CERAMIC MATERIALS I - Mu

CERAMICMATERIALS IAsst. Prof. Dr. Ayşe KALEMTAŞakalemtas@mu.edu.tr, akalemtas@gmail.com, Phone: 211 19 17Metallurgical and Materials Engineering Department

Anticipated Learning OutcomesCan explain classification of ceramic materials, theirsub-groups, application areas and general properties.An understanding on the traditional and advancedceramic shaping methods.An understanding on the traditional and advancedceramic sintering methods.Can comment on the traditional and advanced ceramicraw material production processes.Asst. Prof. Dr. Ayşe KALEMTAŞ

SYLLABUSCourse Content:1. WeekIntroduction to ceramic materials. Classification of ceramics and generalproperties.2. WeekTraditional ceramics. Classification and applications of traditional ceramics.3. WeekNatural ceramic raw materials and their properties. Characterization of ceramicpowders.4. WeekNatural ceramic raw materials and their properties.5. WeekAdvanced ceramics. Classification and applications of advanced ceramics.6. Week1. Midterm Exam7. WeekAdvanced ceramic powder synthesis. Characterization of ceramic powders.8. WeekAdvanced ceramic powder synthesis.9. WeekRheology. Stability of ceramic suspensions.10. WeekRheology. Ceramic shaping techniques.11. WeekCeramic shaping techniques.12. Week2. Midterm Exam.13. WeekSintering of ceramic materials.14. WeekSintering of ceramic materials. Finishing of ceramic materials.Asst. Prof. Dr. Ayşe KALEMTAŞ

Reading List1)Reed, J. S., ”Principles of Ceramic Processing” John Wiley&Sons, New York(1995).2)Ring, T. A., "Fundamentals of Ceramic Powder Processing and Synthesis",Academic Press, San Diego (1996).3)Hunter, R., “Introduction to Modern Colloid Science”, Oxford University Press(1993).4)Rahaman, M. N., "Ceramic Processing and Sintering", Marcel Dekker Inc.(1995).5)Hiemenz, P. C. and Rajagopalan, R., "Principles of Colloid and SurfaceChemistry", Marcel Dekker Inc. (1997).6)W.D. Kingery, H.K. Bowen, and D.R. Uhlmann, “Introduction To Ceramics”, JohnWiley and Sons, 1976.7)D. W. Richerson, "Modern Ceramic Engineering," Second Edition, Marcel DekkerInc., (1992).Asst. Prof. Dr. Ayşe KALEMTAŞ

GRADING1 Mid Term Exam: 20 %Lab. Report: 30 %FINAL EXAM : 50 %Asst. Prof. Dr. Ayşe KALEMTAŞ

CLASSIFICATION OF Ceramic ementsAdvancedCeramicsAsst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective Stone Age: 2.5 million years ago Pottery Age: 4000 B.C.E Copper Age: 4000 B.C.E – 3000 B.C.E. Bronze Age: 2000 B.C.E – 1000 B.C.E. Foundation of metallurgy- Alloys of copperand tin Iron Age: 1000 B.C.E – 1B.C.E. Plastics Age: late 20th Century to current time Semiconductor Age: late 20th Century to currenttimeAsst. Prof. Dr. Ayşe KALEMTAŞ

What is "ceramic"? from Greek meaning: "burnt earth" non-metal, inorganic Ceramic materials are inorganic compounds consisting ofmetallic and nonmetallic elements which are held togetherwith ionic and/or covalent bonds.Asst. Prof. Dr. Ayşe KALEMTAŞ

What is "ceramic"? Ceramics are inorganic, nonmetallic, solids, crystalline,amorphous (e.g. glass), hard, brittle, stableto high temperatures, less dense thanmetals, more elastic than metals, and veryhigh melting.Ceramics can be covalent network and/or ionicbonded.Asst. Prof. Dr. Ayşe KALEMTAŞ

What is "ceramic"? Bonding: Mostly ionic, some covalent. % ionic character increases with difference electronegativity.CaF2SiCAsst. Prof. Dr. Ayşe KALEMTAŞ

What is "ceramic"?Ceramic materials brittle fracture !!!Asst. Prof. Dr. Ayşe KALEMTAŞ

