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E-raamat: Modern Ceramic Engineering: Properties, Processing, and Use in Design, Fourth Edition

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David W. Richerson (Retired, University of Utah.), William E. Lee

Formaat: 836 pages
Ilmumisaeg: 27-Apr-2018
Kirjastus: CRC Press Inc
Keel: eng
ISBN-13: 9781498716932

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Formaat: 836 pages
Ilmumisaeg: 27-Apr-2018
Kirjastus: CRC Press Inc
Keel: eng
ISBN-13: 9781498716932

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Since the publication of its Third Edition, there have been many notable advances in ceramic engineering. Modern Ceramic Engineering, Fourth Edition serves as an authoritative text and reference for both professionals and students seeking to understand key concepts of ceramics engineering by introducing the interrelationships among the structure, properties, processing, design concepts, and applications of advanced ceramics. Written in the same clear manner that made the previous editions so accessible, this latest edition has been expanded to include new information in almost every chapter, as well as two new chapters that present a variety of relevant case studies. The new edition now includes updated content on nanotechnology, the use of ceramics in integrated circuits, flash drives, and digital cameras, and the role of miniaturization that has made our modern digital devices possible, as well as information on electrochemical ceramics, updated discussions on LEDs, lasers and optical applications, and the role of ceramics in energy and pollution control technologies. It also highlights the increasing importance of modeling and simulation.

Preface

xxi

Authors

xxiii

Part I: Ceramics as Engineering Materials

Chapter 1 What Is a Ceramic?

(6)

1.1 Definitions of Ceramics

(1)

1.2 Material Types Generally Considered in the Ceramics Family

(2)

1.2.1 Polycrystalline Ceramics Fabricated by Sintering

(1)

1.2.2 Glass

(1)

1.2.3 Glass Ceramics

(1)

1.2.4 Single Crystals of Ceramic Compositions

(1)

1.2.5 Chemical Synthesis or Bonding

(1)

1.2.6 Natural Ceramics

(1)

1.3 So What Is a Ceramic?

(1)

Special Optional Assignment

(1)

References

(1)

Study Guide

(2)

Chapter 2 History of Ceramics

(16)

2.1 Ceramics in the Stone Age

(4)

2.1.1 Use of Natural Ceramics

(2)

2.1.2 Synthetic Stone: Clay Transformed by Fire

(1)

2.1.3 First Practical Use of Earthenware

(1)

2.1.4 Other Neolithic Ceramic Innovations

(1)

2.2 Rise of Traditional Ceramic Industries

(8)

2.2.1 Ceramic Innovations during the Chalcolithic Period

(2)

2.2.2 Ceramics and the Metal Ages

(1)

2.2.3 Emergence of Glass

(1)

2.2.4 Ceramics in Building

(4)

2.2.5 Ceramic Whitewares

(1)

2.3 From Traditional to Modern Ceramics

(2)

2.4 Summary

(1)

References

(1)

Additional Recommended Reading on Technical Aspects of Traditional Ceramics

(1)

Study Guide

(2)

Chapter 3 Applications: Engineering with Ceramics

(72)

3.1 High-Temperature Applications

(14)

3.1.1 Ceramics in Metal Processing

(4)

3.1.2 Glass Production

(1)

3.1.3 Industrial Processes

(5)

3.1.3.1 Furnace and Reaction Vessel Linings

(1)

3.1.3.2 Heat Sources

(1)

3.1.3.3 Heat Exchangers

(3)

3.1.3.4 Heat Exchange for Chemical Processing

(1)

3.1.4 Heat Engines

(5)

3.1.4.1 Gas Turbine Engines

(3)

3.1.4.2 Internal Combustion Engines

(1)

3.1.4.3 Aerospace

(1)

3.2 Wear and Corrosion Resistance Applications

(10)

3.2.1 Seals

(4)

3.2.2 Valves

(3)

3.2.3 Pumps

(1)

3.2.4 Bearings

(2)

3.2.5 Thread Guides

(1)

3.2.6 Ceramics in Papermaking

(1)

3.3 Cutting and Grinding

(5)

3.3.1 Ceramic Cutting Tool Inserts

(3)

3.3.2 Superhard Abrasives

(1)

3.3.3 Waterjet Cutting

(1)

3.4 Electrical Applications of Ceramics

(10)

3.4.1 Ceramic Electrical Insulators

(3)

3.4.2 Dielectric Ceramics

(1)

3.4.3 Semiconductors

(2)

3.4.4 Electrical Conductors

(3)

3.4.5 Ceramic Superconductors

(1)

3.5 Magnetic Ceramics

(1)

3.6 Optical Applications of Ceramics

(6)

3.6.1 Applications Based on Transparency

(3)

3.6.1.1 Window Glass

(2)

3.6.1.2 Container Glass

(1)

3.6.1.3 Optical Glass Fibers

(1)

3.6.1.4 Lenses

(1)

3.6.2 Applications Based on Phosphorescence and Fluorescence

(3)

3.6.2.1 Fluorescent Light

(1)

3.6.2.2 Television and Oscilloscopes

(1)

3.6.2.3 Electroluminescent Lamps

(1)

3.6.2.4 Lasers

(1)

3.7 Composites

(1)

3.8 Medical Applications of Ceramics

(9)

3.8.1 Replacement and Repair

(4)

3.8.1.1 Dental Ceramics

(2)

3.8.1.2 Hip Implants

(1)

