Ceramics and Composites Processing Methods E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 1031

Veröffentlichungsjahr: 2012

Beschreibung

Examines the latest processing and fabrication methods There is increasing interest in the application of advanced ceramic materials in diverse areas such as transportation, energy, environmental protection and remediation, communications, health, and aerospace. This book guides readers through a broad selection of key processing techniques for ceramics and their composites, enabling them to manufacture ceramic products and components with the properties needed for various industrial applications. With chapters contributed by internationally recognized experts in the field of ceramics, the book includes traditional fabrication routes as well as new and emerging approaches in order to meet the increasing demand for more reliable ceramic materials. Ceramics and Composites Processing Methods is divided into three sections: * Densification, covering the fundamentals and practice of sintering, pulsed electric current sintering, and viscous phase silicate processing * Chemical Methods, examining colloidal methods, sol-gel, gel casting, polymer processing, chemical vapor deposition, chemical vapor infiltration, reactive melt infiltration, and combustion synthesis * Physical Methods, including directional solidification, solid free-form fabrication, microwave processing, electrophoretic deposition, and plasma spraying Each chapter focuses on a particular processing method or approach. Collectively, these chapters offer readers comprehensive, state-of-the-science information on the many approaches, techniques, and methods for the processing and fabrication of advanced ceramics and ceramic composites. With its coverage of the latest processing methods, Ceramics and Composites Processing Methods is recommended for researchers and students in ceramics, materials science, structural materials, biomedical engineering, and nanotechnology.