Medium to highmelting pointMedium to highelastic modulusLow densityHigh meltingpointVery high elasticmodulusPOLYMERSHigh densityCERAMICSMETALSIntroduction to Ceramic MaterialsVery low densityLow meltingpointLow elasticmodulusReactiveUnreactiveVery reactiveDuctileBrittleDuctile andbrittle typesExamples of ceramic materials ranging from household to highperformance combustion engines which utilize both metals and ceramics.Asst. Prof. Dr. Ayşe KALEMTAŞ

Introduction to Ceramic MaterialsAsst. Prof. Dr. Ayşe KALEMTAŞ

Introduction to Ceramic MaterialsA comparison of the properties of ceramics, metals, and polymersAsst. Prof. Dr. Ayşe KALEMTAŞ

Ceramic MaterialsCeramic materials have now become thecornerstone of such advanced technologiesas energy transformation, storage andsupply, information technology,transportation systems, medical technology,and manufacturing technologyAsst. Prof. Dr. Ayşe KALEMTAŞ

Future of Materials ScienceDesign of materials having specific desired characteristics directly from ourknowledge of atomic structure. Miniaturization: “Nanostructured" materials, with microstructure that has lengthscales between 1 and 100 nanometers with unusual properties. Electroniccomponents, materials for quantum computing. Smart materials: airplane wings that deice themselves, buildings that stabilizethemselves in earthquakes Environment-friendly materials: biodegradable or photodegradable plastics,advances in nuclear waste processing, etc. Learning from Nature: shells and biological hard tissue can be as strong as themost advanced laboratory-produced ceramics, mollusces produce biocompatibleadhesives that we do not know how to reproduce Materials for lightweight batteries with high storage densities, for turbine blades thatcan operate at 2500 C, room-temperature superconductors? chemical sensors(artificial nose) of extremely high sensitivity, cotton shirts that never require ironing Asst. Prof. Dr. Ayşe KALEMTAŞ

Application Base ClassificationCeramic MaterialsAdvanced CeramicsTraditional CeramicsStructural CeramicsFunctional CeramicsWhitewaresBioceramicsElectronic substrate,package ceramicsCementCeramics used inautomotive industryCapasitor dielectric,piezoelectric ceramicsAbrasivesNuclear ceramicsMagnetic ceramicsRefractoriesWear resistant ceramics(tribological)Optical ceramicsBrick and tileConductive ceramicsStructural clay productsAsst. Prof. Dr. Ayşe KALEMTAŞ

Traditional Ceramics: ApplicationsEarthenware, Stoneware, China, Porcelain, are all distinguishedby their firing temperature and glass forming temperatureTiles are made from similar composition materialStructural bricks are made from cheaper mixtures -often a singleclay (“Fletton Brick”)Refractory bricks have special compositions to withstand hightemperatures or corrosive environmentsAsst. Prof. Dr. Ayşe KALEMTAŞ

Traditional Ceramic ProductsAsst. Prof. Dr. Ayşe KALEMTAŞ

Traditional Ceramic ProductsAsst. Prof. Dr. Ayşe KALEMTAŞ

Traditional Ceramic ProductsClaypipesaresustainableproducts and last longer thanother materialsAsst. Prof. Dr. Ayşe KALEMTAŞ

Traditional Ceramic ProductsInsulating brickRefractory BrickAsst. Prof. Dr. Ayşe KALEMTAŞ

Well Known Glass Productshttp://www.wolfard.comClassic Wolfard Oil LampHeat resistant glassware(microwave safe)Heat resistant glasslidTempered GlassCutting BoardAsst. Prof. Dr. Ayşe KALEMTAŞ

Well Known Glass ProductsTempered glass ass sink cabinets in the bathroom Laminated Windscreen GlassHeat resistantglass doorAsst. Prof. Dr. Ayşe KALEMTAŞ

Well Known Glass Productswww.whitersstreetglass.com.auGlass splashbackswww.toxel.comGlass Bathtubhttp://freshome.comSuperdurable tempered l-to-wall glass windowshttp://www.wickedreport.comHirom Glass Violin is a product of HarioGlass Co. Ltd., Japan. And also, Theworld’s first hand made glass violin.Asst. Prof. Dr. Ayşe KALEMTAŞ

