MM 362

Ceramics and Glasses

Spring Semester 2020, FMCE, GIKI

Lecture 1-3: Introduction to Ceramics and Glasses

Instructor:
Muzammil Irshad
Lecturer

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 PUBLICATIONS
 Investigation of the Structural and Mechanical Properties of Nano/Micro Al2O3and cBN Composites prepared by Spark Plasma
Sintering. (Ceramics International), May 2017, 10645-10653
 Effect of Ni content and particle size of Al2O3 on the Thermal and Mechanical properties of Al2O3/Ni composites Prepared by Spark
Plasma Sintering. (International Journal of Refractory Metals and Hard Materials), 24 May 2018, 76, 25-32
 Carbon/carbon Nano Composites as Counter Electrodes for Platinum free dye-sensitized solar cells (Organic Electronics) 35 (2016):
128-135.
 Synthesis and Water sorption properties of a series of exfoliated graphene/MIL-100(Fe) Composite(RSC Advances), 2017, 17353–17356
 The Effect of Impingement velocity and angle variation on the Erosion-Corrosion performance of API 5L-X65 Carbon Steel in a Flow
Loop. Metals, Special Issue: Failure Mechanisms in Alloys (MDPI), 31 May 2018
 Effect of accumulation of environmental dust and subsequent mud formation on textural, chemical and optical properties of silicon
wafers for photovoltaic cell applications. Published 19 May 2018, IEEE Journal of Photovoltaic.
 Comparison of Corrosion behaviour of commercial Stainless Steels with and without Si addition. (Conference Paper, Bahrain, 2016)
 Structural and Mechanical Properties of Nano and Micro Al2O3-cBN Composites Prepared by SPS. (Patent, 503462US)
 Tribological behaviour and performance of alumina-based nanocomposites reinforced with uncoated and Ni-coated cubic Boron Nitride
for Tool applications.
 Electrochemical corrosion performance of aromatic functionalized imidazole inhibitor under hydrodynamic conditions on API 65
carbon steel in 1Mol HCl solution.
 Solid Particle Erosion Behaviour of Glass Fibre Reinforced Polyester and Epoxy Resin Composite.
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Course Learning Outcomes
Mapping of CLOs and PLOs PLOs
1. Engineering Knowledge
Blooms 2. Problem Analysis
Sr. No Course Learning Outcomes PLOs 3. Design analysis
Taxonomy
4. Design/Development of solutions
5. Investigation
Be able to understand composition- 6. Modern Tool Usage
C2:
CLO_1 structure-property relationships of PLO1 7. The Engineer and Society
Comprehension
different ceramic and glass materials 8. Environment and Sustainability
9. Ethics
Be able to distinguish different 10. Individual and Team Work
C2: 11. Communication
CLO_2 processing techniques for the sintering PLO1
Comprehension 12. Project Management
of ceramics and glasses
13. Lifelong Learning
Be able to apply their knowledge and Bloom Taxonomy Level (BTL)
CLO_3 understanding for a variety of PLO2 C3: Applying 1. Knowledge
professional contexts. 2. Comprehension
3. Application
4. Analysis
5. Evaluation
6. Creating

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Course Grading and Assessment
Overall Grading Policy
Assessment Items Percentage CLO Assessment Mechanism
Quizzes (scheduled/surprise) 25%
Assessment tools CLO_1 CLO_2 CLO_3
Assignments 5%
Midterm Exam 30% Quizzes 100% 100%
Final Exam 40% Final Exam 100%

Administrative Instructions
1. According to institute policy, 80% attendance is mandatory to appear in the final
examination.
2. Assignments must be submitted as per instructions mentioned in the assignments.
3. In any case, there will be no retake of (scheduled/surprise) quizzes.
4. For queries, kindly follow the office hours in order to avoid any inconvenience.

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 Text and Reference Books:

Text Book

 Fundamentals of Ceramics by Michel Barsoum

 Introduction of ceramics by W. David Kingery

Reference books:

 Ceramics and Glass Materials by James F. Shackelford and Robert H. Doremus

 Introduction to Glass Ceramics and Technology by J.E.Shellby, 2nd edition

 Ceramic Materials Science and Engineering by C.Barry Carter, M.Grant Norton

 Advanced Structural Ceramics by Bikramjit Basu

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Text and Reference Books:

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 Ceramics and Glasses (MM212)
Credit hours: 3, Prerequisites: MM102
Brief Outline of the Course

 This course is designed to provide a diverse introduction and knowledge to contemporary

ceramics and glasses with their applications, also enable students to understand composition-
structure-property relationships of different type of ceramics and glasses, so that students can
adapt their knowledge and understanding for a variety of professional contexts.