3.8.1.3 Spine Repair

(1)

3.8.1.4 Middle-Ear Implants

(1)

3.8.1.5 Eye Repairs

(1)

3.8.1.6 Heart Valve Implants

(1)

3.8.1.7 Prosthetic Devices

(1)

3.8.2 Ceramics for Medical Diagnosis

(3)

3.8.2.1 CT Scanner

(1)

3.8.2.2 Endoscopy

(1)

3.8.2.3 Ultrasound Imaging

(1)

3.8.3 Ceramics in Medical Treatment and Therapy

(2)

3.9 Energy Efficiency and Pollution Control

(6)

3.9.1 Energy Savings in the Home

(3)

3.9.1.1 Fiberglass Insulation

(1)

3.9.1.2 Efficient Light Sources

(2)

3.9.1.3 Gas Appliances

(1)

3.9.2 Ceramics for Power Generation

(1)

3.9.3 Ceramics in the Transportation Sector

(2)

3.9.4 Other Uses of Ceramics for Energy Efficiency and Pollution Control

(1)

3.10 Military

(1)

3.11 Recreation

(1)

3.12 Ceramics Modeling and Simulation

(3)

3.13 Summary

(1)

References

(1)

Study Guide

(4)

Part II: Structures and Properties

Chapter 4 Atomic Bonding and Crystal Structure

(26)

4.1 Electronic Configuration of Atoms

(3)

4.2 Bonding

100

(11)

4.2.1 Metallic Bonding

102

(1)

4.2.2 Ionic Bonding

102

(5)

4.2.3 Covalent Bonding

107

(2)

4.2.4 Ionic and Covalent Bond Combinations

109

(1)

4.2.5 van der Waals Bonds

109

(2)

4.3 Polymorphic Forms and Transformations

111

(2)

4.4 Noncrystalline Structures

113

(2)

4.4.1 Glasses

113

(2)

4.4.2 Gels

115

(1)

4.4.3 Vapor Deposition

115

(1)

4.5 Molecular Structures

115

(5)

4.5.1 Hydrocarbons

115

(1)

4.5.2 Addition Polymerization

116

(1)

4.5.3 Condensation Polymerization

117

(1)

4.5.4 Polymer Crystallization

118

(1)

4.5.5 Cross-Linking and Branching

118

(2)

References

120

(1)

Problems

120

(1)

Study Guide

120

(3)

Chapter 5 Crystal Chemistry and Specific Crystal Structures

123

(40)

5.1 Crystal Structure Notations

123

(4)

5.1.1 Crystal Systems and Bravais Lattices

123

(1)

5.1.2 Crystal Directions and Planes

123

(4)

5.1.3 Structure, Composition, and Coordination Notations

127

(1)

5.2 Crystal Chemistry of Ceramics

127

(6)

5.2.1 Crystal Chemistry Concepts

128

(3)

5.2.1.1 Ionic Radius

128

(1)

5.2.1.2 Ionic Packing

128

(2)

5.2.1.3 Effect of Charge

130

(1)

5.2.2 Crystal Chemical Substitutions

131

(1)

5.2.3 Derivative Structures

132

(1)

5.2.3.1 Ordering

132

(1)

5.2.3.2 Nonstoichiometry

132

(1)

5.2.3.3 Stuffing

132

(1)

5.2.3.4 Distortion

133

(1)

5.3 Metallic and Ceramic Crystal Structures

133

(27)

5.3.1 Metallic Crystal Structures

133

(1)

5.3.2 Ceramic Structures with a Single Element

134

(4)

5.3.3 Binary Ceramic Structures

138

(6)

5.3.3.1 [ Rock Salt] Structure A[ 6]X[ 6]

139

(1)

5.3.3.2 [ Nickel Arsenide] Structure A[ 6]X[ 6]

139

(1)

5.3.3.3 [ Cesium Chloride] Structure A[ 8]X[ 8]

139

(1)

5.3.3.4 [ Zinc Blende] and [ Wurtzite] Structures A[ 4]X[ 4]

139

(1)

5.3.3.5 [ Fluorite] Structure A[ 8]X[ 42

140

(1)

5.3.3.6 [ Antifluorite] Structure A[ 4]X[ 8]

141

(1)

5.3.3.7 [ Rutile] Structure A[ 6]X[ 3]

141

(1)

5.3.3.8 Silica Structures A[ 4]X[ 2]2

142

(2)

5.3.3.9 [ Corundum] Structure A[ 6]2X[ 43

144

(1)

5.3.4 Ternary Ceramic Structures

144

(8)

5.3.4.1 A2BX4 Structures

145

(3)

5.3.4.2 ABX4 Structures

148

(1)

5.3.4.3 ABX3 Structures

148

(2)

5.3.4.4 Other Structures

150

(1)

5.3.4.5 Carbide and Nitride Structures

151

(1)

5.3.5 Crystal Defects and Stoichiometry

152

(11)

5.3.5.1 Zero-Dimensional (Point) Defects

152

(2)

5.3.5.2 One-Dimensional (Line) Defects

154

(1)

5.3.5.3 Two-Dimensional (Planar) Defects

154

(5)

5.3.5.4 Three-Dimensional (Volume) Defects

159

(1)

5.3.5.5 Accommodating Nonstoichiometry in Crystals

160

(1)

References

160

(1)

Additional Recommended Reading

161

(1)

Problems

161

(1)

Study Guide

162

(1)

