Ceramics

Ceramics
Greek word “keramikos” – burnt stuff –
normally achieved through high-
temperature heat treatment called firing

Others also say it came from the word

“keramos” – potters clay
Ceramic
When it comes to composition, ceramics are…

Compounds consisting of metals,

covalently bonded to oxygen,
nitrogen, or carbon.
Ceramic
When it comes to application, ceramics are…

Used for high-temperature

applications, abrasives, glasses, and
pottery.
Ceramic
When it comes to properties, ceramics are…

Hard, brittle, strong, non-

conducting, corrosion-resistant and
heat-resistant materials.
Ceramic
When it comes to processing, ceramics are…

made by shaping and firing an

inorganic, non-metallic material such
as clay and other compounds
consisting of metals and non-metals.
The
Firing
Process
of
Making
Pottery
Ceramics
Types of Ceramics

1. Traditional Ceramics

2. Modern or Advanced Ceramics

Traditional Ceramics
The primary raw material is
clay, quartz and sand.

1. Earthenware
2. Stoneware
3. Porcelain
Earthenware
• ceramic ware made of
slightly porous opaque clay
fired at low heat
• Fired below 1,200 Celcius
• Basic earthenware is
terracotta clay
• Flower pots, tiles, bricks,
surface, waste water pipes

Terracota clay
Stoneware
• Harder and denser than
earthenware and fired at
higher temperatures
• Between 2150 – 2330 Celcius
• Durable, nonporous, and
robust.
• Has vitreous material added
Porcelain
• Made of kaolin (china clay),
kaolin, feldspar, quartz and
clay
• Nonporous, white, translucent,
hard, shiny finish
• Decorated, making it more
expensive than stoneware
Advanced Ceramics
Made using synthetic
powders, such as
aluminum oxide, silicon
carbide, silicon nitride,
and others.
Microelectromechanical Systems Application: Sensors

Application:

organic solar cells, long-life batteries, high

temperature, superconductors, molecular
magnets, bio material (artificial skin,
engineered tissues), body armor, and
structural applications
Nanocarbons
New desalination
process uses carbon
nanotubes to filter salt
from seawater
Japanese
Company
Plans to
Build Space
Elevator by
2050 made
of
nanocarbon
materials
Processing of
Ceramics
Processing of Traditional Ceramics
Two Types of Shaping Techniques
Slip Casting
Hydro plastic Forming

Common in making: brick, pipe, ceramic Common in making sanitary lavatory ware,
blocks, and tiles art objects, ceramic tubes
Properties of
Ceramics
Properties
• Great hardness and strength
• Chemical stability/chemical inertness (corrosion resistant, unreactive
with another chemical)
• High-temperature strength (strength retention at very high
temperatures)
• High melting points (they’re heat resistant)
• Low electrical and thermal conductivity (they’re good insulators)
• good optical properties
 Applications and
Processing of Ceramics
Glasses
containing other oxides, notably CaO, Na2O, K2O, and
Al2O3,

Applications:
containers, lenses, and
fiberglass, soda lime
glass (SiO2, Na2O, CaO)
Soda lime glass
Main Types of Glasses
Annealed Glass

- it is the simplest and basic

form of glass. It is also known
as float glass since it is
formed from the annealing
stage of the float process.
Application: glass tabletops, cabinet
doors, basement windows, jealousy
glass
Main Types of Glasses
Semi-Strengthened Glass
- it is a semi-tough glass that is
used to provide extra toughness
to resist thermal stress or wind
pressure.
- Twice as tough as annealed
glass
Application: glass in doors, tub
and shower enclosures, exterior
windows in buildings, curtain
walls,
Main Types of Glasses
Toughened Glass

- known as tempered glass and is

tough in nature.
- five times stronger and safer
than annealed or untreated
glass.

