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Chapter 13 -
Aplikasi dan Proses Fabrikasi
pada Keramik
1
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Chapter 13 - 2
Properties:
-- Tmfor glass is moderate, but large for other ceramics.
-- Small toughness, ductility large moduli ! creep resist.
"pplications: -- #igh T, $ear resistant, no%el uses from charge neutrality.
&abrication -- some glasses can be easily formed
-- other ceramics can not be formed or cast.
Glasses Clayproducts
Refractories Abrasives Cements Advancedceramics
-optical
-composite
reinforce
-containers/household
-whiteware
-bricks
-bricks for
hih T
!furnaces"
-sandpaper
-cuttin
-polishin
-composites
-structural
enine
-rotors
-valves
-bearins
-sensors
"dapted from &ig. 13.1 and discussion inSection 13.2-', Callister 7e.
#a$onomy of Ceramics
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Chapter 13 - 3
(eed a material to use in high temperature furnaces.
Consider the Silica )Si*%+ - "lumina )"l%*&+ system.
Phase diagram sho$s: mullite, alumina, and crystobaliteas candidate refractories.
"dapted from &ig. 12.2,
Callister 7e. )&ig. 12.2
is adapted from &.. lug
and /.#. 0oremus,"lumina Silica Phase
0iagram in the ullite
/egion, J. American
Ceramic Society'()1+,
p. 45, 165.+
Application) Refractories
Composition )$t7 alumina+
8)9C+
1
1'
15
2
22
2 ' 5 1
alumina ;
mullite
mullite; L
mullite
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Chapter 13 -
Sumber: Dedi Supriyadi, Pelatihan Dasar-dasar Refraktori: Teknologi Refraktori, PT. Refratech Mandala Perkasa, 2!!
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Chapter 13 -
Sumber: Dedi Supriyadi, Pelatihan Dasar-dasar Refraktori: Teknologi Refraktori, PT. Refratech Mandala Perkasa, 2!!
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Chapter 13 -
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Chapter 13 -36
tensileforce
Ao
Addie
die
0ie blan>s: -- (eed $ear resistant properties?
0ie surface: -- m polycrystalline diamond
particles that are sintered onto a
cemented tungsten carbide substrate.
-- polycrystalline diamond helps control
fracture and gi%es uniform hardness
in all directions.
Courtesy artin 0ea>ins, @A
Superabrasi%es, Borthington,
*#. sed $ith permission.
"dapted from &ig. 11.5 )d+,
Callister 7e.Courtesy artin 0ea>ins, @A
Superabrasi%es, Borthington,
*#. sed $ith permission.
Application) *ie +lanks
http://blank%20die-working%20animation%20on%20catia%20dmu.mp4/http://blank%20die-working%20animation%20on%20catia%20dmu.mp4/7/26/2019 Aplikasi Dan Proses Fabrikasi Keramik
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Chapter 13 -
8ools: -- for grinding glass, tungsten,
carbide, ceramics
-- for cutting Si $afers
-- for oil drilling
bladesoil drill bits Solutions:
coated single
crystal diamonds
polycrystalline
diamonds in a resin
matriD.
Photos courtesy artin 0ea>ins,
@A Superabrasi%es, Borthington,
*#. sed $ith permission.
Application) Cuttin #ools
-- manufactured single crystal
or polycrystalline diamonds
in a metal or resin matriD.
-- optional coatings )e.g., 8i to help diamonds bond to a Co matriD
%ia alloying+ -- polycrystalline diamonds
resharpen by microfracturing
along crystalline planes.
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Chapter 13 -1
ADample: *Dygen sensor Er*2
Principle: a>e diffusion of ions fast for rapid response.
Application) ,ensors
" Ca2;impurity
remo%es a Er;and a
*2-ion.
Ca2;
"pproach:
"dd Ca impurity to Er*2:
-- increases *2-%acancies -- increases *2-diffusion rate
referencegas at fiDedoDygen content
*2-
diffusion
gas $ith anun>no$n, higheroDygen content
-;%oltage difference produced?
sensor *peration: -- %oltage difference produced $hen
*2-
ions diffuse from the eDternal
surface of the sensor
to the reference gas.