Chapter 6 Phase Equilibria and Phase Equilibrium Diagrams

163

(40)

6.1 Phase Equilibrium Diagrams

163

(25)

6.1.1 Concept of Phase Equilibria

164

(1)

6.1.2 Phase Rule

164

(1)

6.1.3 One-Component Phase Diagrams

165

(1)

6.1.4 Two-Component Systems

166

(3)

6.1.4.1 Binary Eutectic Systems

168

(1)

6.1.5 Intermediate Compounds

169

(8)

6.1.5.1 Solid Solution

174

(1)

6.1.5.2 Liquid Immiscibility

174

(2)

6.1.5.3 Exsolution

176

(1)

6.1.5.4 Polymorphism

176

(1)

6.1.6 Three-Component Systems

177

(11)

6.1.6.1 Simple Eutectic Ternary Diagram

177

(4)

6.1.6.2 Ternary System with Congruently Melting Binary Compound AB

181

(1)

6.1.6.3 Ternary System with Incongruently Melting Binary Compound AB

182

(1)

6.1.6.4 Ternary Compounds

183

(1)

6.1.6.5 Polymorphic Transformations

183

(1)

6.1.6.6 Immiscible Liquids in Ternary Systems

183

(2)

6.1.6.7 Solid Solution in Ternary Systems

185

(2)

6.1.6.8 Real Ternary Systems

187

(1)

6.2 Phase Equilibrium Diagram Composition Calculations

188

(5)

6.2.1 Composition Conversions

188

(3)

6.2.2 Binary Composition Calculations

191

(1)

6.2.3 Ternary Composition Calculations

192

(1)

6.3 Isoplethal Crystallization Paths

193

(3)

6.3.1 Binary Isoplethal Analysis

193

(1)

6.3.2 Ternary System Isoplethal Analysis

194

(2)

6.4 Nonequilibrium Behavior

196

(3)

6.4.1 Sluggish Kinetics

197

(1)

6.4.2 Rapid Heating or Cooling

197

(1)

6.4.3 Nucleation Difficulty

198

(1)

6.4.4 Elastic Constraint of a Polymorphic Transformation

198

(1)

6.4.5 Additional Information on Nonequilibrium

198

(1)

References

199

(1)

Problems

199

(1)

Study Guide

200

(3)

Chapter 7 Physical and Thermal Behavior

203

(32)

7.1 Physical Properties

203

(9)

7.1.1 Density

203

(6)

7.1.1.1 Crystallographic Density

203

(2)

7.1.1.2 Bulk Density

205

(1)

7.1.1.3 Theoretical Density

206

(1)

7.1.1.4 Specific Gravity

207

(1)

7.1.1.5 Open Porosity

207

(2)

7.1.1.6 Density Comparisons

209

(1)

7.1.2 Melting Behavior

209

(3)

7.2 Thermal Properties

212

(9)

7.2.1 Heat Capacity

212

(1)

7.2.2 Thermal Conductivity

213

(8)

7.3 Thermal Expansion

221

(9)

7.3.1 Factors Influencing Thermal Expansion

222

(13)

7.3.1.1 Thermal Expansion of Metals

222

(1)

7.3.1.2 Thermal Expansion of Ceramics

223

(5)

7.3.1.3 Thermal Expansion of Noncrystalline Solids

228

(1)

7.3.1.4 Thermal Expansion of Organic Solids

228

(1)

7.3.1.5 Importance of Thermal Expansion

228

(1)

7.3.1.6 Simulating Thermal Properties

229

(1)

7.3.1.7 Thermal Properties in the Future

230

(1)

References

230

(1)

Problems

231

(1)

Study Guide

232

(3)

Chapter 8 Mechanical Behavior and Measurement

235

(34)

8.1 Elasticity

235

(5)

8.1.1 Modulus of Elasticity

236

(4)

8.1.2 Elastic Modulus Measurement

240

(1)

8.1.3 Poisson's Ratio

240

(1)

8.2 Strength

240

(14)

8.2.1 Theoretical Strength

241

(1)

8.2.2 Effects of Flaw Size

242

(4)

8.2.2.1 Pore Shape

244

(1)

8.2.2.2 Pore-Crack Combinations

244

(1)

8.2.2.3 Internal Pores

244

(2)

8.2.2.4 Pore Clusters

246

(1)

8.2.2.5 Inclusions

246

(1)

8.2.3 Strength Measurement

246

(6)

8.2.3.1 Tensile Strength

246

(2)

8.2.3.2 Compressive Strength

248

(1)

8.2.3.3 Bend Strength

249

(2)

8.2.3.4 Biaxial Strength

251

(1)

8.2.4 Strength Data for Ceramic Materials

252

(2)

8.3 Fracture Toughness

254

(3)

8.4 Ductile versus Brittle Behavior

257

(7)

8.4.1 Mechanism of Plastic Deformation

257

(1)

8.4.2 Deformation Behavior of Metals

258

(2)

8.4.3 Deformation Behavior in Ceramics

260

(4)

8.4.3.1 Single Crystals

260

(4)

8.4.3.2 Polycrystalline Ceramics

264

(1)

8.4.4 Ceramics Deformation Summary

264

(1)

8.5 Advanced Mechanical Testing Techniques and Modeling

264

(1)

References

265

(1)

Additional Recommended Reading

266

(1)

Problems

267

(1)

Study Guide

268

(1)

Chapter 9 Time, Temperature, and Environmental Effects on Properties

269

(46)