Application: mobile screen guards,

glass doors, shop windows, lifts &
modern elevators
Main Types of Glasses
Laminated Glass
- common type of glass which
features two sheets of glass
with a plastic interlayer
separating them.
- Used for safety and security
purposes, for all kinds of
architectural and automotive
projects
Application: car windshield,
skylights, curtain walls
 Glasses-Ceramics
Transform from a non-crystalline state into one that is
crystalline by the proper high-temperature heat treatment
- crystallization

Application: ovenware,
tableware, oven windows, and
range tops, electrical insulators
for printed circuit boards
Clay Product
widely used ceramic raw materials, very amenable to
shaping.

Two classifications:
• Structural clay products – bricks, tiles, sewer pipes
• Whitewares – become white after high-temperature
firing.
Ex. Porcelain, Sanitary ware, tableware,
 Structural Clay
Application

Clay Bricks Roof Bricks

Clay Floor Tiles

 Whitewares

Made of kaolin clay

Porcelain
Sanitary Ware

Pottery China Ware Tableware

Refractories
• capacity to withstand high temperatures without
melting
• remain unreactive and inert when exposed to severe
environments.
• provide thermal insulation

Application: furnace linings for metal refining, glass

manufacturing, metallurgical heat treatment, and power
generation
 Examples of Refractories Application

Furnace in glassblowing
Crucible in metal casting
Abrasives
• used to wear, grind, or cut away other material, which
necessarily is softer
• Hard and has high degree of toughness

Examples: Diamonds, Grinding wheels, sandpaper

 Examples of Abrasives

Grinding Wheels

Sandpaper
Cements
• when mixed with water, they form a paste that
subsequently sets and hardens.
• Cement, plaster of Paris, and limestones
• Portland Cement - hydraulic cement
• Calcination
- process grinding and intimately mixing clay
and lime bearing minerals in the proper
proportions and then heating the mixture to
about 1400C
 Carbon
important in many commercial sectors, including some
cutting-edge technologies.
Two allotropic forms of Carbon

Application: Application:
pencils, machining of
lubricants, batteries, non-ferrous
brushes for electric abrasive
motors, brake linings materials, hard
ceramics,
cutting tool

Graphite Diamond
 Advanced Ceramics
• Produced using highly refined and purified powders -
alumina, aluminum nitride, zirconia, silicon carbide,
silicon nitride, and titania-based materials.
• When formed and sintered properly these powders result in
products that are
✓ very strong
✓ very high in abrasion resistance
✓ can withstand high-use temperatures
✓ very good chemical resistance, and
✓ very stable.
Advanced
Ceramics

TODAY
Application:
Electronics parts,
telecommunications,
manufacturing,
transportation,
medicine, defense
and space
exploration.
Recyclability of Ceramics

Ceramics can be crushed and recycled into a range of useful

products, diverting waste from landfill and decreasing
emissions and toxic outputs used in the production process.
Polymers
Polymers
 Polymers
A polymer is a long-chain molecule that is
composed of a large number of repeating units
called monomers - a molecule that can combine
with another molecule to form a polymer.
Types of Polymers

All those are found in nature, in Man-made polymers,

plants, animals, or even prepared/processed in a
humans. laboratory or industry from
chemical substance
 Natural Polymers

Silkworm Plant DNA

cocoons Fibers

Others are cellulose, protein, gelatin, starch, natural rubber

Other type: Biopolymers
Capsule
• They’re biodegradable
Coatings polymers derived from
living organisms, such as
plants and microbes,
• Can be degraded and
decayed by microorganisms
like bacteria.
Surgical
Bandage
Synthetic Polymers

Plastics Synthetic Synthetic

Fibers Rubbers
Types of Synthetic Polymers

Plastic that requires heat and pressure to mold into

Plastic that softens when heated with or without
shape. Cannot be softened once they have set and
pressure. Easy to mold or shape.
hardened.
Examples of Thermoplastics
Examples of Thermoplastics
Examples of Thermosetting plastics

Bakelite (Phenolic Resin)

