CERAMIC & THEIR PROPERTIES BMFB 3323

18-22/03/2013

OUTLINE

What are ceramics? Classification of ceramics Thermal Properties of ceramics Optical Properties Mechanical Properties Electrical Properties

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SPECTRUM OF CERAMICS USES

http://www.ts.mah.se/utbild/mt7150/051212%20ceramics.pdf

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WHAT ARE CERAMICS?

comes from the Greece word keramicos, which means burnt stuff 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.

A ceramic is an inorganic, nonmetallic solid prepared by the action of heat and subsequent cooling. Ceramic materials may have a crystalline or partly crystalline structure, or may be amorphous (e.g., a glass) .

WHAT ARE CERAMICS?

http://www.ts.mah.se/utbild/mt7150/051212%20ceramics.pdf

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Periodic table with ceramics compounds indicated by a combination of one or more metallic elements (in light color) with one or more nonmetallic elements (in dark color).

WHAT ARE CERAMICS?

To be most frequently silicates, oxides, nitrides and carbides Typically insulative to the passage of electricity and heat More resistant to high temperatures and harsh environments than metals and polymers Hard but very brittle
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TAXONOMY OF CERAMICS

Glasses

Cements

Refractories

Clay products

Abrasives

Advanced ceramics

Fireclay Silicate Glass glass ceramics Silica

Special Basic

Oxides carbides Whitewares

Structural clay products

CERAMICS
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TRADITIONAL CERAMIC Based primarily on natural raw materials; clay and silica Tendency to equate with low technology Has been used for over 25, 000 years

TECHNICAL/ ADVANCED CERAMIC special, technical, engineering Exhibit superior/ specialized properties (mechanical properties, corrosion resistance, or electrical, optical, and/or magnetic properties) Require more sophisticated processing are mainly pure compounds or nearly pure compounds of primarily oxides, carbides, or nitrides Have generally been developed within last 100 years

Chemically prepared powders -Precipitation -Spray dry -Freeze dry -Vapor phase -Sol-gel -Slip casting -Injection molding -Sol-gel -Hot pressing -HIPing -Rapid prototyping

Raw materials preparation

-Raw minerals -Clay -Silica

Forming
-Potters wheel -Slip casting

-Electric furnace -Hot press -Reaction sinter -Vapor deposition -Plasma spraying -Microwave furnace
-Erosion -Laser machining -Plasma spraying -Ion implantation Coating

High-temperature processing
Flame kiln

Finishing process
-Erosion -Glazing

Characterization
-Light microscopy -X-ray diffraction -Electron microscopy -Scanned probe microscopy -Neutron diffraction -Surface analytical methods -Visible examination -Light microscope

PROPERTIES OF CERAMICS

Extreme hardness High wear resistance Extreme hardness can reduce wear caused by friction Corrosion resistance Heat resistance Low electrical conductivity Low thermal conductivity Low thermal expansion Poor thermal shock resistance
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PROPERTIES OF CERAMICS

Low ductility Very brittle High elastic modulus Low toughness Low fracture toughness Indicates the ability of a crack or flaw to produce a catastrophic failure Low density Porosity affects properties High strength at elevated temperatures
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CLASSIFICATION OF CERAMICS

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CLASSIFICATION OF CERAMICS

Traditional Ceramics
The older and more generally known types (porcelain, brick, earthenware, etc.)

Based

primarily

on

natural

raw

materials of clay and silicates

Applications: building materials (brick, clay pipe, glass) household goods (pottery, cooking ware) manufacturing (abbrasives, electrical Traditional Ceramics

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fibers)

CLASSIFICATIONS OF CERAMICS

Advanced Ceramics
have been developed over the past
half century

Include artificial raw materials, exhibit specialized properties, require more

sophisticated processing

Applied as thermal barrier coatings to protect metal structures, wearing surfaces,

Engine applications (silicon nitride

(Si3N4), silicon carbide (SiC), Zirconia (ZrO2), Alumina (Al2O3))

bioceramic implants

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CLASSIFICATION OF CERAMICS
Oxides
CERAMICS Nonoxides Composite

Oxides: Alumina, zirconia Non-oxides: Carbides, borides, nitrides, silicides Composites: Particulate reinforced, combinations of oxides and non-oxides

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CLASSIFICATION OF CERAMICS

Oxide Ceramics:
Oxidation resistant
chemically inert electrically insulating

generally low thermal conductivity

slightly complex manufacturing low cost for alumina

more complex manufacturing

higher cost for zirconia. zirconia

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CLASSIFICATION OF CERAMICS

Non-Oxide Ceramics:
Low oxidation resistance
extreme hardness chemically inert

high thermal conductivity

electrically conducting difficult energy dependent

manufacturing and high cost.

