Advanced Materials: Ceramics and Composites Notes

Topic 1.1: Introduction to Ceramics

Ceramics, Properties of Ceramics (Physical, Mechanical, Thermal, Electrical, and Chemical properties), Advanced Ceramics Materials.

Topic 1.2: Classification of Ceramics

Classification Based on Applications: Traditional Ceramics (Red-clay Products, White-clay Products, Abrasives, Refractories, Cement) and Advanced Ceramics (Electro Ceramics, Structural Ceramics), Classification Based on Chemical Compositions: Oxide Ceramics and Non-oxide Ceramics.

Topic 1.3: Ceramic Fabrication Methods

Gas-Phase Reaction, Liquid-Phase Reaction (Sol-gel Processing, Polymer Pyrolysis), and Solid-Phase Reaction (Melt Casting, Sintering of Powder).

Topic 1.4: Gas-phase Precursor Methods

Chemical Vapor Deposition (General Process, Advantages, Disadvantages), Directed Metal Oxidation/Lanxide process (General Process, Advantages, Disadvantages), Reaction Bonding (Reaction Bonded Silicon Nitride, Reaction Bonded Silicon Carbide, Reaction Bonded Aluminum Oxide).

Topic 1.5: Liquid-phase Precursor Methods

Sol-gel Processing (Process, Flowchart, Advantages, Disadvantages), Polymer Pyrolysis (Production of Silicon Carbide Ceramics, Silicon Nitride Ceramics, Boron Nitride & Boron Carbide Ceramics, Advantages, Disadvantages).

Topic 1.6: Solid-phase Precursor Methods

Melt Casting (production of glass-ceramics, Properties of Glass Ceramic, Advantages & Disadvantages), Sintering/firing of Powder.

Topic 1.7: Types of CVD Reactors

Types of CVD Reactors: Pancake/planetary Reactor, Barrel Reactor, Horizontal Reactor, Low-Pressure Reactor, Plasma Reactor.

Topic 1.8: Sintering Fundamentals

Sintering basics, Stages of Sintering, Types of Sintering: Solid Phase Sintering, Liquid Phase Sintering, Viscous Sintering, and Reactive Sintering.

Topic 1.9: Driving Force for Sintering

Driving Forces for Sintering: Surface Energy, Surface Curvature, External Pressure, Chemical Reaction, Diffusion in Crystalline Solids: Diffusion Mechanism, Fick’s Law of Diffusion.

Topic 1.10: Additives for Ceramics

Additives, Types of Additives: Solvent, Dispersants (Simple ions and Molecules, Surfactants, Low to Medium MW Polymers), Binder, Plasticizers, and Other Additives.

Topic 1.11: Shaping Techniques

Common Terms (Slurry/Slip, Dispersants, Binder, Plasticizers, Green Body, Mold, Firing Sintering), Common Ceramic Shaping Techniques: Mechanical Pressing (Dry Pressing, Hot Pressing, Isostatic Pressing), Casting (Slip Casting, Tape Casting), and Plastic Forming (Extrusion, Injection Molding).

Topic 1.12: Synthesis of Fibers

Fibers, Types of Fibers, Production of Glass Fiber, Production of Boron Fiber, Production of Carbon Fiber, Production of Aramid Fiber, Production of Whiskers from Rice Hulls.

Topic 1.13: Ceramic Powder Synthesis

Synthesis of Ceramics Powder, Desirable Powder Characteristics, Effect of Particle Agglomerations, Powder Synthesis Methods: Mechanical & Chemical Methods

Topic 1.14: Mechanical Methods for Ceramic Powder Synthesis

Mechanical Methods: Comminution (High Compressor Roller Mill, Jet Mill & Ball Mill), and Mechanochemical Synthesis (Spex Mill).

