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1. Introduction
2. Characteristics of Ceramics
3. Classification of Ceramics
4. Crystal structure
4.1. Silicates
a) Silica
b) Silica Glasses
4.2. Carbon
a) Diamond
b) Graphite
c) Fullerenes
d) Carbon Nanotubes
4.3. Other important Ceramic materials
5. Ceramics processing methods
5.1. Processing Glasses
5.2. Ceramic Powder Processing
a) Synthesis of powder
b) Green compound preparation
1. Ceramic powder processing using Casting
2. Ceramic powder processing using Extrusion & Injection molding
3. Ceramic powder processing using Compaction
c) Sintering
6. FAQ
1. Introduction
Ceramics are compounds between metallic and nonmetallic elements for
which the inter-atomic bonds are either ionic or predominantly ionic.
The term ceramics comes from the Greek word keramikos which means
‘burnt stuff’.
Characteristic properties of ceramics are, in fact, optimized through thermal
treatments.
They exhibit physical properties those are different from that of metallic
materials. Thus metallic materials, ceramics, and even polymers tend to
complement each other in service
2. Characteristics of Ceramics
High temperature stability
High hardness
Brittleness
High mechanical strength
Low elongation under application of stress – low thermal and electrical
conductivities
3. Classification of Ceramics
Ceramics greatly differ in their basic composition. The properties of ceramic
materials also vary greatly due to differences in bonding, and thus found a wide
range of engineering applications. Below is the classification of ceramics.
Classification type Examples
Oxides
Carbides
Based on their composition Nitrides
Sulfides
Fluorides
Glasses
Clay products
Based on their specific Refractories
applications Abrasives
Cements
Advanced ceramics for special applications
Traditional ceramics(made-up
Bricks, tiles and porcelain articles
of clay, silica and feldspar)
4. Crystal structure
Both crystalline and noncrystalline states are possible for ceramics.
The crystal structures of those materials for which the atomic bonding is
predominantly ionic are determined by the charge magnitude and the radius
of each kind of ion.
4.1 Silicates
Silicates are composed of primarily of silicon and oxygen. These two are most
abundant elements in the earth’s crust.
Silicates structure is more conveniently represented by means of
interconnecting SiO4-4 tetrahedra as shown below.
As in the figure, four oxygen atoms are situated at four corners of the
tetrahedron with silicon at the center.
This is the basic unit of the silicates
Based on the sharing of corners of SiO4-4 tetrahedron with oxygen atom, below
are different types of silicates
a) Silica
It is a three-dimensional network that is generated when every corner oxygen
atom in each tetrahedron is shared by adjacent tetrahedra.
Chemically, the most simple silicate material is silicon dioxide, or silica
(SiO2).
This material is electrically neutral and all atoms have stable electronic
structures.
Under these circumstances the ratio of Si to O atoms is 1:2, as indicated by
the chemical formula.
b) Silica Glasses
If above silica exists as a noncrystalline solid or glass, which is having a high
degree of atomic randomness, such a material is called fused silica or silica
glass.
It is a liquid in characteristic is liquid
such a material is called fused silica, or vitreous silica.
4.2 Carbon
Is carbon really a ceramic?
Carbon materials does not really fall within any one of the traditional metal,
ceramic, polymer classification schemes.
However, we choose to discuss these materials in this chapter since graphite,
one of the polymorphic forms[FAQ], is sometimes classified as a ceramic, and
the crystal structure of diamond also a polymorph
Carbon exists in various polymorphic forms, as well as in the amorphous
state.
Here brief introduction on diamond, graphite, the fullerenes, and carbon nanotubes
are given below
a) Diamond
Diamond is a metastable[FAQ] carbon polymorph at normal conditions.
Structure:
Each carbon bonds to four other carbons, and these bonds are totally covalent.
This is appropriately called the diamond cubic crystal structure, which is also
found for other elements like germanium, silicon, and gray tin those are in
Group IVA of periodic table.
Properties:
Physical: Extremely hard (the hardest known material)
Electrical: Has a very low electrical conductivity
Due to its crystal structure and
The strong inter-atomic covalent bonds.
Thermal: Has a high thermal conductivity for a nonmetallic material,
Optical: Transparent in the visible and infrared regions of the electromagnetic
spectrum
Applications:
Used as gemstones.
diamonds are utilized to grind or cut other softer materials.
Diamond films are having many uses like
Coating on the surfaces of drills, dies, bearings, knives etc. to increase
surface hardness.
Surface of machine components such as gears, to optical recording heads
and disks, and as substrates for semiconductor devices.
Is artificial diamond preparation possible?
Techniques to produce synthetic diamonds have been developed, and today a
large proportion of the industrial- quality materials are man-made, in addition
to some of those of gem quality.
Over the last several years, diamond in the form of thin films has been
produced. But none of the films yet produced has the long-range crystalline
regularity of natural diamond.
b) Graphite
Graphite is also a polymorph of carbon.It has a crystal structure distinctly different
from that of diamond and is also more stable than diamond at normal conditions.
Structure:
The graphite structure is composed of layers of hexagonally arranged carbon
atoms
Within the layers, each carbon atom is bonded to three coplanar neighbor
atoms by strong covalent bonds.
The fourth bonding electron participates in a weak van der Waals type of
bond between the layers.
How Graphite became a lubricant?
Because of this weak vander waals bonds between the layers, it easy to
achieve inter-planar cleavage.
This gives rise to the excellent lubricative properties of graphite.
Also, the electrical conductivity is relatively high in crystallographic
directions parallel to the hexagonal sheets.
Properties:
Physical: High strength and good chemical stability at elevated temperatures
Thermal:
High thermal conductivity
Low coefficient of thermal expansion
High resistance to thermal shock
High adsorption of gases, and good machinability.
Applications:
Graphite is commonly used as heating elements for electric furnaces
As electrodes for arc welding, in metallurgical crucibles, in casting molds for
metal alloys and ceramics.
For electrical contacts, brushes and resistors.
As electrodes in batteries.
In air purification devices.
c) Fullerenes
Another polymorphic form of carbon was discovered in 1985. It exists in discrete
molecular form and consists of a hollow spherical cluster of sixty carbon atoms; a
single molecule is denoted by C60.
Structure:
Each molecule is composed of groups of carbon atoms that are bonded to one
another to form both
Hexagon (six-carbon atom) and
Pentagon (five-carbon atom) geometrical configurations.
These are arrayed in such a way that no two pentagons share a common side.
The molecular surface is like a soccer ball.
Properties:
These are extremely strong and stiff, and relatively ductile.
This is the strongest known material.
Applications:
The carbon nanotube has been termed the “ultimate fiber” and is extremely
promising as a reinforcement in composite materials.
Nanotube displays in future would be cheaper and will have lower power
requirements than CRT and liquid crystal displays.
Furthermore, it is anticipated that future electronic applications of carbon
nanotubes will include diodes and transistors.
4.3 Other important Ceramic materials
Ceramic type Description
When they are mixed with water, they form slurry which sets
subsequently and hardens finally.
Thus it is possible to form virtually any shape.
Cements
They are also used as bonding phase, for example between
construction bricks.
Eg: Cement, plaster of paris and lime.
a) Synthesis of powder
It involves crushing, grinding, separating impurities, blending different
powders.
b) Green component
It can be manufactured in different ways: tape casting, slip casting, extrusion,
injection molding and cold-/hot- compaction.
Green component is then fired/sintered to get final product.
References
1. William D. Callister, Jr.David G. Rethwisch: Materials Science and Engineering: An Introduction,
Wiley publication, 2014
2. NPTEL material science material by Satish Vasu Kailas (IISc)