 Silicates and clay minerals

 Powder making and characterization of powders
 Traditional ceramics-triaxial porcelain
 Raw materials processing, forming/shaping, glazing, sintering, SPS, Hiping and sintering kilns,
refractories and their applications
 Silicon carbide, silicon nitride, sialon, boron nitride, bioceramics, piezo ceramics
 Biomimetics, cement, glass-ceramics and glasses, glass fibers and optical fibers
 Processing of glasses, heat treatment and testing of glasses, characterization of ceramics

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Introduction to Ceramics and Gasses (Terminologies)
Silicates:
Silicate are rock-forming minerals with predominantly silicate anions. They are the largest and most important
class of rock-forming minerals and make up approximately 90 percent of the Earth's crust.
 7 Major groups are as follows:
Major group Structure Chemical formula Example
isolated silicon
Nesosilicates [SiO4]4− olivine.
tetrahedra

Sorosilicates double tetrahedra [Si2O7]6− epidote, melilite group.

Cyclosilicates rings [SinO3n]2n− tourmaline group.

Inosilicates single chain [SinO3n]2n− pyroxene group.
Inosilicates double chain [Si4nO11n]6n− amphibole group.
Phyllosilicates sheets [Si2nO5n]2n− micas and clays.
quartz feldspars, zeolites
Tectosilicates 3D framework [AlxSiyO(2x+2y)]x−
.

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Introduction to Ceramics and Gasses (Terminologies)
Clay
A stiff, sticky fine-grained earth that can be moulded when wet, and is dried and baked to make bricks, pottery,
and ceramics. (combines one or more clay minerals with possible traces of quartz (SiO2), metal oxides (Al2O3 ,
MgO etc.) and organic matter, (kaolinite, Al2Si2O5(OH)4).

Clay’s plasticity.
When clay is wet with the proper amount of water, to form a cohesive mass and to retain its shape when molded.
This quality is known as clay’s plasticity.

Ceramic material.
When heated to high temperatures, clay also partially melts, resulting in the tight, hard rock-like substance known
as ceramic material.

Glass
An amorphous solid completely lacking in long range, periodic atomic structure, and exhibiting a region of glass
transformation behavior.” Any material, inorganic, organic, or metallic, formed by any technique, which exhibits
glass transformation behavior is a glass.

Glaze : A Type of glass that are especially made to stick onto the ceramic surfaces

Kiln: A furnace for firing Clay etc.

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Introduction of Ceramic Material

 The universe is made up of elements that in turn consist of

neutrons, protons, and electrons.

 There are roughly 100 elements, each possessing a unique

electronic configuration determined by its atomic number Z.

 The periodic table places the elements in horizontal rows of

increasing atomic number and vertical columns or groups, so that
all elements in a group display similar chemical properties.

 For instance, all the elements of group VII referred to as

halides, exist as diatomic gases characterized by a very high
reactivity.

 Conversely, the elements of group VIII the noble gases, are

mono-atomic and are chemically extremely inert.

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Introduction of Ceramic Material

 A large majority of the elements are solids at room temperature, and

because they are shiny, ductile, and good electrical and thermal
conductors, they are considered metals.

 A fraction of the elements most notably, N, O, H, the halides, and the

noble gases are gases at room temperature.

 The remaining elements are covalently bonded solids that, at room

temperature, are either insulators (B, P, S) or semiconductors (Si, Ge).

 These elements for reasons that will become apparent very shortly,
will be referred to as nonmetallic elemental solids (NMESs).

 Very few elements are used in their pure form; most often they are
alloyed with other elements to form engineering materials.

 These engineering materials can be broadly classified as metals,

polymers, semiconductors, or ceramics.
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Introduction of Ceramic Material

 Engineering Materials

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Introduction of Ceramic Material

 Engineering Materials

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 Introduction of Ceramic Material

 In metals, the bonding is predominantly metallic, where delocalized

electrons provide the "glue" that holds the positive ion cores together.

 Polymers consist of very long, for the most part, C-based chains to
which other organic atoms (for example; C, H, N, Cl, F) and molecules are
attached.

 The bonding within the chains is strong, directional, and covalent,

while the bonding between chains is relatively weak.

 Semiconductors are covalently bonded solids that, in addition to Si and

Ge already mentioned, include GaAs, CdTe, and InP, among others.

 Now that these distinctions have been made, it is possible to answer the
non-trivial question: What is a ceramic?

