D AY 22: O VERVIEW OF A DVANTAGES OF C ERAMICS temperature resistance high hardness low density...
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DAY 22: OVERVIEW OF ADVANTAGES OF CERAMICS temperature resistance high hardness low density corrosion resistance
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SPECIAL DESIGN CONSIDERATIONS FOR CERAMICS brittleness difficulty of manufacture.
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Material Melting Temperature, C
NaCl 801
Iron, Fe 1535
Aluminum
Ni based superalloy
1260-1335
W 3300
Al2O3 2045
SiC 2500*
Si3N4 1900*
ZrO2 2700
Melting Temperature
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Material Linear Thermal Exp. Coef. (cm/cm C x 106)
NaCl 40
Nylon 6,6 144
Polycarbonate 122
Fe alloys 12
Al alloys 21-24
Ni based superalloy 12-17
W 4.5
Al2O3 7-8
SiC 4.1-4.6
Si3N4 2.7-3.1
ZrO2 9-10
Thermal Expansion
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Modulus of Elasticity
Material Elastic Modulus(psi x 106)
NaCl 6.4
Nylon 6,6 1.6-3.8
Polycarbonate 1.9-3
Fe alloys 30
Al alloys 10
Ni based superalloy
30.4
W 58
Al2O3 40-55
SiC 30-70
Si3N4 44
ZrO2 20
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Electrical Conductivity
Material Resistivity(ohm-m)
Nylon 6,6 1012
Polycarbonate 1014
Fe alloys 10-7
Al alloys 10-8
Ni based superalloy
10-7
W 10-8
Al2O3 1014
SiC 109
Si3N4 1014
ZrO2 1010
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Thermal Conductivity
Material Thermal Conductivity
W/m-K
Nylon 6,6 0.24
Polycarbonate 0.20
Fe alloys 52
Al alloys 130-220
Ni based superalloy
10-20
W 155
Al2O3 16-40
SiC 70-80
Si3N4 10-30
ZrO2 2-3
Graphite 100-190
Diamond 1500-4700
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http://americas.kyocera.com/kicc/pdf/Kyocera_Material_Characteristics.pdf
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Ductility
Material Fracture Toughness
MPam
Nylon 6,6 2.5-3
Polycarbonate 2.2
Ni based superalloy
60-75
Al alloys 20-60
Fe metal 20-100
ZrO2 7-12
SiC 5-6
Si3N4 4-6
Al2O3 4-6
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Strength
Richerson, 1992
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Richerson, 1992
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COMMON STRUCTURAL CERAMICS
silicon carbide (SiC) silicon nitride (Si3N4) zirconia (ZrO2) alumina (Al2O3)
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Property Ceralloy 147-31E Ceralloy 147-31N Ceralloy 147-1E Ceralloy 147-1
Process Sinter Sinter Hot Press Reaction Bonded
Density (g/cc) 3.25 3.21 3.1 2.4
Density (% Theoretical) >99.3 >99.5 >98.5 75
Flexural Strength (MPa) @ RT
700 800 700 240
Weibull Modulus 10-15 15-30 18 10
Elastic Modulus (GPa) 310 310 310 175
Poisson's Ratio 0.27 0.27 0.27 0.22
Hardness HV(0.3) Kg/mm2
1800 1800 1800 800
Fracture Toughness (MPa m1/2)
6.0 5.8 5.0 2.5
Abrasive Wear Resistance Parameter ***
1130 1110 1120 360
Thermal Exp Coeff. 10-6/C;
3.1 3.1 3.2 3.2
Thermal Cond (W/mK) @ 25 C
26 26 42 14
Thermal Shock Parameter (C)**
530 610 540 330
Elecrical Resistivity (ohm-cm)
10^14 10^14 10^14 10^14
ApplicationsCutting Tools, Wear Components
Automotive Components, Bearings, Wear Components
Semiconductor Components, Wear Components
Electrical Insulators, Sputtering Targets, Semiconductor Components
Key Features Impact Strength, Net Shape Fabrication
Strength, Hertzian Contact Strength, Structural Reliability, Net Shape Fabrication
High Purity, Excellent Mechanical Properties
High Purity, Net Shape Fabrication
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MANUFACTURING CERAMICS
The following methods are used to shape the ceramics. Please not that (wetted) powder is key.
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SINTERING
This is a process in which the small chunks of powder loose their identity, as the whole (porous) part is bonded. Temperature and often pressure are needed. Shrinkage has to be understood.
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DIE PRESSING (UNIAXIAL PRESSING)
Most common and rapid for small ceramic components where speed of manufacture means more than strength and uniformity.
Pressure, and densification is variable through the mold. The object will have varying properties, and maybe differential shrinkage on sintering.
Hot pressing is a combination of sintering and die-pressing happening at once.
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ISOTACTIC PRESSING
Pressure transmitted to the powder from a compressed fluid.
More uniformity, less porosity
An elastomer (rubber mold) serves as the interface.
Slower rate of production.
Best for cylindrical shapes, eg. Spark plug.
Hot isotact pressing (HIP) combines sintering and isotactic
pressing.
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EXTRUSION
We add a plasticizing agent, which is later cooked away during sintering.
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SLIP CASTING
Make a slurry by adding liquid to the powder. Pour into a porous mold. Fluid is absorbed by the mold leaving a drier
layer of powder along the walls. Pour off remaining slurry, slip. Opening the
mold reveals the thin-walled object. Ready to be sintered.