Silicon carbide cermic foam filter (CFS)
http://images.google.com.tr/imgres?imgurl=http://www.made-inchina.com/image/2f0j00avNtpdFnLThyM/Silicon-Carbide-Ceramic-FoamFilter-CFS-.jpg&imgrefurl

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CLASSIFICATION OF CERAMICS

Ceramic-Based Composites:
Toughness low and high oxidation resistance (type related)

variable thermal and electrical conductivity

complex manufacturing processes

high cost.

Ceramic Matrix Composite (CMC) rotor

http://images.google.com.tr/imgres?imgurl=http://www.oppracing.com/images/ cmsuploads/Large_Images/braketech%2520cmc%2520rotor%2520oppracing %2520cbr1000rr.jpg&imgrefurl

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CLASSIFICATION OF CERAMICS

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CLASSIFICATIONS OF CERAMICS
amorphous

CERAMICS
crystalline

Amorphous
the atoms exhibit only shortrange order

no distinct melting temperature (Tm) for these materials as there is with the crystalline materials Amorphous silicon and thin film PV cells

Na20, Ca0, K2O, etc

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http://images.google.com.tr/imgres?imgurl=http://simeonintl.com/sitebuilder/images/A-Si_Solar510x221.jpg&imgrefurl=http://simeonintl.com/Solar.html&usg=__ktCHUAO742PE0hh3U1fGw8go PrM=&h=221&w=510&sz=17&hl=tr&start=68&sig2=9OC7pTtJz2SuK_AKdrqTAA&um=1&tbnid=x QRh5yfCftf89M:&tbnh=57&tbnw=131&prev=/images%3Fq%3Damorphous%2Bceramic%26ndsp %3D18%26hl%3Dtr%26rlz%3D1G1GGLQ_TRTR320%26sa%3DN%26start%3D54%26um%3D 1&ei=9Kv1SrTfAoej_gbrz6WtAw

CLASSIFICATIONS OF CERAMICS Crystalline

atoms (or ions) are arranged in a regularly repeating pattern in three dimensions (i.e., they have longrange order)

Crystalline ceramics are the Engineering ceramics High melting points Strong Hard Brittle

a ceramic (crystalline) and a glass (non-crystalline

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Good corrosion resistance

THERMAL PROPERTIES

Most important thermal properties of ceramic materials:

Heat capacity : amount of heat required to raise material

temperature by one unit (ceramics > metals)

Thermal expansion coefficient: the ratio that a material expands in accordance with changes in temperature

Thermal conductivity : the property of a material that indicates its ability to conduct heat

Thermal shock resistance: the name given to cracking as a result of rapid temperature change
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THERMAL PROPERTIES

Thermal expansion
Comparison of thermal expansion coefficient between metals and fine ceramics

The

coefficients

of

thermal

expansion depend on the bond strength between the atoms that make up the materials.

Strong

bonding

(diamond,

silicon carbide, silicon nitrite) low thermal expansion

coefficient

Weak bonding ( stainless steel) higher thermal expansion

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coefficient in comparison with

fine ceramics

THERMAL PROPERTIES

Thermal conductivity
generally less than that of metals such as steel or copper ceramic materials, in contrast, are used for thermal insulation due to their low thermal conductivity (except silicon carbide, aluminium nitride)

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http://global.kyocera.com/fcworld/charact/heat/images/thermalcond_zu.gif

THERMAL PROPERTIES

Thermal shock resistance

A large number of ceramic materials are sensitive to thermal shock
Some ceramic materials very high resistance to thermal shock is despite of low ductility (e.g. fused silica, Aluminium titanate )

Result of rapid cooling tensile stress (thermal stress)cracks and

consequent failure

The thermal stresses responsible for the response to temperature stress

depend on:
-geometrical boundary conditions -thermal boundary conditions
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-physical parameters (modulus of elasticity, strength)

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OPTICAL PROPERTIES OF CERAMICS

REFRACTION
Light that is transmitted from one medium into another, undergoes refraction.