9.1 Creep

269

(9)

9.1.1 Effects of Temperature and Stress on Creep

270

(1)

9.1.2 Effects of Single-Crystal Structure on Creep

271

(1)

9.1.3 Effects of Microstructure of Polycrystalline Ceramics on Creep

272

(1)

9.1.4 Creep in Noncrystalline Ceramics

273

(1)

9.1.5 Effects of Composition, Stoichiometry, and Environment

274

(1)

9.1.6 Measurement of Creep

274

(3)

9.1.7 Creep Consideration for Component Design

277

(1)

9.2 Static Fatigue

278

(3)

9.3 Chemical Effects

281

(16)

9.3.1 Gas-Solid Reactions

282

(7)

9.3.1.1 Oxidation

282

(4)

9.3.1.2 Reduction and Other Reactions

286

(1)

9.3.1.3 Thermodynamics

287

(1)

9.3.1.4 Interactions with Water Vapor

288

(1)

9.3.1.5 Vaporization and Dissociation

289

(1)

9.3.2 Liquid-Solid Reactions

289

(8)

9.3.2.1 Ambient Temperature Corrosion

290

(1)

9.3.2.2 High-Temperature Corrosion of Oxides

290

(2)

9.3.2.3 Condensed-Phase Corrosion

292

(3)

9.3.2.4 Corrosion in Coal Combustion Environments

295

(2)

9.3.3 Solid-Solid Reactions

297

(1)

9.4 Mechanically Induced Effects

297

(6)

9.4.1 Surface Flaw Formation

297

(4)

9.4.2 Removal of Surface Material

301

(2)

9.5 Thermal Shock

303

(7)

References

310

(2)

Problems

312

(1)

Study Guide

313

(2)

Chapter 10 Electrical Behavior

315

(40)

10.1 Fundamentals and Definitions

315

(1)

10.2 Electronic Conductivity

316

(4)

10.3 Ionic Conductivity

320

(13)

10.3.1 Mechanisms of Ionic Conductivity

320

(1)

10.3.2 Ceramic Materials Exhibiting Ionic Conductivity

321

(2)

10.3.3 Applications of Zirconia Oxygen Ion Conductive Ceramics

323

(6)

10.3.3.1 Oxygen Sensors

323

(2)

10.3.3.2 Oxygen Pumps

325

(1)

10.3.3.3 Electrolysis and Thermolysis

326

(1)

10.3.3.4 SOx-NOx Decomposition

326

(1)

10.3.3.5 Solid Oxide Fuel Cells

326

(2)

10.3.3.6 Resistance Heating Elements

328

(1)

10.3.3.7 Galvanic Cells for Thermodynamic and Kinetic Measurements

329

(1)

10.3.4 Alternative Oxygen Ion Conductors

329

(1)

10.3.5 Sodium Ion Conductors and Applications

329

(3)

10.3.6 Lithium Ion Conduction and Applications

332

(1)

10.4 Conductive Polymers

333

(1)

10.5 Electrical Insulators

333

(5)

10.5.1 Applications of Electrical Insulators

335

(3)

10.5.1.1 Integrated Circuit Substrates and Packages

336

(2)

10.5.1.2 Spark Plug Insulators

338

(1)

10.5.1.3 Power Line Insulators

338

(1)

10.6 Semiconductors

338

(7)

10.6.1 Mechanisms of Semiconduction

338

(3)

10.6.2 Applications of Ceramic Semiconductors

341

(1)

10.6.3 Photovoltaic Semiconductors

342

(3)

10.7 Superconductivity

345

(7)

10.7.1 Mechanism of Superconductivity

345

(2)

10.7.2 Characteristics of Superconductivity

347

(1)

10.7.3 Evolution of Superconductor Materials

348

(1)

10.7.4 Structure of High-Tc Ceramic Superconductors

349

(1)

10.7.5 Characteristics of the 1:2:3 Ceramic Superconductor

349

(2)

10.7.6 Applications of Superconductors

351

(1)

References

352

(1)

Additional Recommended Reading

353

(1)

Problems

353

(1)

Study Guide

354

(1)

Chapter 11 Dielectric, Magnetic, and Optical Behavior

355

(48)

11.1 Dielectric Properties

355

(25)

11.1.1 Polarization

355

(1)

11.1.2 Dielectric Constant

356

(2)

11.1.3 Dielectric Strength

358

(1)

11.1.4 Dielectric Loss

358

(3)

11.1.5 Capacitance

361

(6)

11.1.5.1 Functions of a Capacitor

364

(1)

11.1.5.2 History of Capacitors

364

(1)

11.1.5.3 Mechanism of High Dielectric Constant

364

(2)

11.1.5.4 Types of Capacitors

366

(1)

11.1.6 Piezoelectricity

367

(2)

11.1.7 Pyroelectricity

369

(1)

11.1.8 Ferroelectricity

369

(11)

11.1.8.1 Types of Ferroelectric Crystals

372

(1)

11.1.8.2 Polycrystalline Ferroelectrics

372

(8)

11.2 Magnetic Behavior

380

(8)

11.2.1 Source of Magnetism

380

(4)

11.2.2 Magnetic Terminology

384

(1)

11.2.3 Applications of Magnetic Ceramics

385

(3)

11.3 Optical Behavior

388

(9)

11.3.1 Absorption and Transparency

388

(2)

11.3.2 Color

390

(1)