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Chapter 13 -2
Pressing:
@
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Chapter 13 -3
,heet Glass Formin
Sheet formingH continuous dra$
H originally sheet glass $as made by IfloatingJ glass
on a pool of mercury
"dapted from &ig. 13.6, Callister 7e.
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Chapter 13 -
KuartL is crystalline
Si*%:
Gasic nit: @lass is amorphous
"morphous structure occurs by adding impurities
)(a;,g2;,Ca2;, "l3;+
Fmpurities: interfere $ith formation of
crystalline structure.
)soda glass+
"dapted from &ig. 12.11,
Callister, 7e.
Glass ,tructure
Sitetrahedron-
Si;
*2-
Si;
(a;
*2-
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Chapter 13 -4
Specific %olume)1/+ %s 8emperature )T+:
@lasses:-- do not crystalliLe
-- change in slope in spec. %ol. cur%e at
glass transition temperature, Tg -- transparent
- no crystals to scatter light
Crystalline materials:-- crystalliLe at melting temp, Tm
-- ha%e abrupt change in spec.
%ol. at Tm
"dapted from &ig. 13.', Callister, 7e.
Glass Properties
T
Specific %olume
Supercooled
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Chapter 13 -'
Glass Properties) iscosity
Miscosity, :-- relates shear stress and %elocity gradient:
has units of )Pa-s+
yv
dd=
%elocity gradient
dv
dy
glass dvdy
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Chapter 13 -
Miscosity decreases $ith T
Fmpurities lo$er Tdeform
"dapted from &ig. 13., Callister, 7e.
)&ig. 13. is from A.G. Shand, Engineering
Glass, odern aterials, Mol. ', "cademic
Press, (e$ Nor>, 16'5, p. 2'2.+
Glass iscosity vs0 # and .mpurities
fusedsilica
123sili
ca
soda-lime
lass
Misco
sityOPa
s
1
12
1'
11
11
2 ' 1 1 15 T)9C+
Tdeform
: soft enough
to deform or I$or>J
annealing range
Pyre
$
Tmelt
strain point
fused silica: Q 66.4 $t7 Si*2
soda-lime glass: 7 Si*2
balance (a2
* )soda+ ! Ca* )lime+
Mycor: 6'7 Si*2, 7 G2*3
borosilicate )PyreD+:
137 G2*3, 3.47 (a2*, 2.47 "l2*3
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Chapter 13 -5
"nnealing:
--remo%es internal stress caused by une%en cooling. 8empering: --puts surface of glass part into compression
--suppresses gro$th of crac>s from surface scratches.
--se=uence:
4eat #reatin Glass
further cooled
tension
compression
compression
before cooling
hot
surface cooling
hot
cooler
cooler
--/esult: surface crac> gro$th is suppressed.
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Chapter 13 -6
illing and screening: desired particle siLe
iDing particles ! $ater: produces a slip
&orm a green component
0ryand firethe component
ram billet
container
containerforce
die holder
die
Ao
AdeDtrusion--#ydroplastic forming: eDtrude the slip )e.g., into a pipe+
"dapted from
&ig. 11.5 )c+,
Callister 7e.
Ceramic Fabrication ethods-..A
solid component
--Slip casting:
"dapted from &ig.
13.12, Callister 7e.
)&ig. 13.12 is fromB.0. ingery,
ntrod!ction to
Ceramics, ohn
Biley and Sons,
Fnc., 16'.+
hollo$ component
pour slipinto mold
drain
moldIgreenceramicJ
pour slipinto mold
absorb $aterinto mold
Igreen
ceramicJ
@
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Chapter 13 -4
Clay Composition
" miDture of components used
)47+ 1. Clay
)247+ 2. &illerH e.g. =uartL )finely ground+
)247+ 3. &luDing agent)&eldspar+ binds it together
aluminosilicates ; ;, (a;, Ca;
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Chapter 13 -41
Clay is ineDpensi%e
"dding $ater to clay -- allo$s material to shear easily
along $ea> %an der Baals bonds
-- enables eDtrusion
-- enables slip casting
Structure of
aolinite Clay:"dapted from &ig. 12.1, Callister 7e.