• first synthetic polymer
• Uses: telephone parts,
electrical switches, and
plugs, phonograph
records, buttons, handle
for cooker or frypan
Examples of Thermosetting plastics
 Types of Synthetic Polymers

Uses: ELASTOMERS
• rubber tires and
tubes for vehicles,
motorcycles,
bicycles, and
recreational
vehicles, rubber
gloves, matting,
toy balloons,
rubber bands,
adhesives, and
pencil erasers
Also called elastic polymer - any material exhibiting
elastic or rubber-like properties.
Properties of
Polymers
General Properties of Polymers
• Easy to mold
• Excellent surface finish can be obtained.
• Economical
• Low mechanical properties
• Poor temperature resistance
• Can be produced transparent or in different colors.
• Resistant to chemical & corrosion.
• Thermal and electrical insulators.
• Generally low density.
• Can be processed in various ways.
Recyclability
• Plastics are reheated and reshaped after mixed plastic waste
is sorted and cleaned.
• The waste or used polymers are repurposed in the form of
recycled polymer products.
• The general steps of polymer recycling are collection, sorting,
washing, resizing, identification and compounding.
• Note:
• Since thermoplastic polymers can be melted and reformed,
they are easily recycled. However, their properties do degrade
with each reuse. Thermosetting polymers are much more
difficult to recycle.
Composites
 Composite Material
Composite materials are formed by combining two or
more materials that have quite different properties.

When they are combined, they form a material that is

specialized to perform a certain function, for example,
to become stronger, lighter, or resistant to lightning.
Composites
• Wood is a natural composite of
cellulose fibers
• The most primitive manmade
composite materials were straw
and mud combined to form
bricks for building construction;
Composites

• Plywood is a commonly used

composite material.
• Another well-known
composite is concrete and
fiberglass.
Composition of Composites
Common Composite Materials
• Ceramic Matrix Composite
• Metal Matrix Composite Reinforced Concrete
• Glass Fibre Reinforced Concrete
• Translucent Concrete
• Engineered Wood
• Plywood
• Fiberglass
• Carbon Fiber Reinforced Polymer
• Sandwich Panel
Ceramic matrix composite

Ceramics such as aluminum oxide

and silicon carbide are embedded
with fibers for improved properties,
especially for high-temperature
applications. They are thermal shock
and fracture-resistant.

Uses: gas turbines in the aerospace

sector and fusion reaction walls in
the energy sector
Metal matrix composite

Mixtures of ceramics and metals,

such as cemented carbides,
aluminum, or magnesium reinforced
by strong, high-stiffness fibers.
They’re fire-resistant, high-strength,
resistant to wear and tear, and
lightweight.

Uses: transmission systems,

gearboxes, engine parts, tennis
rackets, bicycle frames
Reinforced Concrete

Reinforced concrete means

concrete that contains a
specific amount of
reinforcing material (steel bars). It is
always used when concrete has to
bear a large amount of weight. For
example in beams, columns,
footings, piers, slabs, etc
Glass Fiber Reinforced
Concrete

GFRC is a composite comprised of

Portland cement, fine aggregate,
water, acrylic co-polymer, and alkali-
resistant glass fiber reinforcement
with high zirconia content. They’re
lightweight, tough, and durable.

Uses: ornamental concrete (statues,

fountains), concrete countertops
(crack-free sinks), artificial rocks
Translucent Concrete

Translucent concrete is made by

combining two major materials; fine
concrete (with cement and
aggregates like sand) and optical
fibers. It has transmissive properties
due to embedded light optical
elements.
Uses: floorings and pavements, staircase,
desks, partition walls, doors, panels, and adds
to the beauty of the interior by illuminating the
area during day time.
Engineered Wood

This type of wood often utilizes

waste wood from sawmills and is
treated through chemical or heat
processes to produce wood that
meets size requirements that are
hard to find in nature. They’re
stronger and more durable.

