MTEN 303: Introduction To Materials Processing: (2 Credits)
MTEN 303: Introduction To Materials Processing: (2 Credits)
MTEN 303: Introduction To Materials Processing: (2 Credits)
INTRODUCTION TO MATERIALS
PROCESSING (2 credits)
3
Historical Development of Materials and
Manufacturing Process
IDENTIFICATION -- SELECTION -- PROCESSING -- PERFORMANCE
Material Types & Properties
• Metals:
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.
12
• Transmittance:
-- Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.
polycrystal: polycrystal:
single crystal low porosity high porosity
13
SUMMARY
Course Goals:
• Use the right material for the job.
15
Which Operations are described here?
The ‘Hows’?
What are my Expectations?
•Students must attend at least 70% of all classes with the expectation that students only miss
classes due to illness or unforeseen circumstances
•Students must read through lecture notes/slides prior to class
•During class, students are expected to engage actively in class discussions
•Students should work through lecture, tutorial and textbook questions
•Students should read through the relevant chapters of the prescribed textbook.
•Students should complete all assessment tasks and submit them on time.
ed C McGraw-Hill Company,
Thermal Conductivity
Rethwisch 3e. (Courtesy
of Lockheed
Missiles and Space
Company, Inc.) 300
(W/m-K)
200
100
0
0 10 20 30 40
Composition (wt% Zinc)
Adapted from Adapted from Fig. 19.4, Callister & Rethwisch
Fig. 19.4W, Callister 8e. (Fig. 19.4 is adapted from Metals Handbook:
6e. (Courtesy of Properties and Selection: Nonferrous alloys and
Lockheed Aerospace Pure Metals, Vol. 2, 9th ed., H. Baker,
Ceramics Systems, (Managing Editor), American Society for Metals,
Sunnyvale, CA) 1979, p. 315.)
(Note: "W" denotes fig.
100 mm is on CD-ROM.) 35
Property Enhancing - MAGNETIC
• Magnetic Storage: • Magnetic Permeability
-- Recording medium
vs. Composition:
is magnetized by
-- Adding 3 atomic % Si makes
recording head.
Fe a better recording medium!
Magnetization
Fe+3%Si
Fe
Magnetic Field
36
SUMMARY
SUMMARY Cont’d
Processing of Ceramics
• Issues to address:
Polymorphism
1. Purity strongly influences high-temperature properties such as strength, toughness,
oxidation resistance, etc. and also electrical properties
2. Particle Size:
Sintering temperatures and time for densification, eventually affects
the strength
3. Reactivity : Surface free energy is the
driving force. Very small particles have high
surface energies, and thus strong thermodynamical
drive to bond.
Powder/Particulate Pressing
POWDER PREPARATION & SIZING
53
Mechanical Sizing: Screening
• Screening is a sorting method of particle sizing
• Screen sizes are classified according to openings per inch,
referred to us MESH SIZES.
• Powder designated -100 mesh +150 mesh consists of particle
size range that was small enough to go through 100 mesh but
too large for 150 mesh.
• Form of liners
• Particles size distribution
• Mill Size or Volume
• %tage of Solids in Mill Volume
• more in, more out? What Do
you think
*Wet Milling vrs Dry Milling?
Which is more effective? Yes /No,
Why?
Advantages of Wet Milling
1. Low power required
2. No dust problems
3. Higher rotational speeds
4. Can wet screen through fine screen
5. Good homogenization
6. Smaller particles than dry
7. Narrow particle size distribution than dry
8. Compatible with spray drying and casting
Routes to thick films, Robert Dorey, in Ceramic Thick Films for MEMS and Microdevices, 2012
Pigments, Fillers, and Extenders, Laurence W. McKeen, in Fluorinated Coatings and Finishes Handbook, 2006
End of Lecture for today
a. Derive an expression for the critical size beyond which the crystal is stable
during homogeneous nucleation.
The S(Ө) is a function only of Ө (i.e., the shape of the nucleus), with value between zero and
unity
Growth
The growth step in a phase transformation begins once an embryo has exceeded
the critical size, r* and becomes a stable nucleus.
Powder Pressing:
used for both clay and non-clay compositions.
