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Whilst the most extravagant claims of the 1980s in favour of advanced ceramic materials (such as the all ceramic
engine) have largely proved inaccurate, it is true to say that ceramics have established themselves as key
engineering materials.
When used in conjunction with other materials, usually metals, they provide added functionality to components
thereby improving application performance, once the appropriate joint design and technology have been identified.
Ceramic materials
Ceramics exhibit very strong ionic and/or covalent bonding (stronger than the metallic bond) and this confers the
properties commonly associated with ceramics: high hardness, high compressive strength, low thermal and
electrical conductivity and chemical inertness.
This strong bonding also accounts for the less attractive properties of ceramics, such as low ductility and low
tensile strength. The wider range of properties, however, is not widely appreciated. For example, whilst ceramics
are perceived as electrical and thermal insulators, ceramic oxides (initially based on Y-Ba-Cu-O) are the basis for
high temperature superconductivity. Diamond, beryllia and silicon carbide have a higher thermal conductivity than
aluminium or copper.
Control of the microstructure can overcome inherent stiffness to allow the production of ceramic springs, and
ceramic composites have been produced with a fracture toughness about half that of steel.
The main compositional classes of engineering ceramics are the oxides, nitrides and carbides. The Table gives the
general properties of the most used ceramics.
Nitrides
Silicon nitride (Si 3N4), and aluminium nitride (AlN) are the main advanced engineering ceramics in this category.
There is a wide range of grades and types of these materials, particularly of silicon nitride with each grade having
specific properties.
Carbides
Silicon carbide (SiC) is widely used for its high thermal conductivity, corrosion resistance and hardness, although as
an engineering ceramic its toughness is lower than that of some silicon nitride grades. Boron carbide (B4C) is the
third hardest industrial material (after diamond and cubic boron nitride) and is used for components needing very
high wear performance.
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Ceramic-based composites
Ceramics are used as the reinforcement of composite systems such as GRP (glass reinforced plastics) and metal
matrix composites such as alumina reinforced aluminium (Al/Al 2O 3). Advanced ceramic materials are also used as
the matrix materials in composites. Currently the most widely available materials are based on SiC and carbon.
Joining
There are many possible techniques for joining ceramics to themselves and to dissimilar materials. These
technologies range from mechanical fixturing to direct bonding. Fig.1 gives an overview of these methods.
The selection of one of these techniques to manufacture a particular component will depend on a number of factors
including:
Whilst all these considerations must be taken into account, generally the two important factors are the similarity
of the materials to be joined and the required temperature capability. Fig. 2 gives the temperature capability of a
number of joining media.
When joining ceramics to metals it is necessary to create an interface between the materials. In general the
interface must accommodate the following:
Applications
Compared to metals and plastics, ceramics are hard, non-combustible and inert. Thus they can be used in high
temperature, corrosive and tribological applications. These applications rely on combinations of properties that are
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5/7/2017 Ceramics - materials, joining and applications - Job Knowledge 54
unique to industrial ceramics and which include:
Engineering ceramics are used to fabricate components for applications in many industrial sectors, including
ceramic substrates for electronic devices (Fig. 3), turbocharger rotors (Fig. 4), and tappet heads for use in
automotive engines. Other examples of where advanced ceramics are used include oil-free bearings in food
processing equipment, aerospace turbine blades, nuclear fuel rods, lightweight armour, cutting tools, abrasives,
thermal barriers and furnace/kiln furniture.
Summary
When selecting a material for use in a specific component the applicability and suitability of the candidate
materials need to be considered in detail. When a ceramic material is being selected the fitness-for-purpose
criteria that should be applied include:
Future development is likely to come from improved processing and fabrication techniques that will lower
component costs or improve behaviour, an increasing demand for higher performance materials necessitating the
use of more ceramics. Whilst it is difficult to predict new materials, improvements in existing ones can be readily
foreseen. The most significant area of development is likely to be in the ceramic matrix composites.
Whilst existing composites based on SiC will improve as porosity levels are reduced by improved processing
techniques, the development of high temperature oxide-based composites is likely to provide a competitor material
system with wider applicability in the near future. In the future we can expect to see a still greater contribution to
industrial growth and technological development from these materials.
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