Uses: home construction to

commercial buildings to industrial
products.
Ply Wood

Plywood is a material manufactured

from thin layers or "plies" of wood
veneer that are glued together with
adjacent layers having their wood
grain rotated up to 90 degrees to
one another.

Uses: partitions, floors, ceilings,

roofing, furnitures
Carbon Fiber Reinforced
Polymer

Composed of carbon fibers

embedded in a polymer resin
(polyester, nylon, and vinyl), in
which the carbon fibers function as
the reinforcement material and the
polymer resin functions as the
matrix to hold the fibers.

Uses: aircraft bodies, automobiles

bodies, body armor, and the sports
sector.
Fiberglass or Fiber
Reinforced Plastic

Fiberglass is a combination of
polyester resins and glass fibers
which creates a fiber-reinforced
plastic. They’re low maintenance, Fiberglass boat

anti-magnetic, fire resistant, good

electrical insulator, and
weatherproof.
Fiberglass tank

Uses: insulation, cladding, surface

coating, and roofing raw material, Insulation
Properties of
Composites
General Properties of Composites
• High Strength To Weight Ratio
• Light Weight
• Fire Resistance
• Electrical Properties
• Chemical And Weathering Resistance
• Design flexibility
• Translucency
• Low Thermal Conductivity
Recyclability of Composites
• Composite materials are difficult to recycle due
to the heterogeneous hybrid structure.
• Mechanical, thermal and chemical methods
could be applied for materials and/or energy
recovery.
• There are no commercial operations for
economically recycling composite materials.
Corrosion and
Degradation of
Materials
 Corrosion
Corrosion is the process of deterioration of
materials as a result of chemical (acids),
(electrochemical oxidation/dissolution of the
metal), or other reactions (environment).
 Corrosion
Corrosion is the process of deterioration of materials
as a result of chemical (acids), (electrochemical
oxidation/dissolution of the metal), or other reactions
(environment).

Rusting is a part of corrosion and is a chemical process that results

in the formation of red or orange coating on the surface of metals
and alloys. It occurs when a metal is exposed to air and moisture.
Corrosion on Metals

• A natural process, which

converts a refined
metal to a more
chemically-stable form,
such as its oxide,
hydroxide, or sulfide.
Causes of Corrosion Among
Metals
Metal corrodes when it reacts with another
substance such as:
• oxygen
• hydrogen
• an electrical current
• placed under too much stress causing the
material to crack.
Types of Corrosion

•Uniform Corrosion
•Atmospheric Corrosion
•Erosion Corrosion
•Selective Corrosion
•Pitting Corrosion
•Fretting Corrosion
Types of Corrosion

•Stress Corrosion
•Inter-granular Corrosion
•Corrosion Fatigue
•Galvanic Corrosion
•Water Line Corrosion
Uniform Corrosion
Uniform Corrosion is formed in a uniform
layer on the surface of the metals and
that is extended all over the surface of
the metal.