11.3.3 Phosphorescence

391

(1)

11.3.4 Lasers

392

(1)

11.3.5 Index of Refraction

393

(4)

11.3.6 Electro-Optics and Integrated Optic Devices

397

(1)

References

397

(1)

Problems

398

(1)

Study Guide

399

(4)

Part III: Processing of Ceramics

Chapter 12 Introduction to Ceramic Fabrication Approaches Including Powder Processing

403

(44)

12.1 General Ceramic Processing Approaches

403

(10)

12.1.1 Conventional Ceramic Processing by Compaction of Powders

403

(2)

12.1.2 Refractory Processing

405

(1)

12.1.3 Melting and Fusion Ceramic Processing

406

(3)

12.1.4 Room-or Low-Temperature Processing

409

(1)

12.1.5 Other Ceramic Processing Options

409

(4)

12.1.5.1 Coatings

410

(1)

12.1.5.2 Infiltration Processes

410

(1)

12.1.5.3 Metal-Gas Reaction

411

(1)

12.1.5.4 Porous Ceramics

412

(1)

12.1.5.5 Advanced and Emerging Processes

412

(1)

12.2 Powder Processing

413

(5)

12.2.1 Raw Materials

414

(2)

12.2.1.1 Traditional Ceramics

414

(1)

12.2.1.2 Modern Ceramics

414

(2)

12.2.2 Raw Material Selection Criteria

416

(2)

12.2.2.1 Purity

416

(1)

12.2.2.2 Particle Size and Reactivity

417

(1)

12.3 Powder Preparation and Sizing

418

(18)

12.3.1 Mechanical Sizing

418

(11)

12.3.1.1 Screening

418

(2)

12.3.1.2 Air Classification

420

(1)

12.3.1.3 Elutriation

421

(1)

12.3.1.4 Ball Milling

422

(3)

12.3.1.5 Attrition Milling

425

(1)

12.3.1.6 Vibratory Milling

426

(2)

12.3.1.7 Fluid Energy Milling

428

(1)

12.3.1.8 Hammer Milling

428

(1)

12.3.1.9 Roll Crushing

428

(1)

12.3.1.10 Miscellaneous Crushing

429

(1)

12.3.2 Chemical Sizing

429

(6)

12.3.2.1 Precipitation

429

(1)

12.3.2.2 Freeze Drying

429

(1)

12.3.2.3 Hot Kerosene Drying

430

(1)

12.3.2.4 Sol-Gel

431

(1)

12.3.2.5 Liquid Mix Process

432

(1)

12.3.2.6 Spray Roasting

432

(1)

12.3.2.7 Decomposition

433

(1)

12.3.2.8 Hydrothermal Synthesis

433

(2)

12.3.2.9 Plasma Techniques

435

(1)

12.3.2.10 Laser Techniques

435

(1)

12.3.3 Miscellaneous Powder Synthesis/Sizing Techniques

435

(1)

12.3.3.1 Calcining

435

(1)

12.3.3.2 Rotary Kiln

435

(1)

12.3.3.3 Fluidized Bed

436

(1)

12.3.3.4 Self-Propagating Combustion

436

(1)

12.3.3.5 Gas Condensation

436

(1)

12.4 Preconsolidation

436

(5)

12.4.1 Additives

437

(2)

12.4.2 Spray Drying

439

(1)

12.4.3 Granulation

440

(1)

12.5 Batch Determination

441

(2)

References

443

(2)

Additional Recommended Reading

445

(1)

Problems

445

(1)

Study Guide

445

(2)

Chapter 13 Shape-Forming Processes

447

(76)

13.1 Pressing

447

(19)

13.1.1 Steps in Pressing

447

(1)

13.1.2 Selection of Additives

448

(7)

13.1.2.1 Binders and Plasticizers

448

(5)

13.1.2.2 Lubricants and Compaction Aids

453

(1)

13.1.2.3 Removal of Organic Additives

454

(1)

13.1.3 Uniaxial Pressing: Presses and Tooling

455

(6)

13.1.3.1 Dry Pressing

457

(1)

13.1.3.2 Wet Pressing

457

(1)

13.1.3.3 Uniaxial Pressing Problems

457

(4)

13.1.4 Isostatic Pressing

461

(4)

13.1.4.1 Wet-Bag Isostatic Pressing

463

(1)

13.1.4.2 Dry-Bag Isostatic Pressing

464

(1)

13.1.5 Applications of Pressing

465

(1)

13.2 Casting

466

(23)

13.2.1 Slip Casting

466

(20)

13.2.1.1 Raw Materials

466

(1)

13.2.1.2 Powder Processing

467

(1)

13.2.1.3 Slip Preparation and Rheology

468

(1)

13.2.1.4 Particle Size and Shape Effects

468

(2)

13.2.1.5 Particle Surface Effects

470

(7)

13.2.1.6 Slip Preparation

477

(1)

13.2.1.7 Mold Preparation

478

(1)

13.2.1.8 Casting

479

(6)

13.2.1.9 Casting Process Control

485

(1)

13.2.1.10 Drying

485

(1)

13.2.2 Tape Casting

486

(3)

13.2.2.1 Doctor Blade Process

486

(1)

13.2.2.2 Other Tape-Casting Processes

486

(1)

13.2.2.3 Preparation of Tape-Casting Slurries

487

(1)

13.2.2.4 Applications of Tape Casting

488

(1)

13.3 Plastic Forming

489

(26)

