1. D AY 24: C ERAMICS Design Concepts Review The Concept of Thermal Shock Resistance Review of Selected Engineering Ceramics Glass

2. Q UICK R EVIEW OF D ESIGN C ONCEPTS Design to a minimum safe value is not possible! We must design to an accepted probability of failure. Weibull statistics is used instead of normal statistics in fitting data and computing probabilities. The Weibull modulus indicates the extent to which the strength data is scattered. Want it as high as possible. The size of the object being designed must be accounted for. Designs that work for small components won’t work for large.

3. T HE I MPORTANCE OF F RACTURE M ECHANICS Recall that fracture mechanics allows predictions of whether a flaw in a known material will be stable. Brittle materials are very prone to cracking and fracture. Hence fracture mechanics is incorporated into the design of engineering ceramics.

4. T HERMAL S TRESS What is thermal stress? Mismatched materials and uniform heating.  T > 0  1 <  2 11 22 Material 1 in compression. Material 2 in tension. Think about what would happen if there were a surface crack.

5. T HERMAL S HOCK Consider uniform material and nonuniform temperature. I took something hot out of the oven and poured cold water on it. Hot, in compression Cold, in tension Gradient is actually gradual. What would happen to a crack about right here? COULD FAIL SUDENLY!

6. T HERMAL S HOCK R ESISTANCE To have thermal shock resistance what’s needed. 1. Strength High 2. Modulus of Elasticity Low 3. Coefficient of Linear Expansion Low 4. Thermal Conductivity High

7. T WO F ORMULAS F OR T HERMAL S HCOK R ESISTANCE Here’s the one in the notes. Here’s another one that is sometimes used.

8. V ALUES OF R From Notes:

9. R EVIEW OF THE M AJOR F AMILIES : A LUMINA Lowest cost Cheapest—Most Commonly used – excellent environmental resistance, room temperature strength. Not really a high temperature material Alumina ceramic is the most widely used material out of a variety of fine ceramics.This material is applied to widely diversified industrial field for its superb material characteristics such as high electrical insulation, high mechanical strength, high wear and chemical resistance. Uses: seals, liners, substrates for electronics, electrical insulators, body armor plates.

10. R EVIEW OF THE M AJOR F AMILIES : Z IRCONIA Toughest Highest Coefficient of Thermal Expansion Close to Steel Best Low Temperature strength Not really a high temperature material Zirconia ceramic has high mechanical strength and toughness at room temperature out of a series of engineering fine ceramics. Zirconia was the first material adopted to fine ceramic scissors or knife application. Its excellent surface smoothness has brought this material into parts for pump products.

11. W HY IS Z IRCONIA T OUGH ? Zirconia contains material that experiences a martensite type transformation – when it sees high enough stress. Such as just in front of a growing microcrack. The transformed material expands, and is compressed by the unexpanded untressed material in the vicinity. The compression blunts the crack making it harder for it to expand. Thereby toughening the material.

12. R EVIEW OF THE M AJOR F AMILIES : S ILICON C ARBIDE Best Strength at Highest Temperatures Best Thermal Conductivity Best Corrosion Resistance Silicon carbide maintains its high mechanical strength up to as high temperature as 1,400 C. Typical application is part for mechanical seal ring and pump due to higher chemical corrosion resistance than other ceramics. Uses: seals, rings for harsh environments, also for high temperatures.

13. R EVIEW OF THE M AJOR F AMILIES : S ILICON N ITRIDE Best Thermal Shock Resistance Lowest Coefficient of Thermal Expansion Silicon nitride exceeds other materials in thermal shock resistance. This material does not deteriorate at high temperature, therefore it's appropriate for automotive engine and parts for gas turbine, including turbocharger rotor, glow plug of diesel engine and hot plug. It is expected that the field range this material can be applied to will widely expand.

14. A PPLICATIONS

15. G LASS Glass is a very important family of ceramic materials. Common, cheap, very, very useful. Plates, containers, optical cables, fibers, art! Glass is often based on SiO 2, the oxide of silicon. If you add other oxides, such as Na 2 O, or Na 2 CO 3, sodium carbonate, you get a much lower melting point. Other additives are CaO and MgO to make it more chemically stable. This is soda-lime glass which is about 90% of the glass produced.

16. S TRUCTURE AND P ROPERTIES OF GLASS Glass is amorphous. (We briefly mentioned amorphous metals.) Amorphous means that there is no discernable crystal structure. The consituents form a 3D network with strong bonds. The name “glass” is applied to all such solids be they metal, ceramic or polymer. One consequence is the transparency which is such a desirable feature in glass. (Due to time limits we will not dwell on optical properties.) Another consequence in terms of mechanical behavior is brittleness.

18. G LASS IS A MORPHOUS

19. G LASS T RANSITION T EMPERATURE, T G T Specific Vol TgTg Solidification of a crystalline material Supercooled liquid Glass Note: slope change M.P.

20. G LASS T RANSITION Used not just for ceramic glasses but also for polymers.

21. T EMPERING G LASS Heat to above Tg. Cool suddenly with blast of air or quench bath. Different cooling rates lead to the following stress pattern: compression on the surface and tension in the interior. Outside cools first and rigidifies, holding inner portion in tension. Tension Compression

22. G LASS A RMOR It is fundamentally made by layering a polycarbonate substance between ordinary glass pieces in a process of lamination. http://www.technical-discovery.com/2009/04/nature-of-bulletproof-glass.html

23. In the new paper, Ortiz and her colleagues, including MIT Dean of Engineering Subra Suresh, report that the shell of the hot vent gasotropod has several features that help dissipate mechanical energy from a potential penetrating predatory attack. Of particular importance is its tri-layered shell structure, which consists of an outer layer embedded with iron sulfide granules, a thick organic middle layer, and a calcified inner layer. Most other snail shells have a calcified layer with a thin organic coating on the outside. In the scaly foot gastropod, simulations suggest that the relatively thick organic middle layer can absorb much energy during a penetrating attack. It may also help to dissipate heat and thermal fluctuations exhibited near hydrothermal vents. http://www.rdmag.com/News/2010/01/Materials-Soldiers-may-one-day-defend-with- sea-snail-armor/