It is also known as the general types of

corrosion and these uniform corrosion
have a relatively low impact on the
performnce of the material.
Inter-granular Corrosion
Intergranular Corrosion occurs
along the grain boundaries.
It is caused when there is a
noticeable difference in reactivity
against impurities grains and
grain boundaries, also this
difference occurs due to heat
treatment, stainless steel, copper,
and defective weldings.
Stress Corrosion
This stress Corrosion occurs by the
combination of mechanical stress and
corrosive environment stresson the
surface of the materials,
and initially, small cracks are developed
lastly this cracks leads to the failure of
the whole structure,and the stress
corrosion is unpredictable in nature.
Also you can call an " SCC" as abreviated
form of Stress Corrosion Cracking.
Pitting Corrosion
Pitting Corrosion is form that rust pits or
holes on the metal surface and it is
localized form of corrosion. Corrosion is
hemispherical in shape.
Pitting Corrosion occurs in
aluminum, nickel alloys, steel and
etc.
Atmospheric Corrosion
Atmospheric Corrosion is wet
types of corrosion that is caused
by the action of the electrolyte, in
the rainy season atmosphere is
damp at that time electrolytes
trigger corrosion of the exposed
metal surface.
Erosion Corrosion
Erosion Corrosion is caused by
mechanical abrasion due to the
movement between corrosive fluids
and metal surface. Metal surface
gets damaged or deteriorated slowly
by the fast moving fluids. Also, the
erosion-corrosion has mostly seen
in metal tubes carrying moving
fluids in it.
Selective Corrosion
Selective types of corrosion
occurs in alloys where one of the
metal components is de-alloyed by
the corrosive environment, this
type of corrosion can be seen in
brass alloy pipes where zinc is
commonly used as another
component, and here zinc metal is
de-alloy.
Fretting Corrosion
Fretting is a combined action
of fretting as well as
corrosion at points where two
metal plates or surface make
contact by means of gnawing
action or rubbing action,
fretting corrosion is
sometimes known as chafing
corrosion.
This fretting Corrosion can be
seen in rivet joints, clamped
surfaces, and bolted
connections.
Corrosion Fatigue
Corrosion Fatigue by defined as
fatigue in a corrosive environment,
and also the aggresive environment
can be harmful to fatigue life of a
structure.
The surface of a material can be
loaded dynamically at that time
corrosion fatigue can be a serious
problem.
Corrosion Fatigue/Galvanic
Corrosion
This galvanic corrosion occurs
when different metals are
exposed to a corrosive
atmosphere, the metal which has
a higher alectrode electrode
potential value will form an
anode and undergoes this types
of corrosion.
Water Line Corrosion
The oxygen concentration
dissolved in water is greater at the
surface than deep, this lead to the
formation of a concentration cell,
an anode has a lower portion, and
the cathode is at water level.
Due to poor water conductivity, the ions
below water level and available for
reaction and the metal surface corrodes
below the water level.
 Degradation
Degradation is another process that can cause
a material to become less useful over time.

It’s another term used to describe corrosion

among polymers/plastic and ceramics.
Degradation on Polymers
Polymer degradation is a
change in the properties of the
polymer, such as tensile
strength, color, shape, and
molecular weight.
Factors that Affect Polymers
• Heat
• UV radiation
• Ozone – occurs on rubber
• Water, solution, oils
• Chemicals
• Soil
Forms of Polymeric Deterioration
• Swelling - small solvent
molecules enter into space
between the macromolecules
of polymer.

• Dissolution – they can

dissolve in a solvent when the
solvent has a similar chemical
structure (for example:
hydrocarbon in gasoline)
Degradation on Ceramics
Degradation of an object
occurs as a result of the
interaction between the
environment or with the
materials that form the
object however, in the case
of ceramics, environmental
factors are the major cause.
Types of Ceramic Degradation
• Physical Degradation due to
their fragility, damage to
ceramics typically comes
from mishandling and
packing.

1. Impact of Abrasion – when ceramics

are used over a period of time, they
will develop cracks, nicks, and
blemishes.
Types of Ceramic Degradation
2. Frost – damage can occur when
ceramics are exposed to freezing
temperatures and frost.

3. Mold Growth – It particularly

affects ceramic with no glaze or
coatings, with its delicate nature.
Earthenware ceramics are
frequently affected due to their
porosity and lack of glaze.
Types of Ceramic Degradation
• Chemical Degradation – it
weakens the stability of the
object when exposed to
water, air, pollution, heat,
humidity, and the like.

1. Water – water can dissolve or

deform ceramics that been low
fired (temperatures around 600
degree Celcius).
Types of Ceramic Degradation
2. Soluble salts – they can enter the clay
body from the environment, for example
when a ceramic is buried underground for
decades, they are already naturally
occurring due to the components of
materials or clay used.
Factors that affect Ceramics
• Temperature
• External Loads
• Vibrations
• Environment (biological organisms)

Life span of ceramics can be increased by controlling

the environment they are exposed to; operational
load sand temperature; altering the component
design