Refractive index, (n) of a material is the ratio of the speed of light in a vacuum (c = 3 x 108 m/s) to the speed of light in that material. n = c/v
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http://matse1.mse.uiuc.edu/ceramics/prin.html

OPTICAL PROPERTIES OF CERAMICS

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http://matse1.mse.uiuc.edu/ceramics/prin.html

OPTICAL PROPERTIES OF CERAMICS

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Callister, W., D., (2007), Materials Science And Engineering, 7 th Edition,

OPTICAL PROPERTIES OF CERAMICS

ABSORPTION
Color in ceramics Most dielectric ceramics and glasses are colorless. By adding transition metals (TM) Ti, V, Cr, Mn, Fe, Co, Ni

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Carter, C., B., Norton, M., G., Ceramic Materials Science And Engineering,

MECHANICAL PROPERTIES OF CERAMICS

STRESS-STRAIN BEHAVIUR of selected materials

Al2O3

thermoplast ic

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http://www.keramvaerband.de/brevier_engl/5/5_2.htm

MECHANICAL PROPERTIES OF CERAMICS

Flexural Strength
The stress at fracture using this flexure test is known as the flexural strength. Flexure test :which a rod specimen having either a circular or rectangular cross section is bent until fracture using a three- or four-point loading technique

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Callister, W., D., (2007), Materials Science And Engineering, 7th Edition,

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MECHANICAL PROPERTIES OF CERAMICS

Stress is computed from, specimen thickness the bending moment the moment of inertia of the cross section For a rectangular cross section, the flexural strength

fs

is equal to,

L is the distance between support points When the cross section is circular,

R is the specimen radius

32 24.03.2013
Callister, W., D., (2007), Materials Science And Engineering, 7th Edition,

MECHANICAL PROPERTIES OF CERAMICS

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Callister, W., D., (2007), Materials Science And Engineering, 7th Edition,

MECHANICAL PROPERTIES OF CERAMICS

Hardness
Hardness implies a high resistance to deformation and is associated with a large modulus of elasticity. In metals, ceramics and most polymers, the deformation considered is plastic deformation of the surface. For elastomers and some polymers, hardness is defined at the resistance to elastic deformation of the surface.

Technical ceramic components are therefore characterised by their stiffness and dimensional stability. Hardness is affected from porosity in the surface, the grain size of the microstructure and the effects of grain boundary phases.

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http://www.dynacer.com/hardness.htm http://www.keramvaerband.de/brevier_eng/5/3/%_3_5.htm http://www.ndt-ed.org/EducationResources/CommunityCollege/Materials/Mechanical/Hardness.htm

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MECHANICAL PROPERTIES OF CERAMICS

Test procedures for determining the hardness according to Vickers, Knoop and Rockwell. Some typical hardness values for ceramic materials are provided below:
Material Class Glasses Zirconias, Aluminium Nitrides Vickers Hardness (HV) GPa 5 10 10 - 14

Aluminas, Silicon Nitrides

Silicon Carbides, Boron Carbides Cubic Boron Nitride CBN Diamond

15 - 20
20 - 30 40 - 50 60 70 >

The high hardness of technical ceramics results in favourable wear resistance. Ceramics are thus good for tribological applications.
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http://www.dynacer.com/hardness.htm

MECHANICAL PROPERTIES OF CERAMICS

Elastic modulus
The elastic modulus E [GPa] of almost all oxide and non-oxide ceramics is consistently higher than that of steel. This results in an elastic deformation of only about 50 to 70 % of what is found in steel components. The high stiffness implies, however, that forces experienced by bonded ceramic/metal constructions must primarily be taken up by the ceramic material.

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http://www.keramverband.de/brevier_engl/5/3/4/5_3_4.htm

MECHANICAL PROPERTIES OF CERAMICS

Density
The density, (g/cm) of technical ceramics lies between 20 and 70% of the density of steel.

The relative density, d [%], has a significant effect on the properties of the ceramic.

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http://www.keramverband.de/brevier_engl/5/3/4/5_3.htm

MECHANICAL PROPERTIES OF CERAMICS

A comparison of typical mechanical characteristics of some ceramics with grey cast-iron and construction steel

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http://www.keramverband.de/brevier_engl/5/5_2.htm

MECHANICAL PROPERTIES OF CERAMICS

Toughness
Ability of material to resist fracture affected from, temperature strain rate relationship between the strenght and ductility of the material and presence of stress concentration (notch) on the specimen surface

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http://www.subtech.com/dokuwiki/doku.php?id=fracture_toughness

MECHANICAL PROPERTIES OF CERAMICS

Material KIc (MPa-m1 / 2)

Metals
Aluminum alloy (7075) 24 Steel alloy (4340) Titanium alloy Aluminum Ceramics Aluminum oxide Silicon carbide Soda-lime-glass Concrete Polymers Polystyrene Composites 50 44-66 14-28 3-5 3-5 0.7-0.8 0.2-1.4 0.7-1.1

Some typical values of fracture toughness for various materials

Mullite fiber reinforced1.8-3.3 mullite composite

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http://en.wikipedia.org/wiki/Fracture_toughness

ELECTRICAL PROPERTIES OF CERAMIC

Electrical conductivity of ceramics varies with

The

Frequency of field applied effect

charge transport mechanisms are frequency dependent.