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Introduction of Ceramic Material

 Ceramic material

 Solid compounds that are formed by the application of heat, and sometimes
heat and pressure, comprising at least two elements provided one of them is a non-
metal or a nonmetallic elemental solid. The other element(s) may be a metal(s) or
another nonmetallic elemental solid(s)

 The art and science of making and using solid particles, which have, as their
essential component, and are composed in large part of inorganic nonmetallic
materials.

 MgO, is a ceramic since it is a solid compound of a metal bonded to the

nonmetal O2.

 TiC and ZrB2 are ceramics since they combine metals (Ti,Zr) and the non-metal
(C,B)

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Introduction of Ceramic Material

 Ceramic material

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 Introduction of Ceramic Material
Ceramic material

 The term “ ceramics” comes from the Greek word keramikos, which means “burnt stuff”,
indicating that desirable properties of these materials are normally achieve through a high-
temperature heat treatment process called FIRING.

 Early Greeks used “keramos” when describing products obtained by heating clay-
containing materials.

 The term has long included all products made from fired clay, for example, bricks, fireclay
refractories, sanitaryware, and tableware

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Introduction of Ceramic Material

 Ceramic material
 To illustrate, consider the following examples: Magnesia or MgO, is a ceramic since it is a solid compound of
a metal bonded to the nonmetal O2.

 Silica is also a ceramic since it combines a NMES and a nonmetal.

 Similarly, TiC and ZrB2 are ceramics since they combine metals (Ti,Zr) and the NMES (C,B)- SiC is a
ceramic because it combines two NMESs.

 Also ceramics are not limited to binary compounds: BaTiO3, YBa2Cu3O7, and Ti3SiC2 are all perfectly
respectable class members.

 It follows that the oxides, nitrides, borides, carbides, and silicides (not to be confused with silicates) of all
metals and NMESs are ceramics.

 A note on nomenclature: The addition of the letter a to the end of an element name implies that one is referring to the oxide
of that element. For example, while silicon refers to the element Si, silica is SiO2 or the oxide of silicon. Similarly, alumina is
the oxide of aluminum or A12O3; magnesium; magnesia; etc.
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Introduction of Ceramic Material
Ceramics
materials

Clay Advance
glasses refractories abrasives
products ceramics

Structural
glass clay fireclay
products

Glass-
White ware silica
ceramics

basic

special
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Introduction of Ceramic Material (Comparison between ceramic and metallic material)

Metals Ceramics

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Introduction of Ceramic Material
 An inorganic nonmetallic solid ( or at least as major part)

 Traditional ceramics (silicates e.g. clays, cements, glasses)

 Advanced ceramics (Hydroxyapatite, TiN, WC)

 Abundant in earth’s crust

 Cost effective

 Low density ( 2.4 g/cm3 for typical concrete)

Brittle (Usually)

Low strength (Typical Concrete; 17-40 MPa Compressive strength 2-5 MPa Tensile strength)

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Introduction of Ceramic Material
Why ceramic materials are harder yet more brittle than metal?
 One reason for the hardness and brittleness of ceramic materials is the difficulty of slip or
dislocation motion.

 Reasons why slip is difficult and why they are brittle

 The ionic/covalent bonds are relatively strong
 There are also limited numbers of slip system
 Dislocation structures are complex

 We cannot say “ceramics are brittle” because some can be superplastically deformed and some
metals can be more brittle

 We cannot say “ceramics are insulators” unless we put a value on the band gap (Eg) where a
material is not a semiconductor.

 We cannot say “ceramics are poor conductors of heat” because diamond has the highest
thermal conductivity of any known material
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Introduction of Ceramic Material

In general, structural ceramics can be further classified into two classes:

(1) oxide ceramics (Al2O3, ZrO2, SiO2, etc.)

(2) non-oxide ceramics (SiC, TiC, B4C, TiB2, Si3N4, TiN, etc.).

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Introduction of Ceramic Material

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Introduction of Ceramic Material

 A comparison of different aspects of traditional

and advanced ceramics.

 Ceramic science or engineering can be divided

into traditional and modern ceramics.

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26
 Introduction of Ceramic Material
Traditional Versus Advanced Ceramics

 They are typically formed by mixing clays and feldspars,

followed by forming either by slip casting or on a potter's wheel,
firing in a flame kiln to sinter them, and finally glazing.

 Traditional ceramics are characterized by mostly silicate-based

porous microstructures that are quite coarse, nonuniform, and
multiphase.

 Ceramics that were not clay or silicate-based depended on

much more sophisticated raw materials, such as binary oxides,
carbides, perovskites, and even completely synthetic materials for
which there are no natural equivalents are modern ceramics or
technical ceramics.