Leseprobe

Table of Contents

Cover

Title page

Copyright page

PREFACE

CONTRIBUTORS

PART I: DENSIFICATION

1 SINTERING: FUNDAMENTALS AND PRACTICE

1.1 INTRODUCTORY OVERVIEW

1.2 PHYSICAL DESCRIPTION

1.3 VISCOUS SINTERING

1.4 SOLID-STATE SINTERING

1.5 LPS

1.6 DENSIFICATION AND DEFORMATION IN CONSTRAINED SINTERING

1.7 MICROSTRUCTURE-BASED MODELS

1.8 STRESS-ASSISTED SINTERING

1.9 FIELD-ASSISTED SINTERING (FAST)

1.10 SINTERING PRACTICE

1.11 SUMMARY

ACKNOWLEDGMENT

2 THE ROLE OF THE ELECTRIC CURRENT AND FIELD DURING PULSED ELECTRIC CURRENT SINTERING

2.1 INTRODUCTION

2.2 GRAIN GROWTH DURING SINTERING

2.3 MASS TRANSPORT DURING SINTERING PROCESSES

2.4 MACROSCOPIC PECS EFFECTS

2.5 MICROSCOPIC PECS EFFECTS

2.6 CONCLUSIONS AND FUTURE PROSPECTS

ACKNOWLEDGMENTS

3 VISCOUS-PHASE SILICATE PROCESSING

3.1 INTRODUCTION

3.2 SURFACE NUCLEATION

3.3 OVERALL CRYSTALLIZATION OF GLASS POWDERS

3.4 VISCOUS SINTERING

3.5 VISCOUS SINTER RETARDATION

3.6 APPLICATIONS AND PROCESSES

ACKNOWLEDGMENTS

ABBREVIATIONS

PART II: CHEMICAL METHODS

4 COLLOIDAL METHODS

4.1 INTRODUCTION

4.2 INTRODUCTION TO CERAMIC PROCESSING

4.3 ADDITIVES FOR CERAMIC PROCESSING

4.4 INTRODUCTION TO COLLOIDAL SCIENCE

4.5 RHEOLOGY OF CERAMIC SUSPENSIONS

4.6 SHAPING

4.7 CONCLUDING REMARKS

5 PROCESSING AND APPLICATIONS OF SOL–GEL GLASS

5.1 INTRODUCTION AND BACKGROUND

5.2 METHOD/TECHNIQUE/APPROACH

5.3 APPLICATIONS

5.4 GENERAL DISCUSSION

5.5 CONCLUDING REMARKS AND FUTURE DIRECTIONS

ACKNOWLEDGMENTS

6 GELCASTING OF CERAMIC BODIES

6.1 INTRODUCTION AND BACKGROUND

6.2 GEL-CASTING SYSTEMS

6.3 THE GEL-CASTING PROCESS: CASTING THROUGH SINTERING

6.4 APPLICATIONS IN PROCESSING/FABRICATION OF GELCAST CERAMICS

6.5 CHALLENGES AND OPPORTUNITIES IN GELCASTING

6.6 FINAL REMARKS

ACKNOWLEDGMENTS

7 POLYMER PROCESSING OF CERAMICS

7.1 INTRODUCTION

7.2 SILICON-CONTAINING PRECERAMIC POLYMERS: SYNTHESIS, CROSS-LINKING, AND CERAMIZATION

7.3 PDC MONOLITHS: FILLER-CONTROLLED PYROLYSIS

7.4 PDC FIBERS

7.5 PDC COATINGS AND MEMBRANES

7.6 PDC FOAMS

7.7 MICROFABRICATION OF PDC-BASED COMPONENTS FOR MICROELECTROMECHANICAL SYSTEMS (MEMS) APPLICATIONS

7.8 NONCONVENTIONAL PROCESSING TECHNIQUES

7.9 CONCLUSION

ACKNOWLEDGMENTS

8 CHEMICAL VAPOR DEPOSITION OF STRUCTURAL CERAMICS AND COMPOSITES

8.1 INTRODUCTION

8.2 CVD OF NONOXIDE STRUCTURAL CERAMICS AND COMPOSITES

8.3 CVD OF OXIDE STRUCTURAL CERAMICS AND COMPOSITES

8.4 CONCLUDING REMARKS AND FUTURE DIRECTIONS

9 CVI PROCESSING OF CERAMIC MATRIX COMPOSITES

9.1 INTRODUCTION AND BACKGROUND

9.2 DETAILED DESCRIPTION OF THE CVI METHOD

9.3 APPLICATIONS IN PROCESSING/FABRICATION OF CERAMICS AND COMPOSITES

9.4 GENERAL DISCUSSION

9.5 CONCLUDING REMARKS AND FUTURE DIRECTIONS

10 REACTIVE MELT-INFILTRATION PROCESSING OF FIBER-REINFORCED CERAMIC MATRIX COMPOSITES

10.1 INTRODUCTION

10.2 RMI

10.3 PROCESS MODELING

10.4 MICROSTRUCTURE AND PROPERTIES OF MELT-INFILTRATED COMPOSITES

10.5 APPLICATIONS

10.6 CONCLUSIONS AND FUTURE DIRECTIONS

11 COMBUSTION SYNTHESIS: AN UPDATE

11.1 INTRODUCTION

11.2 THEORETICAL CONSIDERATIONS

11.3 ELECTROMAGNETIC FIELD CS

11.4 GRAVITY-ASSISTED CS

11.5 CONCLUDING REMARKS

ACKNOWLEDGMENTS

PART III: PHYSICAL METHODS

12 DIRECTIONAL SOLIDIFICATION

12.1 INTRODUCTION

12.2 BACKGROUND

12.3 FABRICATION METHODS

12.4 CERAMIC EUTECTIC SYSTEMS

12.5 APPLICATIONS OF CERAMIC EUTECTICS

12.6 CONCLUSIONS AND FINAL REMARKS

ACKNOWLEDGMENTS

13 SOLID FREE-FORM FABRICATION OF 3-D CERAMIC STRUCTURES

13.1 INTRODUCTION

13.2 CAD

13.3 COMPONENT DEPOSITION AND POSTPROCESSING

13.4 CONCLUSIONS

14 MICROWAVE PROCESSING OF CERAMIC AND CERAMIC MATRIX COMPOSITES

14.1 PRINCIPLES OF DIELECTRIC HEATING

14.2 MICROWAVE APPLICATORS

14.3 MICROWAVE PROCESSING OF CERAMICS AND COMPOSITES

14.4 ADVANTAGES/DISADVANTAGES OF MICROWAVE PROCESSING OF CERAMICS AND COMPOSITES

14.5 CONCLUDING REMARKS: SCALE-UP AND INDUSTRIAL PERSPECTIVES

15 ELECTROPHORETIC DEPOSITION

15.1 INTRODUCTION

15.2 MECHANISMS AND FUNDAMENTALS OF EPD

15.3 APPLICATIONS OF EPD

15.4 FUTURE DEVELOPMENTS

