Ceramics

The word ceramic is derived from the Greek word Κεραμεικος (the name of a suburb of Athens), and in its strictest sense refers to clay in all its forms. However, modern usage of the term broadens the meaning to include all inorganic non-metallic materials. Up until the 1950s or so, the most important of these were the traditional clays, made into pottery, bricks, tiles and the like, along with cements and glass. The traditional crafts are described in the article on pottery. A composite material of ceramic and metal is known as cermet.

Processing of Ceramic Materials

Non-crystalline ceramics, being glasses, tend to be formed from melts. The glass is shaped when either fully molten, by casting, or when in a state of toffee-like viscosity, by methods such as blowing to a mould. If later heat-treatments cause this class to become partly crystalline, the resulting material is known as a glass-ceramic.

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Crystalline ceramic materials are not amenable to a great range of processing. Methods for dealing with them tend to fall into one of two categories - either make the ceramic in the desired shape, by reaction in situ, or by forming powders into the desired shape, and then sintering to form a solid body. A few methods use a hybrid between the two approaches.

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In situ manufacturing

The most common use of this method is in the production of cement and concrete. Here, the dehydrated powders are mixed with water. This starts hydration reactions, which result in long, interlocking crystals forming around the aggregates. Over time, these result in a solid ceramic.

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The biggest problem with this method is that most reactions are so fast that good mixing is not possible, which tends to prevent large-scale construction. However, small-scale systems can be made by deposition techniques, where the various materials are introduced above a substrate, and react and form the ceramic on the substrate. This borrows techniques from the semiconductor industry, such as chemical vapour deposition, and is very useful for coatings.

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These tend to produce very dense ceramics, but do so slowly.

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Sintering-based methods

The principles of sintering-based methods is simple. Once a roughly held together object (called a "green body") is made, it is baked in a kiln, where diffusion processes cause the green body to shrink. The pores in the object close up, resulting in a denser, stronger product. The firing is done at a temperature below the melting point of the ceramic. There is virtually always some porosity left, but the real advantage of this method is that the green body can be produced in any way imaginable, and still be sintered. This makes it a very versatile route.

Related Topics:
Sintering - Diffusion - Porosity

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There are thousands of possible refinements of this process. Some of the most common involve pressing the green body to give the densification a head start and reduce the sintering time needed. Sometimes organic binders such as polyvinyl alcohol are added to hold the green body together; these burn out during the firing (at 200-350°C). Sometimes organic lubricants are added during pressing to increase densification. It is not uncommon to combine these, and add binders and lubricants to a powder, then press. (The formulation of these organic chemical additives is an art in itself. This is particularly important in the manufacture of high performance ceramics such as those used by the billions for electronics, in capacitors, inductors, sensors, etc. The specialized formulations most commonly used in electronics are detailed in the book "Tape Casting," by R.E. Mistler, et al., Amer. Ceramic Soc. , 2000.) A comprehensive book on the subject, for mechanical as well as electronics applications, is "Organic Additives and Ceramic Processing," by D. J. Shanefield, Kluwer Publishers , 1996.

Related Topics:
Binders - Polyvinyl alcohol - Lubricant - Electronics - Capacitor - Inductor - Sensor

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A slurry can be used in place of a powder, and then cast into a desired shape, dried and then sintered. Indeed, traditional pottery is done with this type of method, using a plastic mixture worked with the hands.

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If a mixture of different materials is used together in a ceramic, the sintering temperature is sometimes above the melting point of one minor component - a liquid phase sintering. This results in shorter sintering times compared to solid state sintering.

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