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Introduction of Ceramic Material (General Characteristics of Ceramics)

 Ceramics are hard and Wear-resistant

 As with all generalizations, there will be
 Brittle exceptions; some ceramics are electrically and
thermally quite conductive, while others are
 Prone to thermal shock even superconducting and some ceramics are
magnetic.
 Refractory
Ceramics can also have high electrical
 Electrically and thermally insulative (poor electrical and conductivity:
thermal conduction) (1) the oxide ceramic, Rhenium trioxide
(ReO3), has an electrical conductivity at
 Intrinsically transparent room temperature similar to that of Cu
(2) the mixed oxide yttrium barium copper
 Nonmagnetic oxide (YBa2Cu3O7) is an HTSC; it has
zero resistivity below 92 K. These are two
 Chemically stable examples that contradict the conventional
wisdom when it comes to ceramics.
 Oxidation-resistant.
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Introduction of Ceramic Material (Applications)

 Traditional ceramics: ranging from sanitary ware to fine chinas and porcelains to glass products.

 Currently ceramics ranging from ceramic engines to optical communications, electrooptic

applications to laser materials, and substrates in electronic circuits to electrodes in
photoelectrochemical devices.

 Historically, ceramics were mostly exploited for their electrical insulative properties, for which
electrical porcelains and aluminas are prime examples.

 The development of the perovskite family with exceedingly large dielectric constants holds a
significant market share of capacitors produced.
Perovskite is a calcium titanium oxide mineral, with the chemical formula CaTiO3 (some perovskites
are superconductors)

 Similarly, the development of magnetic ceramics based on the spinel ferrites is today a mature
technology.

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Introduction of Ceramic Material (Applications)

 Other electronic/electrical properties of ceramics that are being commercially exploited

include piezoelectric ceramics for sensors and actuators.

 Mechanical applications of ceramics at room temperature usually exploit hardness,

wear, and corrosion resistance.
 The applications include cutting tools, nozzles, valves, and ball bearings in aggressive
environments.

 It is the refractoriness of ceramics and their ability to sustain high loads at high
temperatures, together with their low densities, that has created the most interest.
 Applications in this area include all ceramic engines for transportation and turbines for
energy production.

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Introduction of Ceramic Material (Applications)
Whitewares

Made from components of

clay, silica, and feldspar for
which the composition is
controlled.

Example:

 Electrical porcelain

 Dinner china

 Sanitary ware

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Introduction of Ceramic Material (Applications)
Properties and applications of advanced ceramics.

Thermal:

Insulation: High-temperature furnace linings for insulation (oxide

fibers such as SiO2, A12O3, and ZrO2)

Refractoriness: High-temperature furnace linings for insulation and

containment of molten metals and slags

Thermal conductivity: Heat sinks for electronic packages (A1N)

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Introduction of Ceramic Material (Applications)
Silicon Nitride for welding tools:

Such as welding rollers, centering pins and gas nozzles.

 The outcome: Welding process components featuring

remarkable hardness and wear resistance, and very high
temperature and chemical resistance.
 They vastly extend service life, reduce overall retooling
times, extend machine running times and enhance end-
product quality.
 In other words: Silicon nitride ceramics create added value
in the welding process.

Applications:
 Wear Guides
 Seals and Bearings
 Grinding Media

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 Introduction of Ceramic Material (Applications)

Piezoelectric Ceramics

Piezo-ceramic materials are categorized as

functional ceramics:

 A piezoelectric ceramic is a smart

material that converts a mechanical effect
(such as pressure, movement, or vibration)
into an electrical signal and vice versa.

 Materials for power transducers

(ultrasonic applications)

 Materials for sensor applications

(ultrasonic transmitters and receivers)

 Materials for actuating applications

(precision positioning or injection systems
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Introduction of Ceramic Material (Applications)

Electrical and dielectric

Conductivity: Heating elements for furnaces (SiC,

ZrO2, MoSi2)

Ferroelectricity: Capacitors (Ba-titanate-based

materials)

Low-voltage insulators: Ceramic insulation

(porcelain, steatite, forsterite)

Insulators in electronic applications: Substrates for

electronic packaging and electrical insulators in
general (Al2O3, A1N)

Insulators in hostile environments: Spark plugs

(Al2O3)

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Introduction of Ceramic Material (Applications)

Electrical and dielectric

Ion-conducting: Sensor and fuel cells (ZrO2,

A12O3, etc.)

