?v=69Y0VuOYqkU
19. 19
Ceramics in Terms of Applications Areas
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
20. 20
Ceramics in Terms of Applications Areas
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
Advanced Ceramic Applications
21. 21
Ceramics in Terms of Applications Areas
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
22. 22
Ceramics in Terms of Applications Areas
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
23. 23
Ceramics in Terms of Applications Areas
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
Advanced Ceramic Applications
24. 24
Ceramics in Terms of Applications Areas
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
25. 25
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.
26. 26
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 !!
27. 27
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.
28. 28
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.
29. 29
How are Ceramics Studied and Organized?
By Composition and Atomic Structure
By Micro and Macro Structure
By Engineering Properties
By Fabrication Method
30. 30
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, Anisotropy
Grain Boundaries – Composition, Crystallinity, Morphology, Volume Fraction
Volume defects -- Pores, Cracks, inclusions, agglomerates
Surface Condition and Defects – roughness, scratches, pits, chips, cracks
Residual Stresses -- Processing and microstructure differences
Chemical Composition Crystallinity and Phases
Microstructure Features
31. 31
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
32. 32
Ceramics in Terms of Macrostructure
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
33. 33
Ceramics in Terms of Macrostructure
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
35. 35
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
36. 36
Ceramics in Terms of Engineering Properties
Fundamental Engineering Properties
– Electrical Properties
– Optical Properties
– Magnetic Properties
Index of Refraction, Transmission,
Absorption, Reflection, Color,
Phosphorescence,
High Temperature Emissivity
Volume resistivity, dielectric strength
Dielectric constant, loss tangent,
loss factor, Te
Permeability, Permitivity,
Saturation flux density
Hysteresis, Coercive Force,
37. 37
Ceramics in Terms of Engineering Properties
• 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
39. 39
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
40. 40
Major Ceramic Technical Landmarks
In the 20th Century
From 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 Century
The Erie Canal
41. 41
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. Make
a copy for yourself and turn the original in
(paper, email (sgonczy@iit.edu), 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.
43. 43
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 Concept
is the FUNDAMENTAL framework for materials engineering and
design.
44. 44
Don’t Forget
The 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!!
45. 45
Where are we headed over the next 3½ Months?
1. Aug 29– Atomic Bonding and Crystal Structure
2. Sep 5– Labor Day – No Class
3. Sep 12 – Crystal Chemistry and Defects
4. Sep 19 – Phase Diagrams
5. Sep 26 – Ceramic Design and the
Structure-Processing-Properties Paradigm
6. Oct 3– Processing and Fabrication #1
7. Oct 10 – Fall Break
8. Oct 17 -- Sintering and Densification
9. Oct 26 – Mid Term Exam
10. Oct 31 -- Ceramic Processing and Fabrication #2
11. Nov 7 – Mechanical Properties – Fast Fracture
12. Nov 14– Mechanical Properties – Durability
13. Nov 21 -- Electronic Properties,
14. Nov 28– Piezoelectric, Dielectric and Magnetic Properties
15. Dec 5- Final Exam
Lesson Structure
1. Basic Principles,
Terms, Theories
Mechanisms
2. Controlling Factors
and Relative Effects
3. Practical
Applications and
Considerations
4. Testing and
Measurement
Methods
46. 46
Next Class
Atomic Bonding and Crystal Structure in Ceramics
and Glasses (Aug 29)
Electronic Configuration of Atoms
Bonding Principles and Types of Bonds in Ceramics
Ionic Bonding
Covalent Bonding
Van der Waals Bonding
Bonding, Crystal Structure, and Stability in Ceramics
Glass/Non-Crystalline Structures
Read Ahead -- Richerson, Chapter 4