13.3.1 Extrusion

491

(9)

13.3.1.1 Extrusion Equipment

491

(1)

13.3.1.2 Binders and Additives for Extrusion

492

(3)

13.3.1.3 Extrusion Steps

495

(3)

13.3.1.4 Common Extrusion Defects

498

(1)

13.3.1.5 Applications of Extrusion

499

(1)

13.3.2 Injection Molding

500

(14)

13.3.2.1 Injection-Molding Parameters

500

(5)

13.3.2.2 Injection-Molding Defects

505

(5)

13.3.2.3 Applications of Injection Molding

510

(1)

13.3.2.4 Nonthermoplastic Injection Molding

511

(3)

13.3.3 Compression Molding

514

(1)

13.3.4 Roll Forming

514

(1)

13.3.5 Jiggering

515

(1)

13.4 Green Machining

515

(1)

References

516

(2)

Additional Recommended Reading

518

(1)

Problems

518

(2)

Study Guide

520

(3)

Chapter 14 Densification

523

(54)

14.1 Theory of Sintering

523

(19)

14.1.1 Stages of Sintering

523

(2)

14.1.2 Mechanisms of Sintering

525

(11)

14.1.2.1 Vapor-Phase Sintering

525

(2)

14.1.2.2 Solid-State Sintering

527

(6)

14.1.2.3 Liquid-Phase Sintering

533

(1)

14.1.2.4 Reactive Liquid Sintering

534

(2)

14.1.3 Control of Conventional Sintering

536

(4)

14.1.3.1 Atmosphere

537

(1)

14.1.3.2 Time and Temperature Cycle

537

(1)

14.1.3.3 Design of the Furnace

537

(3)

14.1.4 Sintering Problems

540

(2)

14.1.4.1 Warpage

540

(1)

14.1.4.2 Overfiring

541

(1)

14.1.4.3 Burn-Off of Binders

541

(1)

14.1.4.4 Decomposition Reactions

541

(1)

14.1.4.5 Polymorphic Transformations

542

(1)

14.2 Modified Densification Processes

542

(30)

14.2.1 Modified Particulate Processes

542

(2)

14.2.1.1 Overpressure Sintering

542

(2)

14.2.2 Hot Pressing

544

(6)

14.2.2.1 Unique Hot-Pressed Properties

547

(1)

14.2.2.2 Hot-Pressing Limitations

548

(2)

14.2.3 Hot Isostatic Pressing

550

(2)

14.2.4 Field-Assisted Sintering Techniques

552

(2)

14.2.5 Chemical Processes

554

(5)

14.2.5.1 Chemical Reaction

554

(5)

14.2.6 Cementitious Bonding

559

(1)

14.2.7 Pyrolysis

560

(2)

14.2.8 Melt Processing

562

(1)

14.2.8.1 Casting, Drawing, and Blowing

562

(1)

14.2.8.2 Spraying

562

(1)

14.2.9 Crystallization

563

(4)

14.2.10 Vapor Processing

567

(4)

14.2.11 Infiltration

571

(1)

14.2.12 Metal-Gas Reaction

571

(1)

References

572

(2)

Additional Recommended Reading

574

(1)

Problems

575

(1)

Study Guide

575

(2)

Chapter 15 Final Machining

577

(18)

15.1 Mechanisms of Material Removal

577

(4)

15.1.1 Mounted-Abrasive Machining

577

(1)

15.1.2 Free-Abrasive Machining

578

(1)

15.1.3 Impact Abrasive Machining

578

(1)

15.1.4 Chemical Machining

579

(1)

15.1.4.1 Photoetching

579

(1)

15.1.5 Electrical Discharge Machining

579

(1)

15.1.6 Laser Machining

580

(1)

15.2 Effects on Strength

581

(11)

15.2.1 Effect of Grinding Direction

582

(1)

15.2.2 Effects of Microstructure

583

(1)

15.2.3 Effects of Grinding Parameters

584

(2)

15.2.4 Optimization of Grinding

586

(12)

15.2.4.1 Lapping

588

(2)

15.2.4.2 Annealing

590

(1)

15.2.4.3 Oxidation

590

(1)

15.2.4.4 Chemical Etching

590

(1)

15.2.4.5 Surface Compression

590

(1)

15.2.4.6 Flame Polishing

591

(1)

15.3 Additional Sources of Information

592

(1)

References

592

(1)

Additional Recommended Reading

593

(1)

Problems

593

(1)

Study Guide

594

(1)

Chapter 16 Quality Assurance

595

(28)

16.1 In-Process QA

595

(1)

16.2 Specification and Certification

596

(2)

16.3 Proof Testing

598

(1)

16.4 Nondestructive Inspection

598

(11)

16.4.1 Penetrants

599

(1)

16.4.2 X-Ray Radiography

599

(4)

16.4.2.1 Conventional X-Ray Radiography

599

(2)

16.4.2.2 Microfocus X-Ray Radiography

601

(1)

16.4.2.3 Image Enhancement

601

(2)

16.4.3 Computed Tomography

603

(3)

16.4.4 Ultrasonic NDI

606

(3)

16.4.5 Other NDI Techniques

609

(1)

16.5 Quality Problem Solving and Improvement

609

(7)

16.5.1 Nature of Variation in a Fabrication Process

609

(1)

16.5.2 SPC Tools and Techniques

610

(5)

16.5.2.1 Flow Chart

610

(1)