Semiconducting: Thermistors and heating

elements (oxides of Fe, Co, Mn)

Nonlinear I-V characteristics: Current surge

protectors (Bi-doped ZnO, SiC)

Gas-sensitive conduct: Gas sensors (SnO2, ZnO)

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Introduction of Ceramic Material (Applications)
Magnetic and superconductive

Hard magnets Soft magnets: Ferrite magnets [(Ba,

Sr)O6Fe2O3]Transformer cores [(Zn, M)Fe2O3, with M = Mn,
Co, Mg]; magnetic tapes (rare-earth garnets)

Superconductivity: Wires and SQUID magnetometers

(YBa2Cu3O7)

Optical
Transparency: Windows (soda-lime glasses), cables for optical
communication (ultra-pure silica)

Translucency and chemical inertness: Heat- and corrosion-resistant

materials, usually for Na lamps Al2O3MgO)

Nonlinearity IR transparency: Switching devices for optical

computing (LiNbO3) Infrared laser windows (CaF2, SrF2, NaCl)

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Introduction of Ceramic Material (Applications)

Nuclear applications
Fission: Nuclear fuel (UO2, UC), fuel cladding (C, SiC), neutron
moderators (C, BeO)

Fusion: Tritium breeder materials (zirconates and silicates of Li,

Li2O); fusion reactor lining (C, SiC, Si3N4)

Chemical
Catalysis: Filters (zeolites); purification of exhaust gases
Anticorrosion: Heat exchangers (SiC), chemical equipment in
corrosive environments
Biocompatibility: Artificial joint prostheses (Al2O3)
Mechanical
Hardness: Cutting tools (SiC whisker-reinforced A12O3, Si3N4)
High-temperature strength retention: Stators and turbine blades,
ceramic engines (Si3N4)
Wear resistance: Bearings (Si3N4)

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Introduction of Ceramic Material (Applications)

 Abrasives

 Grinding tools

 Cutting tools

Boron Carbide (B4C)

Crystalline compound
of boron and carbon. It
is an extremely hard,
synthetically produced
material that is used in
abrasive and wear-
resistant products.

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Introduction of Ceramic Material (Applications)

 Wear Resistant Coatings

 Ceramic coatings in Automotive

industry

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Introduction of Ceramic Material (Applications)

 Drill Bits

 Surgical Imstruments

 Automotive Ceramics

 Cements

 AlN electronic substrates, chip

carriers where high thermal
conductivity is essential

 Military applications (radar

systems , electronic surveillance
etc.)

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Introduction of Ceramic Material (Applications)

Lead Zirconate Titanate

 Undersea exploration (imaging, current meters)

 Aerospace (gyroscopes, accelerometers, level sensing)

 Telecommunications (optical switching of telecom lines, buzzers

and alarms, Haptics feedback, mobile phone cameras)

 Automotive (power seat controls, reversing/collision avoidance

sensors, anti-knock sensors)

 Scientific research (nano positioning stages and analytical tools,

scanning probe microscopy, advanced acoustics)

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Introduction of Ceramic Material
Market Of Ceramics:  More than half of advanced ceramics is
electrical and electronic ceramics and ceramic
 Ceramics is a multibillion dollar industry. Worldwide sales are packages:
about $100 billion per year.
36% Capacitors/substrates/packages
 U.S. market alone is over $35 billion annually. 23% Other electrical/electronic ceramics
13% Other
 The general distribution of industry sales is as follows: 12% Electrical porcelain
8% Engineering ceramics
55% Glass 8% Optical fibers
17% Advanced ceramics
10% Whiteware
9% Porcelain enamel
7% Refractories
2% Structural clay

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 Introduction of Ceramic Material (Critical Issues For The Future)
There are key issues to solve in order to expand
the use of structural ceramics:
Structural ceramics ((Si3N4), silicon carbide (SiC), zirconia
(ZrO2), boron carbide (B4C), and alumina (Al2O3).
 Reducing cost of the final product
 Improving reliability
 Improving reproducibility
Electronic ceramics: ((BaTiO3), zinc oxide (ZnO), aluminum
nitride (AlN), and HTSCs.
 Integrating with existing semiconductor technology
 Improving processing
 Enhancing compatibility with other materials
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Bioceramics:
(Al2O3) and zirconia (ZrO2).
 Matching mechanical properties to human tissues
 Increasing reliability
 Improving processing methods
Coatings and fi lms:
 Understanding film deposition and growth
 Improving film/substrate adhesion
 Increasing reproducibility
Composites: (1) Reducing processing costs, (2)
Developing compatible combinations of materials (e.g.,
matching coefficients of thermal expansion) , (3)
Understanding interfaces
Nanoceramics:
Making them Integrating them into devices, ensuring that
they do not have a negative impact on society