Description
Taylor & Francis Ceramic Processing 2Nd Edn by Mohamed N. Rahaman
Many of the properties critical to the engineering applications of ceramics are strongly dependent on their microstructure which, in turn, is dependent on the processing methods used to produce the ceramic material. Ceramic Processing, Second Edition provides a comprehensive treatment of the principles and practical methods used in producing ceramics with controlled microstructure. Covering the main steps in the production of ceramics from powders, the book also provides succinct coverage of other methods for fabricating ceramics, such as sol gel processing, reaction bonding, chemical vapor deposition and polymer pyrolysis. While maintaining the objectives of the successful first edition, this new edition has been revised and updated to include recent developments and expanded to feature new chapters on additives used in ceramic processing; rheological properties of suspensions, slurries, and pastes; granulation, mixing, and packing of particles; and sintering theory and principles.Intended as a textbook for undergraduate and graduate courses in ceramic processing, the book also provides an indispensable resource for research and development engineers in industry who are involved in the production of ceramics or who would like to develop a background in the processing of ceramics. Chapter 1 Ceramic Fabrication Processes - An Introductory Overview1.Introduction2. Ceramic Fabrication Processes3.Fabrication of Ceramics from Powders: An Overview1.3.1 Powder Synthesis and Characterization1.3.2 Powder Consolidation1.3.3 The Sintering Process1.3.4 Ceramic Microstructures1. Case Study in Processing: Fabrication of Al2O3 from Powders2. Concluding RemarksReferencesChapter 2 Synthesis and Preparation of Powders: Mechanical Methods2.1 Introduction2.2 Powder Characteristics2.3 Powder Preparation by Mechanical Methods2.4 High Compression Roller Mills2.5 Jet Mills2.6 Ball Mills2.7 High-Energy Ball Milling2.8 Concluding RemarksProblems ReferencesChapter 3 Powder Synthesis by Chemical Methods3.1 Introduction3.2 Solid State Reactions3.2.1 Decomposition3.2.2 Reaction between Solids3.3.2 Reduction3.3 Precipitation from Liquid Solutions3.3.1 Principles of Precipitation from Solution3.3.2 Methods for Preparing Powders by Precipitation from Solution3.3.3 Precipitation Methods Based on Evaporation of the Liquid3.4 Freeze Drying3.5 Gel Routes3.5.1 Sol- Gel Processing3.5.2 Pechini Method3.5.3 Citrate Gel Method3.5.4 Glycine Nitrate Process3.6 Non-Aqueous Liquid Reactions3.7 Vapor Phase Reactions3.7.1 Gas- Solid Reaction3.7.2 Reaction between Gases3.8 Concluding RemarksProblems ReferencesChapter 4 Synthesis of Ceramic Nanoparticles4.1 Introduction4.2 Methods for Synthesizing Ceramic Nanoparticles4.3 Solid- Solid Methods4.4 Solid- Vapor- Solid Methods4.5 Liquid- Solid Methods4.6 Liquid- Vapor- Solid Methods4.7 Concluding RemarksProblemsReferencesChapter 5 Powder Characterization5.1 Introduction5.2 Physical Characterization5.2.1 Types of Particles5.2.2 Particle Size and Particle Size Distribution5.2.3 Particle Shape5.2.4 Measurement of Particle Size and Size Distribution5.2.5 Surface Area5.2.6 Porosity of Particles5.3 Chemical Composition5.4 Crystal Structure and Phase Composition5.5 Surface Characterization5.5.1 Surface Structure5.5.2 Surface Chemistry5.6 Concluding RemarksProblemsReferencesChapter 6 Science of Colloidal Processing6.1 Introduction6.2 Types of Colloids6.3 Attractive Surface Forces6.3.1 Van der Waals Forces between Atoms and Molecules6.3.2 Van der Waals Forces Macroscopic Bodies6.3.3 The Hamaker Constant6.3.4 Effect of the Intervening Medium 6.4 Stabilization of Colloidal Suspensions6.5 Electrostatic Stabilization6.5.1 Charges on Particles in a Liquid6.5.2 Origins of the Electrical Double Layer6.5.3 Isolated Double Layer6.5.4 Surface