The

temperature effect

The activation energy needed for charge migration is achieved through thermal energy and immobile charge career becomes mobile.

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ELECTRICAL PROPERTIES OF CERAMIC

Most of ceramic materials are dielectric. (materials, having very low electric conductivity, but supporting electrostatic field). Dielectric ceramics are used for manufacturing capacitors, insulators and resistors.

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SUPERCONDUCTING PROPERTIES

Despite of very low electrical conductivity of most of the ceramic

materials, there are ceramics, possessing superconductivity properties

(near-to-zero electric resistivity).

Lanthanum (yttrium)-barium-copper oxide ceramic may be

superconducting at temperature as high as 138 K. This critical

temperature is much higher, than superconductivity critical temperature of other superconductors (up to 30 K).

The critical temperature is also higher than boiling point of liquid Nitrogen (77.4 K), which is very important for practical application of superconducting ceramics, since liquid nitrogen is relatively low cost

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material.

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Types of ceramics

Applications: Automotive
Spark plugs, water pump seals, catalytic converter. Heat engine: Higher operating temperatures Better fuel efficiency Lower frictional forces & ability to operate with no cooling system Excellent wear & corrosion resistance Lower densities Decreased engine weight

Disadvantages: Brittle Too easy to have voids weaken the engine Difficult to machine
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Applications: Aerospace

Coating of metal heat engine parts improved wear &/or high temperature damage. Their low densities lighter turbine blades VS superalloys Materials considered: Si3N4, SiC and ZrO2 Draw back: disposition to brittle & catastrophic

Helicopter gas turbine

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Applications: Aerospace
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Engines ; Shielding a hot running airplane engine from damaging other components. Airframes; Used as a high-stress, high-temp and lightweight bearing and structural component. Missile nose-cones; Shielding the missile internals from heat. Space Shuttle tiles Space-debris ballistic shields -- Ceramic fiber woven shields offer better protection to hypervelocity (~7 km/s) particles than aluminum shields of equal weight. Rocket Nozzles; Withstands and focuses the exhaust of the rocket booster.

Applications: Electronics
Packaging of integrated circuits --(substrate):

Chosen to securely hold microelectronics & provide heat transfer

electrically insulating.
low dielectric characteristics. thermally conductive.

Aluminum oxide:

standard bearer. low thermal conductivity & poor electrical conductivity.

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Aluminum nitride

Materials currently used include:

Boron nitride (BN) Silicon Carbide (SiC) Aluminum nitride (AlN) thermal conductivity 10x that for Alumina good expansion match with Si

good thermal & electrical properties. bonding with metals: poor.

payoff for metal pattern to stick: Mo paste + additive @ 1600C or special direct Cu bonding.

Applications: Biomaterial
Alumina in orthopedic implants

Excellent corrosion resistance Wear resistance High strength Biocompatibility Various component for total hip prostheses including the stem with an alumina femoral head, and alumina AC cup, and a metal base for the AC cup

a) Extensive arthritis damage, b) same hip after total hip replacement

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Bone joint

Alumina in dental implants

High-strength Al2O3 joint prostheses of complex shape for femur joint component.

Artificial root which supports tooth replacement and crown (porcelain).

Ceramic Biomaterials (Alumina, Hydroxyapatite, Zirconia etc) Biocompatibility Bond well to bone (implant-tissue attachment) Corrosion resistance High stiffness Wear resistance
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Summary of applications: i ) Electronics IC packaging and substrates : Al2O3 (insulation) , AlN, BeO, SiC Capacitor: BaTiO3, SrTiO3 Thermistor-Spinel (NiMn)3O4, NiMnCo)3O4, KTaNbO3 Varistor - ZnO2 Piezoelecctric PZT(lead zirconate titanate). PLZT (lead lanthanum zirconate titanate), LiNbO3, LiTaO3 Ferroelectric BaTiO3, Pb(TiZr)O3, K(TaNb)O3, LiTaO3 Ferrite SrFe12O19, Y3Fe5O12 Sensors oxygen sensors (Y-doped ZrO2), humidity sensors (Tidoped MgCr2O4) Hydrocarbon gas sensor (doped SnO2) Superconductores Ba2YCu3O7-x

Example: ceramic soleplate for irons

System Development with Si3N4 Ceramics
A soleplate of a highquality iron has to meet specific requirements: easy glide high mechanical strength and hardness good thermal conductivity non-stick properties Silicon nitride ceramics fulfill these requirements much better than currently used materials like aluminum or stainless steel.

Heating element is directly applied on the ceramic soleplate by screen printing and subsequently is co-fired with the soleplate to achieve a strong bonding.