Topic 1.15: Chemical Methods for Ceramic Powder Synthesis

Chemical Methods: Solid-state Reactions (Reaction Between Solids & Decomposition Reactions), Synthesis From Liquid Solutions (Precipitation & Solvent Vaporization) and Vapor-phase Reaction (Gas-solid Reaction, Gas-liquid & Gas-gas Reaction).

Topic 1.16: Non-conventional Composites

Composite Materials, Nanocomposite, Polymer Nanocomposite, Polymer-clay Nanocomposite (Morphology and Preparation), Self-Healing Composite, Self-reinforced Composite, Bio-composites (Challenges and Applications), Laminates (Types and Ceramic Laminates), Hybrid Composites or Fiber Metal Laminate (FML).

Topic 1.17: Additives for Composites

Composite, Matrix, Reinforcement, Compounding Materials or Additives, Types of Compounding Materials or Additives: Fillers, Colorants, Plasticizers, Flame Retardants, Lubricants, Resins.

Topic 1.18: Mixing Equipment

Mixing, Extensive or Distributive Mixing or Blending, Intensive or Dispersive Mixing or Compounding, Blending Equipment (Twin-drum Tumbler, Ribbon Blender, Henschel Mixer, Z-blade Mixer, Paddle Mixer, Cowles Dissolver and Ball Mill), Compounding Equipment (Two-roll Mill, Banbury Mixer, and Twin-screw Extruder).

Topic 1.19: Introduction to Metal Matrix Composites

Introduction, Metal Matrix, Reinforcement, Types of Metal Matrix Composites, Metal Matrix Composites, Advantages of MMCs, Applications of MMCs.

Topic 1.20: MMCs Synthesis Methods

Liquid State Processing (Stir Casting, Liquid Infiltration, Spray Forming), Solid State Processing (Diffusion Bonding, Deforming Processing, Powder Processing/Metallurgy, Sinter Forging), In-situ Processing, Deposition Techniques (PVD, CVD, Spray Deposition, Dipping or Immersion Plating, Electroplating)

Topic 1.21: Liquid State Processing Methods

Stir Casting, Liquid Infiltration (Duralcan Process, Lanxide Process, Pressure/squeeze Infiltration, Gas Infiltration), Spray Forming.

Topic 1.22: Solid State Processing Methods

Diffusion Bonding (Foil-Fiber-Foil Process), Deforming Processing (Roll Bonding Process), Powder Processing/Metallurgy, Sinter Forging.

Topic 1.23: In-situ Processing Method

In-situ Processing: Unidirectional Solidification of a Eutectic Alloy, Advantages, Disadvantages.

Topic 1.24: Deposition Techniques Methods

Physical vapor deposition (PVD), Chemical Vapor Deposition (CVD), Spray Deposition, Dipping or Immersion Plating, Electroplating.

Topic 1.25: Introduction to Ceramic Matrix Composites

Ceramic Matrix, Reinforcement, Ceramic Matrix Composites, Advantages of CMCs, Disadvantages of CMCs, Applications of CMCs, Properties of CMCs.

Topic 1.26: CMCs Synthesis Methods

Powder-based Methods (Cold Pressing & Sintering, Hot Pressing, Self-propagating High Temperature Synthesis), Infiltration-based Methods (Non-reactive Infiltration, Reactive Infiltration), Deposition-based Methods (Chemical Vapor Impregnation, Electrophoretic Deposition)

Topic 1.27: Powder-based Methods for CMCs

Cold Pressing & Sintering, Hot Pressing, Self-propagating High-Temperature Synthesis (SHS), Advantages, Challenges

Topic 1.28: Infiltration-based Methods for CMCs

Non-reactive Infiltration: Melt Infiltration, Slurry Infiltration, Polymer Infiltration and Pyrolysis (PIP), & Sol-gel, Reactive Infiltration: Reactive Melt Infiltration (RMI) or Liquid Silicon Infiltration (LSI), GE’s Melt Infiltration Process, & Lanxide Process, Advantages, Challenges