Charge6.5.5 Repulsion between Two Double Layers6.5.6 Stability of Electrostatically Stabilized Colloids6.5.7 Kinetics of Flocculation6.5.8 Electrokinetic Phenomena6.6 Steric Stabilization6.6.1 Adsorption of Polymers from Solution6.6.2 Origins of Steric Stabilization6.6.3 Effect of Solvent and Temperature6.6.4 Stability of Sterically Stabilized Suspensions6.6.5 Stabilization by Polymers in Free Solution6.7 Electrosteric Stabilization6.7.1 Dissociation of Polyelectrolytes in Solution6.7.2 Adsorption of Polyelectrolytes from Solution6.7.3 Stability of Electrosterically Stabilized Suspensions 6.8 Structure of Consolidated Colloids6.9 Concluding RemarksProblemsReferencesChapter 7 Rheology of Colloidal Suspensions, Slurries and Pastes7.1 Introduction7.2 Types of Rheological Behavior7.2.1 Viscous Flow Behavior7.2.2 Viscoelastic Behavior7.3 Rheological Measurement7.4 Factors Influencing the Viscosity of Colloidal Suspensions7.4.1 Interparticle Forces7.4.2 Particle Concentration7.4.3 Particle Size and Particle Size Distribution7.4.4 Particle Morphology7.4.5 Suspension Medium 7.5 Concluding RemarksProblemsReferencesChapter 8 Processing Additives 8.1 Introduction8.2 Types of Additives8.3 SolventsSelection of a Solvent8.4 Dispersants8.4.1 Inorganic Acid Salts8.4.2 Surfactants8.4.3 Low to Medium Molecular Weights Polymers8.5 Binders8.5.1 Inorganic Binders8.5.2 Synthetic Organic Binders8.5.3 Natural Organic Binders8.5.4 Selection of a Binder8.6 Plasticizers8.7 Other Potential Additives8.8 Concluding RemarksProblemsReferencesChapter 9 Granulation, Mixing and Packing of Particles9.1 Introduction9.2 Granulation of Particles9.2.1 Desirable Characteristics of Binders9.2.2 Preparation of Granules9.2.3 Spray Drying9.2.4 Factors Controlling the Strength of Granules9.2.5 Spray Freeze Drying9.3 Mixing of Particles9.3.1 Mixing and Segregation Mechanisms9.3.2 Mixture Composition and Quality9.3.3 Statistical Methods9.3.4 Measurement Techniques9.3.5 Mixing Technology9.4 Packing of Particles9.4.1 Regular Packing of Monosize Spheres9.4.2 Random Packing of Particles9.4.3 Packing of Continuous Size Distributions9.5 Concluding RemarksProblemsReferencesChapter 10 Forming of Ceramics; Conventional Methods10.1 Introduction10.2 Dry and Semi-Dry Pressing10.2.1 Die Pressing10.2.2 Isostatic Pressing10.3 Suspension-Based Methods10.3.1 Slip Casting10.3.2 Pressure Casting10.3.3 Tape Casting10.3.4 Centrifugal Consolidation10.3.5 Dip and Spin Coating10.3.6 Electrophoretic Deposition10.3.7 Freeze Casting10.3.8 Gelcasting10.3.9 Direct Coagulation Casting10.3.10 Aqueous Injection Molding 10.4 Plastic Forming Methods10.4.1 Extrusion10.4.2 Injection Molding10.5 Concluding RemarksProblemsReferencesChapter 11 Additive Manufacturing of Ceramics11.1 Introduction11.2 Powder-Based Methods11.2.1 Selective Laser Sintering11.2.2 Three-Dimensional Printing11.3 Particle-Filled Polymer Methods11.3.1 Fused Deposition Modeling11.3.2 Laminated Object Manufacturing11.4 Suspension-Based Methods11.4.1 Stereolithography11.4.2 Inkjet Printing11.4.3 Robocasting11.4.4 Freeze Extrusion FabricationProblemsReferencesChapter 12 Drying, Debinding and Microstructural Characterization of Green Articles12.1 Introduction12.2 Drying of Granular Ceramics12.2.1 Drying of Drops of a Suspension on a Surface12.2.2 Drying of Adherent Coatings12.2.3 Drying of Three-Dimensional Solids12.2.4 Drying Technology12.3 Binder Removal12.3.1 Extraction by Capillary Flow12.3.2 Solvent Extraction12.3.3 Supercritical Extraction12.3.4 Thermal Debinding12.3.5 Thermal Debinding Process Design12.4 Green Microstructures and Their Characterization12.5 Concluding RemarksProblemsReferences Chapter 13 Sintering Theory and Fundamentals13.1 Introduction13.1.1 Types of Sintering13.1.2 Measurement of Sintering13.1.3 Analysis of Sintering13.2 Solid-State Sintering13.2.1 Driving Force for Sintering13.2.2 Effects