15.5 CONCLUSIONS

ACKNOWLEDGMENTS

16 PROCESSING OF CERAMICS BY PLASMA SPRAYING

16.1 INTRODUCTION AND BACKGROUND

16.2 DETAILED DESCRIPTION OF THE TECHNIQUE

16.3 APPLICATIONS IN PROCESSING/FABRICATION OF CERAMICS AND COMPOSITES

16.4 GENERAL DISCUSSION

16.5 CONCLUDING REMARKS AND FUTURE DIRECTIONS

ACKNOWLEDGMENTS

Index

Copyright © 2012 by The American Ceramic Society. All rights reserved.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey.

Published simultaneously in Canada.

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Library of Congress Cataloging-in-Publication Data:

Ceramics and composites processing methods / edited by Narottam P. Bansal, Aldo R. Boccaccini.

p. cm.

Includes bibliographical references and index.

 ISBN 978-0-470-55344-2

 1. Ceramic materials. 2. Composite materials. I. Bansal, Narottam P. II. Boccaccini, A. R. (Aldo R.)

 TA455.C43C469 2012

 666–dc23

2011041443

PREFACE

NAROTTAM P. BANSAL AND ALDO R. BOCCACCINI

There is increasing interest in the application of advanced ceramic materials in areas as diverse as transport, energy, environment, communications, health, and aerospace. The increasing scope for the utilization of ceramic materials in a wide range of applications makes the in-depth understanding of processing technologies more necessary than ever before, which can lead to ceramic products and components having the desired properties and performance in-service. This book was conceived to offer in a single volume a broad selection of key processing techniques for ceramics and their composites incorporating different chapters written by internationally recognized experts in their respective fields. This book includes traditional fabrication routes as well as advanced approaches, which are being developed to tackle the increasing demand for more reliable ceramic materials.

This book is divided into three sections: “Densification,” “Chemical Methods,” and “Physical Methods.” The fundamentals and practice of sintering, pulsed electric current sintering and viscous phase silicate processing are covered in the first section on Densification. The Chemical Methods section consists of eight chapters covering colloidal methods, sol–gel, gel casting, polymer processing, chemical vapor deposition, chemical vapor infiltration, reactive melt infiltration, and combustion synthesis. The chapters on directional solidification, solid free-form fabrication, microwave processing, electrophoretic deposition, and plasma spraying are included under Physical Methods. Each chapter is focused on a particular processing method/approach based on the expertise of the respective authors who are specialists and internationally renowned researchers from various countries. The readers of this book will thus be able to find at one place state-of-the-art and comprehensive information on various approaches, techniques, and methods for processing and fabrication of advanced ceramics and ceramic composites.

This book is directed toward scientists, engineers, technologists, and researchers working in the industry, national research laboratories, and academia with interest in traditional and advanced ceramics as well as ceramic composites. Senior undergraduates as well as graduate students pursuing a degree in ceramics or materials science and engineering will also find this book useful. All the chapters are stand-alone pieces. Some duplication, especially in the introductory sections, and nonuniformity of symbols and nomenclature may be present.

This book is the result of truly an international effort with contributions by authors from 10 different countries. The editors are grateful to all the authors for their valuable contributions as well as their cooperation, which led to the timely publication of this volume. Thanks are due to Ms. Anita Lekhwani, Senior Acquisitions Editor for Chemistry, Biotechnology, and Materials Science, John Wiley & Sons, Inc., for her help, cooperation, and understanding through the entire publication process of this book.