Figure 19.4 –(from Asby ) Hot-isostatic pressing (“HIPing”): the powder, in a thin steel pre-
form, is heated & compressed by high-pressure argon
Hydro-plasticity of Clay
• Clay is inexpensive Shear
• When water is added to clay
-- water molecules fit in between
layered sheets charge
-- reduces degree of van der Waals neutral
bonding
-- when external forces applied – clay
particles free to move past one weak van
another – becomes hydroplastic der Waals
bonding
• Structure of Kaolinite Clay: charge Si
4+
Adapted from Fig. 12.14, Callister & Rethwisch 8e. (Fig. 3+
12.14 is adapted from W.E. Hauth, "Crystal Chemistry of neutral Al
Ceramics", American Ceramic Society Bulletin, Vol. 30 -
(4), 1951, p. 140.) OH
2-
O
Shear 114
Ceramic Fabrication Methods (ii)
Slip Casting
micrograph of porcelain
Si02 particle
• Firing: (quartz)
-- heat treatment between glass formed
900-1400ºC around
the particle
-- vitrification: liquid glass forms
from clay and flux – flows
between SiO2 particles. (Flux 70 mm
Adapted from Fig. 13.14, Callister & Rethwisch 8e.
lowers melting temperature). (Fig. 13.14 is courtesy H.G. Brinkies, Swinburne
University of Technology, Hawthorn Campus,
Hawthorn, Victoria, Australia.) 117
Sintering
Sintering occurs during firing of a piece that has
been powder pressed
-- powder particles coalesce and reduction of pore size
122
Filtration Mechanisms
• Size Exclusion: size of pores are usually 0.3- Sedimentation: Removes particulate suspended
2.5microns, thus capable of restricting small matter of finer sizes than the pore openings by
bacteria(Lantagne,2001) precipitation upon the surface of the clay
material.
Diffusion: random motion of particles caused
by collision with surrounding molecules, which
could eventually lead to adsorption by filter
material.
Adsorption: removing finely divided suspended
matter as well as colloidal and molecular
Types of pores (Xialong 2005)
dissolved impurities.
123
Bacteria & De-activation
124
Summary
• Categories of ceramics:
-- glasses (Assignment 1)
-- clay products
-- refractories -- cements
-- advanced ceramics
• Issues to address:
• Overview – Glass Ceramics
• Glasses:
-- do not crystallize
-- change in slope in spec. vol. curve at
glass transition temperature, Tg
-- transparent - no grain boundaries to
scatter light
Glass Viscosity vrs. Temperature
• viscosity, h relates shear stress () and velocity gradient (dv/dy):
• Viscosity decreases with Temp
• Borosilicate (Pyrex):
81% SiO213% B2O3, 3.5% Na2O,
2.5% Al2O3
• Silica Glass ( Vycor)
96% SiO2, 4% B2O3
Adapted from Fig. 13.7, Callister & Rethwisch 8e. (Fig. 13.7 is from E.B. Shand, Engineering Glass, Modern Materials, Vol. 6,
Academic Press, New York, 1968, p. 262.)
Key Points and definitions relating Glass Processing
What is the difference between Glass-ceramics may not be transparent
Glass and Glass Ceramics? Ans: because they are polycrystalline. Light will be
Crystallized glass is glass ceramics scattered at grain boundaries in polycrystalline
materials if the index of refraction is
anisotropic,
and when those grains adjacent to the
boundary have different crystallographic
orientations.
146
• Glass Toughening: The strength of a glass piece may be
enhanced by intentionally inducing compressive residual surface
stresses. This can be accomplished by a heat treatment procedure
called thermal tempering.
-- puts surface of glass part into compression
-- suppresses growth of cracks from surface scratches.
-- sequence:
before cooling initial cooling at room temp.
cooler compression
hot hot tension
cooler compression
The binary system SiO2-Al2O3 is an important one since most ceramics have these two constituents. A
narrow phase field shown on the above figure is the range over which, intermediate compound, mullite, is
formed. Mullite is known to be a refractory ceramic material. For the above system (a) what is the
maximum temperature that is possible without the formation of liquid phase (b) What composition range
will this maximum temperature be achieved?
2.
(a)With the aid of a plot, briefly describe how glass is produced.
(b) Briefly describe the following terms: Annealing point, Glass transition temperature,
Glass toughening process, Working point for glass, supercooled liquid
(c) How does the thickness of a glassware affects the magnitude of thermal stresses that
may be introduced? And why?
Homework:
End of Lecture(s) on
Glass production
Glass forming processes
Heat Treatment techniques