of Surface Curvature13.2.3 Grain Boundary Effects13.2.4 Mechanisms of Sintering13.2.5 Stages of Sintering13.2.6 Theoretical Analysis of Solid-State Sintering 13.3 Grain Growth in Solid-State Sintering13.3.1 Types of Grain Growth13.3.2 Importance of Controlling Grain Growth13.3.3 Normal Grain Growth13.3.4 Abnormal Grain Growth13.3.5 Ostwald Ripening13.3.6 Control of Grain Growth13.3.7 Grain Growth in Porous Ceramics13.3.8 Simultaneous Densification and Grain Growth13.4 Viscous Sintering13.5 Liquid-Phase Sintering13.5.1 Stages of Liquid-Phase Sintering13.5.2 Microstructures of Liquid-Phase Sintered Ceramics13.5.3 Role of Solid-State Sintering in Liquid-Phase Sintering13.5.4 Thermodynamic and Kinetic Factors13.5.5 Mechanisms of Liquid-Phase Sintering13.5.6 Phase Diagrams in Liquid-Phase Sintering 13.6 Pressure-Assisted Sintering13.6.1 Pressure-Assisted Sintering Models13.6.2 Mechanisms of Pressure-Assisted Sintering13.7 Field-Assisted Sintering Techniques13.7.1 Spark Plasma Sintering13.7.2 Flash Sintering13.8 Concluding RemarksProblemsReferencesChapter 14 Sintering Process Variables and Techniques14.1 Introduction14.2 Sintering Furnaces and Furnace Supports14.3 Effect of Particle Size and Packing14.3.1 Particle Size14.3.2 Particle Size Distribution14.3.3 Particle Shape and Particle Structure14.3.4 Particle Packing14.3.5 Effect of Green Density14.4 Anisotropic Shrinkage14.4.1 Pore Shape Anisotropy14.4.2 Particle Alignment14.5 Heating Schedule14.5.1 Design and Prediction of the Heating Schedule14.5.2 Effect of Heating Rate on Sintering14.5.3 Special Heating Schedules14.6 Sintering Atmosphere14.6.1 Gases in Pores14.6.2 Effect on Vapor Transport14.6.3 Volatilization and Decomposition14.6.4 Oxidation State14.7 Microwave Sintering14.8 Pressure-Assisted Sintering14.8.1 Hot Pressing14.8.2 Hot Isostatic Pressing14.9 Spark Plasma Sintering14.10 Sintering of Ceramic Composites, Coatings and Multilayers14.10.1 Sintering of Ceramic Composites14.10.2 Sintering of Adherent Coatings14.10.3 Co-sintering of Ceramic Multilayers 14.11 Conclusions ProblemsReferences14.9 Spark Plasma Sintering14.10 Sintering of Ceramic Composites, Coatings and Multilayers14.10.1 Sintering of Ceramic Composites14.10.2 Sintering of Adherent Coatings14.10.3 Co-sintering of Ceramic Multilayers Chapter 15 Sol Gel Processing15.1 Introduction15.2 Sol Gel Processing of Aqueous Silicates15.3 Metal Alkoxides15.3.1 Preparation of Metal Alkoxides15.3.2 Basic Properties of Metal Alkoxides15.4 Sol Gel Processing of Silicon Alkoxides15.4.1 Precursors15.4.2 Hydrolysis and Condensation15.4.3 Polymer Growth15.4.4 Gelation15.4.5 Drying of Gels15.4.6 Gel Densification during Sintering 15.5 Sol Gel Preparation Techniques15.5.1 Preparation of Particulate Gels15.5.2 Preparation of Polymeric Gels15.6 Applications of Sol Gel Processing15.6.1 Thin Films and Coatings15.6.2 Fibers15.6.3 Monoliths15.6.4 Porous Materials15.6.5 Porous Materials15.7 Concluding RemarksProblemsReferencesChapter 16 Ceramic Fabrication Methods for Specific Shapes and Architectures16.1 Introduction16.2 Chemical Vapor Deposition16.2.1 Plasma-Assisted Chemical Vapor Deposition16.2.2 Chemical Vapor Infiltration16.3 Directed Metal oxidation16.4 Reaction Bonding16.4.1 Reaction-Bonded Silicon Nitride16.4.2 Reaction-Bonded Silicon Carbide16.4.3 Reaction Bonding of Oxide Ceramics16.5 Polymer Pyrolysis16.6 Fabrication Routes for Fiber-Reinforced Ceramic Matrix Composites16.6.1 Processing of SiC Fiber-Reinforced SiC Matrix Composites16.6.2 Processing of Oxide Fiber-Reinforced Oxide Matrix Composites16.7 Concluding RemarksProblemsReferencesAppendix A: Physical ConstantsAppendix B: SI Units - Names and SymbolsAppendix C: Conversion of UnitsAppendix D: Aperture size of U.S. Standard Wire Mesh Sieves (ASTM E 11:87)Appendix E: Densities and Melting Points of Some Elements, Ceramics and Mineralsshow more