Narottam P. Bansal

Cleveland, Ohio

Aldo R. Boccaccini

Erlangen, Germany

CONTRIBUTORS

Narottam P. Bansal, NASA Glenn Research Center, Structures and Materials Division, Cleveland, OH

Laxmidhar Besra, Institute of Minerals and Materials Technology (IMMT), Bhubaneswar, Orissa, India

S. B. Bhaduri, Departments of MIME and Surgery, University of Toledo, Toledo, OH

Aldo R. Boccaccini, Institute of Biomaterials, University of Erlangen-Nuremberg, Erlangen, Germany

Rajendra K. Bordia, Department of Materials Science and Engineering, University of Washington, Seattle, WA

Héctor Camacho-Montes, Basic Science Department, Institute for Engineering and Technology (UACJ), Cd. Juarez, Chih., Mexico

Maria Cannio, Department of Materials and Environmental Engineering, University of Modena and Reggio Emilia, Modena, Italy

Bruce Dunn, Department of Materials Science and Engineering, University of California at Los Angeles, Los Angeles, CA

Katherine T. Faber, Department of Materials Science and Engineering, Robert R. McCormick School of Engineering and Applied Science, Northwestern University, Evanston, IL

Takashi Goto, Institute for Materials Research, Tohoku University, Japan

S. G. Huang, K.U.Leuven, Department of Metallurgy and Materials Engineering (MTM), Heverlee, Belgium

Emanuel Ionescu, Technische Universität Darmstadt, Institut für Materialwissenschaft, Darmstadt, Germany

Esther H. Lan, Department of Materials Science and Engineering, University of California at Los Angeles, Los Angeles, CA

A. Laptev, K.U.Leuven, Department of Metallurgy and Materials Engineering (MTM), Heverlee, Belgium and Donbass State Engineering Academy, Department of Mechanical Engineering, Kramatorsk, Ukraine

Andrea Lazzeri, Department of Chemical Engineering, Industrial Chemistry and Materials Science, University of Pisa, Pisa, Italy

Cristina Leonelli, Department of Materials and Environmental Engineering, University of Modena and Reggio Emilia, Modena, Italy

Jennifer A. Lewis, Department of Materials Science and Engineering, University of Illinois, Urbana, IL

Rodrigo Moreno, Instituto de Cerámica y Vidrio, CSIC, Madrid, Spain

Ralf Müller, BAM Federal Institute for Materials Research and Testing, Berlin, FRG

Saša Novak, Department for Nanostructured Materials, Jožef Stefan Institute, Ljubljana, Slovenia

Víctor M. Orera, Instituto de Ciencia de Materiales de Aragón, CSIC-Universidad de Zaragoza, Facultad de Ciencias, Zaragoza, Spain

José I. Peña, Instituto de Ciencia de Materiales de Aragón, CSIC-Universidad de Zaragoza, Facultad de Ciencias, Zaragoza, Spain

Stefan Reinsch, BAM Federal Institute for Materials Research and Testing, Berlin, FRG

Ralf Riedel, Technische Universität Darmstadt, Institut für Materialwissenschaft, Darmstadt, Germany

Noah O. Shanti, Department of Materials Science and Engineering, Robert R. McCormick School of Engineering and Applied Science, Northwestern University, Evanston, IL

James E. Smay, School of Chemical Engineering, Oklahoma State University, Stillwater, OK

O. Van der Biest, K.U. Leuven, Department of Metallurgy and Materials Engineering (MTM), Heverlee, Belgium

K. Vanmeensel, K.U. Leuven, Department of Metallurgy and Materials Engineering (MTM), Heverlee, Belgium

Robert Vaßen, IEF-1, Forschungszentrum Jülich GmbH, 52425 Jülich, Germany

Paolo Veronesi, Department of Materials and Environmental Engineering, University of Modena and Reggio Emilia, Modena, Italy

J. Vleugels, K.U. Leuven, Department of Metallurgy and Materials Engineering (MTM), Heverlee, Belgium

Natalie Wali, Honeywell Aerospace, Phoenix, AZ

J.-M. Yang, Department of Materials Science and Engineering, University of California, Los Angeles, CA

PART I DENSIFICATION

1

SINTERING: FUNDAMENTALS AND PRACTICE

RAJENDRA K. BORDIA AND HÉCTOR CAMACHO-MONTES

1.1 INTRODUCTORY OVERVIEW

Although sintering has been practiced for thousands of years [1], significant advances in scientifically understanding the phenomenon have been made only in the last six decades. In a broad sense, sintering is the extension of the contact area between powder particles by the transport of material to or around pores under appropriate conditions of temperature, pressure, and environment [2]. The goal of the sintering practice, in general, is to produce a coherent body (from rather fragile green bodies) with controlled microstructure, in some cases with controlled porosity [3, 4]. The emphasis of sintering theory, modeling, and analysis is to predict the path of the microstructural development and its dependence on controllable parameters (e.g., temperature, time, environment, and particle size).