Special Glass ProductsLaminated GlassLaminated glass iswidely used forbullet ong corridorsidelite, etc.http://www.livingetc.comGlass staircasewww.aarticommercial.comLaminated Windscreen GlassIf the laminated glass is made from “ordinary” float glass, it is stillworkable (cutting and drilling is possible) and the PVB helps thefractured glass to stay put inside the construction.Asst. Prof. Dr. Ayşe KALEMTAŞ

Special Glass ProductsLaminated GlassBULLETPROOF GLASSBulletproof glass is made of laminated glassesand films which have special shieldingcapability towards bullets.The different levels of bullet proof glasses areable to shield the bullets from penetrationand prevent the broken parts from injuringpeople. They are widely applied inbank,counters of jewelry and gold shops,cash trucks andother hapolycarbonate coating on the inside to prevent flyingsplinters. The 22-millimetre glass protects against: Blunt instruments .44 Magnum with full-jacket flat-nose bullets .357 Magnum with coned bullets 9-millimetre Luger with round-nose bulletssafetyAsst. Prof. Dr. Ayşe KALEMTAŞ

CEMENT AND CONCRETE tionsGravelMillMixerCementAdmixturesWaterAsst. Prof. Dr. Ayşe KALEMTAŞ

Advanced CeramicsAsst. Prof. Dr. Ayşe KALEMTAŞ

Design ObjectivesPerformanceLife . Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsApplicationPropertyMaterialCutting toolsHardness, toughnessAlumina, SiAlONBearing, liners, sealsWear resistanceAlumina, zirconiaAgricultural machineryWear resistanceAlumina, zirconiaEngine and turbinepartsHeat, wear resistanceSiC, Alumina, Si3N4Shielding, armourHardness, toughnessAlumina, B4CHig performancewindowsTranslucence, strenghtAlumina, MagnesiaArtificial bones, teethWear resistance, strenghtZirconia, AluminaAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsAsst. Prof. Dr. Ayşe KALEMTAŞ

Advanced Ceramic Application TreeLimitations due to- High cost- Low toughness- Low reliabilityM. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of MaterialsProcessing Technology 175 (2006) 364–375Asst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsCeramic filterCeramic KnifeFoam ceramic molten metal filterCeramic Fiber Boards As The Heat InsulationAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsCeramic fittingsCeramic Fiber ProductsCeramics are used in various textilemachines as guide parts, threadprocessing nozzles, oiling nozzles,rollers and twister parts.Cutting and wear-resistant partsCeramic faucet valves with a Ceramic Pipe LiningAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced pAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsBall HeadsKneeJointComponents.Improved quality of life,reduce wear and minimize therisk of allergies.Cup Inserts. For insertinginto the acetabular cupCeramic seal rings, axial bearings and radial bearings ensure highly reliable operation and long service lifewherever fluids are pumped or gas is compressed.Hightemperaturewearresistance industrial zirconiaadvanced ceramic insulatorproductsAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsSheer VeneersZrO2-metal freerestorationsBiocompatible ceramic parts fordrug-delivery systems.With its extensive material range and continuously growing productionexpertise in the field of ceramic components for textile processing,Asst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsBearing Rollers made from Silicon NitrideCeramic gas nozzles made of silicon nitrideIn engine design or exhaust systems, in liquid or gascircuits – automotive industry demands on sealrings, bearings and sealing technology are especiallyhigh. Technical ceramics ensure wear resistance,temperature resistance and stability in theseaggressive environments.Ceramic rollersAsst. Prof. Dr. Ayşe KALEMTAŞ

Applications of Advanced CeramicsInserts from CeramTec's latest generation ofceramic cutting materials. Designed specificallyfor high-perfor mance machining of cast ironmaterials.CBN indexable inserts (polycrystalline cubic boron nitride) forefficient machining of cast iron materials and sintered steels forturning, milling, boring and grooving.The proven performance standard forefficient machining with indexable insertsmade of ceramic cutting materials.Whether filtration, galvanization, water heating or soil analysis; fields ofapplication such as the chemicals industry, laboratories, electronics andelectrical engineering, environmental technology or foundry technologyAsst. Prof. Dr. Ayşe KALEMTAŞ

Ceramics in AerospaceAsst. Prof. Dr. Ayşe KALEMTAŞ

CERAMIC icalprocessingGreen bodyFinal ProductPowderPowderprocessingAsst. Prof. Dr. Ayşe KALEMTAŞ