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INJECTION MOLDING
This method holds the most promise for mass production of complex shapes as evidenced by its use in producing ceramic turbocharger rotors. A combination of 60-70% powder mixed with an organic binder to provide flow is injected into a mold. Prior to sintering, burnout of the binder must be done. Current restrictions include small wall thickness. Because of the cost of equipment, this is only cost-effective for large volumes, and for simple shapes, the dry pressing methods are more cost-effective.
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REACTION BONDING
A solid powder and a gas or liquid react during sintering to densify and bond.
In Reaction Bonded Silicon Nitride, silicon powder is fired in the presence of high pressure nitrogen gas, and the reaction forms Si3N4.
Advantage: very low shrinkage. Disadvantage: high porosity and lower
strengths.
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MORE REACTION BONDING
Reaction bonded silicon carbide, RBSC, is made by infiltrating liquid silicon into a compact of carbon and silicon carbide. The Si reacts with the carbon to form SiC which then bonds with the original SiC particles. Pores are filled with liquid Si. Consequently, high temperature strength falls off at silicon's melting temperature. Dimensional changes with RBSC can be less than 1%. One interesting variation is to use carbon fibers rather than carbon particles.
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ENGINE PRODUCTSKyocera engine products include cam rollers, turbocharger rotors, glow plugs, cylinder liners, seals, pistons, piston pins, valve and valve guides, fuel injection parts and various custom made components made from a wide selection of advanced ceramic materials.
Ceramic Piston Head and
Rings
Ceramic Cam Roller
Ceramic Seal Assembly
Ceramic Turbocharger
Rotor
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TEXTILE MANUFACTURING
Kyocera's wide range of ceramic materials, such as alumina, cermet, sapphire, zirconia and silicon nitride, coupled with excellent forming and finishing capabilities provides the basis for expanding the applications of ceramic textile components.
Guides and Finish Tips
http://americas.kyocera.com/kicc/industrial/textiles.html
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SEAL, PUMP AND VALVEKyocera seal, pump and valve products include alumina faucet discs, alumina and silicon carbide automotive water pump seals, alumina appliance seals, alumina blood seals, zirconia containment shells and various custom made components made from a wide range of advanced ceramic materials.
http://americas.kyocera.com/kicc/industrial/seal.html
Shafts and Valves Pump Parts
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http://ceramics.org/ceramictechtoday/tag/capacitor/
http://www.amjorthopedics.com/html/new/0605.asp
Hip implants
Advantages of Ceramics•Low friction•Biocompatibility•Compressive strength
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Hip implants
Disadvantage of Ceramics•Low Ductility
http://emedicine.medscape.com/
article/398669-media
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ARMOR
http://www.coorstek.com/resources/8510-091_Ceramic_Armor.pdf
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ARMOR
http://www.coorstek.com/resources/8510-091_Ceramic_Armor.pdf
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THERMAL SHOCK RESISTANCE
http://americas.kyocera.com/kicc/industrial/seal.html
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ALUMINAAlumina is the most widely used advanced ceramic material. It offers very good performance in terms of wear resistance, corrosion resistance and strength at a reasonable price. Its high dielectric properties are beneficial in electronic products.
Applications include armor, semiconductor processing equipment parts, faucet disc valves, seals, electronic substrates and industrial machine components.
http://americas.kyocera.com/kicc/industrial/types.html
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SILICON CARBIDE
Silicon carbide has the highest corrosion resistance of all the advanced ceramic materials. It also retains its strength at temperatures as high as 1400°C and offers excellent wear resistance and thermal shock resistance.
Applications include armor, mechanical seals, nozzles, silicon wafer polishing plates and pump parts.
http://americas.kyocera.com/kicc/industrial/types.html
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SILICON NITRIDE
Silicon nitride exceeds other ceramic materials in thermal shock resistance. It also offers an excellent combination of low density, high strength, low thermal expansion and good corrosion resistance and fracture toughness.
Applications include various aerospace and automotive engine components, papermaking machine wear surfaces, armor, burner nozzles and molten metal processing parts.
http://americas.kyocera.com/kicc/industrial/types.html
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ZIRCONIAZirconia has the highest strength and toughness at room temperature of all the advanced ceramic materials. The fine grain size allows for extremely smooth surfaces and sharp edges.
Applications include scissors, knifes, slitters, pump shafts, metal-forming tools, fixtures, tweezers, wire drawing rings, bearing sleeves and valves.
http://americas.kyocera.com/kicc/industrial/types.html
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SUMMARY OF MATERIALS Hot-pressed silicon nitride (HPSN) has the strongest specific
strength (strength/density) at 600oC of any material. It has excellent thermal shock resistance.
Sintered silicon nitride (SSN) has high strength and can be formed into complex shapes.
Reaction-bonded silicon nitride (RSBN) can be formed into complex shapes with no firing shrinkage.
Hot-pressed silicon carbide (HPSC) is the strongest of the silicon carbide family and maintains strength to very high temperatures (1500oC).
Sintered silicon carbide (SSC) has high temperature capability and can be formed into complex shapes
Reaction-bonded silicon carbide (RSBC) can be formed into complex shapes and has high thermal conductivity.
Partially stabilized zirconia (PSZ) is a good insulator and has high strength and toughness. It has thermal expansion close to iron, facilitating shrink fit attachments.