16.5.2.2 Check Sheet

611

(1)

16.5.2.3 Pareto Chart

612

(1)

16.5.2.4 Brainstorming

612

(1)

16.5.2.5 Cause and Effect Diagram (Fishbone Diagram)

612

(1)

16.5.2.6 Five-Whys Diagram

613

(1)

16.5.2.7 Run Charts and Control Charts

613

(2)

16.5.3 Use of SPC Tools for Continuous Improvement

615

(1)

16.5.4 QA Perspective of the End User

616

(1)

16.6 Future Developments in QA

616

(1)

References

616

(2)

Additional Recommended Reading

618

(1)

Problems

618

(1)

Study Guide

618

(5)

Part IV: Design with Ceramics

Chapter 17 Design Considerations

623

(8)

17.1 Requirements of the Application

623

(1)

17.2 Property Limitations

624

(2)

17.3 Fabrication Limitations

626

(2)

17.4 Cost Considerations

628

(1)

17.5 Reliability Requirements

628

(1)

17.6 Summary

629

(1)

References

629

(1)

Study Guide

629

(2)

Chapter 18 Design Approaches

631

(16)

18.1 Empirical Design

631

(1)

18.2 Deterministic Design

631

(3)

18.3 Probabilistic Design

634

(7)

18.3.1 Weibull Statistics

634

(5)

18.3.2 Use of the Weibull Distribution in Design

639

(1)

18.3.3 Advantages of Probabilistic Design

639

(2)

18.3.4 Limitations of Probabilistic Design

641

(1)

18.4 Linear Elastic Fracture Mechanics Approach

641

(1)

18.5 Combined Approaches

642

(1)

18.6 Computer-Assisted Design

642

(1)

References

643

(1)

Additional Recommended Reading

643

(1)

Problems

644

(1)

Study Guide

645

(2)

Chapter 19 Failure Analysis

647

(30)

19.1 Fractography

647

(27)

19.1.1 Location of the Fracture Origin

648

(5)

19.1.1.1 Fracture Mirror and Hackle

649

(2)

19.1.1.2 Wallner Lines

651

(1)

19.1.1.3 Other Features

651

(2)

19.1.2 Techniques of Fractography

653

(3)

19.1.3 Determining Failure Cause

656

(21)

19.1.3.1 Material Flaws

658

(1)

19.1.3.2 Machining Damage

659

(2)

19.1.3.3 Residual Stresses

661

(1)

19.1.3.4 Thermal Shock

662

(3)

19.1.3.5 Impact

665

(2)

19.1.3.6 Biaxial Contact

667

(2)

19.1.3.7 Oxidation-Corrosion

669

(4)

19.1.3.8 Slow Crack Growth

673

(1)

19.2 Summary

674

(1)

References

674

(2)

Additional Recommended Reading

676

(1)

Study Guide

676

(1)

Chapter 20 Toughening of Ceramics

677

(62)

20.1 Toughening Mechanisms

677

(12)

20.1.1 Modulus Transfer

678

(3)

20.1.1.1 Effect of Elastic Modulus

678

(1)

20.1.1.2 Effect of Volume Fraction and Architecture

678

(2)

20.1.1.3 Effect of Fiber Length

680

(1)

20.1.1.4 Effect of Interfacial Bond

681

(1)

20.1.2 Prestressing

681

(1)

20.1.3 Crack Deflection or Impediment

682

(2)

20.1.4 Crack Bridging

684

(1)

20.1.5 Pullout

685

(1)

20.1.6 Crack Shielding

685

(3)

20.1.7 Energy Dissipation

688

(1)

20.2 Examples of Toughened Ceramics

689

(39)

20.2.1 Self-Reinforced Ceramics

689

(4)

20.2.1.1 Self-Reinforced Si3N4

690

(1)

20.2.1.2 Self-Reinforced ZrC

690

(1)

20.2.1.3 Aluminate Platelet-Reinforced Transformation-Toughened ZrO2

690

(1)

20.2.1.4 La beta-Alumina-Reinforced Transformation-Toughened ZrO2

690

(3)

20.2.2 Transformation-Toughened Ceramics

693

(5)

20.2.2.1 Transformation-Toughened ZrO2

693

(4)

20.2.2.2 Other Transformation-Toughened Ceramics

697

(1)

20.2.3 Particulate-Reinforced Ceramics

698

(1)

20.2.4 Whisker-Reinforced Ceramics

698

(1)

20.2.5 A1203 Reinforced with SiC Whiskers

699

(5)

20.2.6 Si3N4 Reinforced with SiC and Si3N4 Whiskers

704

(1)

20.2.7 MoSi2 and MoSi2-WSi2 Reinforced with SiC Whiskers

704

(1)

20.2.8 Fiber-Reinforced Ceramics

704

(8)

20.2.8.1 Glass Fibers

704

(1)

20.2.8.2 Carbon Fibers

705

(2)

20.2.8.3 Oxide Fibers

707

(2)

20.2.8.4 Nonoxide Fibers

709

(3)

20.2.9 Examples of Ceramic Matrix Composites Reinforced with Ceramic Fibers

712

(27)

20.2.9.1 Cement Matrix Composites

712

(1)

20.2.9.2 Glass Matrix Composites

712

(2)

20.2.9.3 Glass-Ceramic Matrix Composites

714

(2)

20.2.9.4 SiC Matrix Composites Fabricated by Chemical Vapor Infiltration

716

(3)