)&ig. 12.1 is adapted from B.A. #auth,
Crystal Chemistry of Ceramics,American
Ceramic Society "!lletin, Mol. 3 )+, 1641,
p. 1.+
Features of a ,lip
$ea> %ander Baalsbonding
chargeneutral
chargeneutral
Si ;
"l3;
-*#
*2-
Shear
Shear
*ryin and Firin
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Chapter 13 -42
0rying: layer siLe and spacing decrease."dapted from &ig.
13.13, Callister 7e.
)&ig. 13.13 is from
B.0. ingery,ntrod!ction to
Ceramics, ohn
Biley and Sons,
Fnc., 16'.+
*ryin and Firin
0rying too fast causes sample to $arp or crac> due to non-uniform shrin>age
$et slip partially dry IgreenJceramic
&iring: --Traised to )6-19C+
--%itrification: li=uid glass forms from clay and flo$s bet$een
Si*2particles. &luD melts at lo$er T."dapted from &ig. 13.1,
Callister 7e.)&ig. 13.1 is courtesy #.@.
Grin>ies, S$inburne
ni%ersity of 8echnology,
#a$thorn Campus,
#a$thorn, Mictoria,
"ustralia.+
Si2particle
)=uartL+
glass formedaroundthe particle
micrograph ofporcelain
m
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Chapter 13 -43
Sintering: useful for both clay and non-clay compositions.
Procedure:
-- produce ceramic andRor glass particles by grinding -- place particles in mold
-- press at ele%ated Tto reduce pore siLe.
"luminum oDide po$der: -- sintered at 19C
for ' minutes.
"dapted from &ig. 13.1, Callister 7e.
)&ig. 13.1 is from B.0. ingery, #..
Go$en, and 0./. hlmann, ntrod!ction
to Ceramics, 2nd ed., ohn Biley and
Sons, Fnc., 16', p. 53.+
Ceramic Fabrication ethods-..+
56 m
@
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Chapter 13 -4
Powder Pressin
Sintering- po$der touches - forms nec> ! gradually nec> thic>ens
H add processing aids to help form nec>
H little or no plastic deformation
"dapted from &ig. 13.1', Callister 7e.
niaDial compression - compacted in single direction
Fsostatic)hydrostatic+ compression- pressure applied byfluid - po$der in rubber en%elope
#ot pressing- pressure ; heat
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Chapter 13 -44
#ape Castin
thin sheets of green ceramic cast as fleDible tape
used for integrated circuits and capacitors
cast from li=uid slip )ceramic ; organic sol%ent+
"dapted from &ig. 13.15, Callister 7e.
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Chapter 13 -4'
Produced in eDtremely large =uantities.
Portland cement: -- miD clay and lime bearing materials
-- calcinate )heat to 19C+
-- primary constituents:
tri-calcium silicate
di-calcium silicate
"dding $ater -- produces a paste $hich hardens -- hardening occurs due to hydration )chemical reactions
$ith the $ater+.
&orming: done usually minutes after hydration begins.
Ceramic Fabrication ethods-...
@
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Chapter 13 -4
Applications) Advanced Ceramics
#eat Angines
"d%antages:
H /un at higher
temperature
H ADcellent $ear !
corrosion resistanceH
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Chapter 13 -45
Applications) Advanced Ceramics
Ceramic "rmor
H"l2*3, G:C, SiC ! 8iG2
H ADtremely hard materials
shatter the incoming proectile
energy absorbent material underneath
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Chapter 13 -46
Applications) Advanced Ceramics
Alectronic Pac>aging
Chosen to securely hold microelectronics ! pro%ideheat transfer
ust match the thermal eDpansion coefficient of themicroelectronic chip ! the electronic pac>aging
material. "dditional re=uirements include:H good heat transfer coefficient
H poor electrical conducti%ity
aterials currently used include:
Goron nitride )G(+ Silicon Carbide )SiC+
"luminum nitride )"l(+H thermal conducti%ity 1D that for "lumina
H good eDpansion match $ith Si
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Gasic categories of ceramics:-- glasses
-- clay products
-- refractories
-- cements
-- ad%anced ceramics &abrication 8echni=ues: -- glass forming)impurities affect forming temp+.
-- particulate forming)needed if ductility is limited+
-- cementation )large %olume, room Tprocess+
#eat treating: sed to -- alle%iate residual stress from cooling,
-- produce fracture resistant components by putting
surface into compression.
,ummary
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