Numerous attempts have been made to model the sintering phenomenon, and many experimental studies have been conducted to evaluate the theories and also the important effects of process parameters. Some of the important aspects of the sintering theory and practice are reviewed in this chapter. Readers are referred to many excellent reviews, monographs, and textbooks for a more in-depth study [5–16]. Section 1.2 deals with the physical description of the process, viz., the stages of sintering and the thermodynamic driving force for sintering. The next three sections deal with the classical models for sintering (Section 1.3 for viscous sintering, Section 1.4 for solid-state sintering, and Section 1.5 for liquid-phase sintering [LPS]). Section 1.6 focuses on constrained sintering and Section 1.7 summarizes the advanced kinetic and microstructural evolution models. Section 1.8 focuses on the effect of external stresses on sintering. Section 1.9 focuses on the newly discovered significant effect of external fields on sintering. Finally, in Section 1.10, some of the important aspects of sintering practice are presented.

1.2 PHYSICAL DESCRIPTION

1.2.1 The Stages of Sintering

It is widely accepted to divide the overall sintering process in three sequential stages. In general, these stages are not discrete, and usually, there is a considerable overlap between two consecutives ones. These stages are defined according to the morphology of the grains and the porosity.

The first stage or the initial stage of sintering corresponds to the situation when necks are forming and growing between particles, and they remain distinct as shown schematically in Figure 1.1a,b. At the end of this stage, the contact area increases by up to 20% with only a small densification (interparticle penetration). Consequently, the compact densification is only a few percent. A marked decrease in the specific surface area of the compact occurs due to surface smoothing. The grain boundaries between the particles remain in the contact plane due to the tensile stresses resulting from the surface tension.

Figure 1.1. Illustrations of the stage of sintering: (a) initial stage—spheres in tangential contact; (b) near the end of the initial stage, the neck between particles starts to grow; (c) intermediate stages with continuous pore channels at grain edges and large contact area between grains; (d) final stage, tetrahedral pores at four grain intersections.

Reprinted with permission from Coble [17], copyright 1961, American Institute of Physics.

The second stage, or the intermediate stage of sintering, is characterized by a more or less continuous network of pore channels along the grain edges (Fig. 1.1c). During this stage, the pore channel shrinks and grains grow. Most of the densification, and also the growth in the contact area, occurs during this stage.

The pore channels continue to shrink until they pinch off and form isolated spheriodized pores (Fig. 1.1d). This marks the beginning of the third or the final stage of densification. In this stage, the pore volume fraction asymptotically approaches zero. In some cases, these closed pores may trap gases, making their elimination difficult.

1.2.2 The Thermodynamic Driving Force

There is broad agreement in the literature regarding the driving force for sintering. The starting particulate configuration is far from the equilibrium state, and the driving force comes from the excess free energy. Hence, the reduction of the free energy is taken as the sintering driving force.

This excess free energy exits in the powder compact due to the large surface area and defects. In the classical sintering literature, emphasis has been on the excess free energy due to surfaces. As sintering proceeds, porosity decreases, leading to a reduction of the solid–vapor interfacial area. The solid–vapor interfaces are replaced by solid–solid interfaces. When grain growth occurs, the solid–solid interfacial area also decreases. Thermodynamically, the change in free energy can be written as

(1.1)

where δGsystem is the change in the free energy of the sintering system, γSV is the energy per unit area of the solid–vapor interface, and γSS is the energy/area of the solid–solid interface. In this equation, during sintering, the first term is negative since the area of the solid–vapor interface (ASV) decreases. Considering that grain growth implies a decrease of the solid–solid interface, the second term may be either positive or negative since grain boundary area (ASS) may increase or decrease depending on how fast grain growth is going on. If grain growth does not occur, the second term is always positive as grain contacts grow during sintering. As long as is negative, a driving force for sintering exits.