20.2.9.5 SiC Matrix Composites Fabricated by Si Melt Infiltration

719

(1)

20.2.9.6 SiC Matrix Composites Fabricated by Preceramic Polymer Infiltration

720

(1)

20.2.9.7 Oxide Matrix Composites Fabricated by Infiltration

721

(1)

20.2.9.8 Si2N4 Matrix Composites

721

(3)

20.2.9.9 Other Fiber-Reinforced Ceramic Matrix Composites

724

(2)

20.2.10 Composites with Surface Compression

726

(1)

20.2.11 Fibrous Monolith

727

(1)

20.3 Summary

728

(1)

References

729

(5)

Problems

734

(1)

Study Guide

734

(5)

Part V: Applying Ceramics to Real-World Challenges

Chapter 21 Solving Past Challenges: Case Studies

739

(32)

21.1 Evolution of the Integrated Circuit

739

(7)

21.1.1 Silicon Crystal Growth

741

(1)

21.1.2 Slicing, Grinding, and Polishing

742

(1)

21.1.3 Doping to Achieve Semiconductor Behavior

742

(1)

21.1.4 Buildup of the Device Layers

743

(3)

21.2 Evolution of the Flash Memory and the Digital Camera

746

(1)

21.3 Challenges of the Digital Watch

747

(1)

21.4 Invention and Evolution of the Catalytic Converter

747

(3)

21.4.1 Ceramic Material Selection and Development

748

(1)

21.4.2 Design Selection and Fabrication Development

748

(1)

21.4.3 Improvements in Catalytic Converters

749

(1)

21.5 Bioglass and Bioceramics

750

(1)

21.6 Refractory Evolution

750

(4)

21.6.1 Refractories Development

750

(2)

21.6.2 In Situ Refractories

752

(2)

21.7 Ceramics in the Nuclear Industry

754

(9)

21.7.1 Development of Nuclear Fuel

755

(5)

21.7.2 Nuclear Wasteforms

760

(3)

21.8 Silicon Nitride: Seeking Uses for a New Material

763

(5)

References

768

(3)

Chapter 22 Where Next for Ceramics? Future Trends and Challenges

771

(16)

22.1 Nanotechnology and Nanoprocessing

771

(5)

22.1.1 Review of Importance of Particle Size and Arrangement

771

(2)

22.1.2 Further Nanoscale Manipulation

773

(6)

22.1.2.1 Control of Chemistry for Self-Assembly and Engineered Structures

773

(2)

22.1.2.2 Quantum Dots

775

(1)

22.1.2.3 Nanoscale Thin Film Deposition

776

(1)

22.1.2.4 Carbon Nanotubes

776

(1)

22.2 Ceramics in Environmental Cleanup

776

(2)

22.3 Raw Materials Challenges

778

(1)

22.4 Modeling

778

(1)

22.5 Advances in Processing

779

(3)

22.5.1 Additive Layer Manufacture

779

(2)

22.5.2 Cold Sintering

781

(1)

22.6 Extreme Environment Challenges

782

(2)

22.6.1 Thermal and Environmental Barrier Coatings

782

(2)

22.6.1.1 Using Coupled Modeling to Help Solve a Materials

Problem

784

(1)

References

785

(2)

Appendix A: Glossary

787

(8)

Appendix B: Effective Ionic Radii for Cations and Anions

795

(6)

Appendix C: The Periodic Table of the Elements

801

(2)

Index

803

David W. Richerson received degrees in Ceramic Science and Engineering from the University of Utah (1967) and The Pennsylvania State University (1969). He conducted research on boron carbide armor, silicon nitride, and composites at Norton Company from 1969 to 1973; coordinated materials efforts from 1973 to 1985 at Garrett Turbine Engine Company to integrate ceramic materials into gas turbine engines; and conducted and managed a wide range of materials programs while Director of Research and Development and later Vice President at Ceramatec, Inc. from 1985 to 1991. From 1991 to the present Mr. Richerson has worked as a consultant, taught at the University of Utah, and planned and conducted volunteer science outreach projects in schools and in the community. Mr. Richerson has authored or co-authored 9 books, 13 book chapters, 21 government program final reports, 5 patents, and 59 technical publications and has made numerous technical and educational presentations including two-day to four-day short courses worldwide. Mr. Richerson is a Fellow and past board member of the American Ceramic Society, a member of the National Institute of Ceramic Engineers and the Ceramic Education Council, and a past member of ASM International.

William E. Lee received a BSc in Physical Metallurgy from Aston University in the UK (1980) and a DPhil from Oxford University (1983) on radiation damage in sapphire. After post-doctoral research at Case Western Reserve University he became an Assistant Professor at the Ohio State University USA before returning to a lectureship at Sheffield University in the UK in 1989 and becoming Professor there in 1998. He moved to be head of the Materials Department at Imperial College London in 2006. His research has covered structure-property-processing relations in a range of ceramics including electroceramics, glasses and glass ceramics, nuclear ceramics, refractories, Ultra-high Temperature Ceramics and whitewares. He has supervised 61 students to completion of their PhDs, and authored and co-authored over 400 articles including 5 books, 7 edited proceedings or journal special issues, 6 invited book/encyclopaedia chapters and 14 invited review papers. Prof. Lee is a Fellow of the UKs Royal Academy of Engineering, the City and Guilds Institute, the Institute of Materials, Minerals and Mining and the American Ceramic Society for whom he was President in 2016/17.

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