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Ceramics, Glasses, Ceramics, Glasses, Superconductors P i dE i t Processing and Equipment Text Reference: “Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 18

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Page 1: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

Ceramics, Glasses,Ceramics, Glasses, Superconductors

P i d E i tProcessing and Equipment

Text Reference: “Manufacturing Engineering and Technology”, g g g gy ,Kalpakjian & Schmid, 6/e, 2010

Chapter 18

Page 2: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

FIGURE 18.1 (a) Examples of typical glass parts. (b) Examples of ceramic parts. ( ) p p

Source: (a) Courtesy of Commercial Optical Manufacturing, Inc. (b) Courtesy Kyocera.

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TABLE 18.1 General Characteristics of Ceramics Processing

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FIGURE 18.2 Processing steps involved in making ceramic parts.

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FIGURE 18.3 Sequence of operations in slip casting a ceramic part. After the slip has been poured, the part is dried and fired in an oven to p p p

give it strength and hardness. Source: After F.H. Norton.

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FIGURE 18.4 Production of ceramic sheets through the doctor-blade process.

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FIGURE 18.5 (a) Extruding and (b) jiggering operations. Source: After R F StoopsR.F. Stoops.

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FIGURE 18.6 Shrinkage of wet clay caused by the removal of water during drying. Shrinkage may be as much as 20% by volume. Source: g y g g y y

After F.H. Norton.

Page 9: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

Finishing Operations• May be employed to

– Give final shapeI f fi i h & t l– Improve surface finish & tolerances

– Remove surface flaws• Possible Finishing Operations:Possible Finishing Operations:

– Grinding– Lapping & honing– Ultrasonic machining– Drilling

Electrical discharge machining– Electrical-discharge machining– Laser-beam machining– Abrasive water-jet cuttingj g– Tumbling

Page 10: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

Forming & Shaping of GlassGeneral process for glass:• Melt

– 1000o to 1200oC– A red-hot, viscous, syrup

• Shape– in Molds– with Tools– by Blowing

• Improve strength by– Chemical & thermal treatments– Lamination with thin layer of tough plastic

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FIGURE 18.7 The float method of forming sheet glass.g g

Page 12: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

FIGURE 18.8 (a) Drawing process for drawing sheet glass from a molten bath (b) Rolling process Source: After W D Kingerymolten bath. (b) Rolling process. Source: After W.D. Kingery.

Page 13: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

FIGURE 18.9 Manufacturing process for glass tubing. Air is blown through the mandrel to keep the tube from collapsing. Glass tubes for g p p g

fluorescent bulbs are made by this method.

Page 14: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

FIGURE 18.10 Steps in manufacturing an ordinary glass bottle. Source: After F.H. Norton.

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FIGURE 18.11 Manufacturing a glass item by pressing glass into a mold Source: Courtesy of Corning Glass Worksmold. Source: Courtesy of Corning Glass Works.

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FIGURE 18.12 Pressing glass into a split mold. Source: After E.B. ShandShand.

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FIGURE 18.13 Centrifugal casting of glass. Large telescope lenses and television-tube funnels are made by this process. Source: Courtesy y p y

of Corning GlassWorks.

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FIGURE 18.14 (a) The stages involved in inducing compressive surface residual stresses for improved strength. p g(b) Residual stresses in a tempered glass plate.

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Design Considerations for C i d GlCeramics and Glasses

• Balance limitations (poor tensile strength, sensitivity to i t l & t l d f t l i t t h )internal & external defects, low impact toughness) against advantages ( hardness, scratch resistance, compressive strength both cold & hot)I t t t t l i t d th• Important to control processing parameters and the quality & amount of impurities in raw materials

• Consider relative costs of quantity, tooling, equipment, labourlabour

• Consider dimensional changes, warping, possibility of cracking during processing & service lifeC tibilit ith th t i l i bl• Compatibility with other materials in an assembly

• Allow for static fatigue (failure over time under static loading)

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SuperconductorsSuperconductors• Superconductivity is the phenomenon of near p y p

zero electrical resistivity that occurs in some materials below a critical (very cold) temperature

• Superconductors have major energy-savingSuperconductors have major energy-saving potential, but difficult to achieve in ceramics due to brittleness and anisotropy M t l LTSC L T t• Metals: LTSC – Low Temperature Superconductors

• Ceramics: HTSC – High Temperature Ce a cs SC g e pe atu eSuperconductors

• HTSC available in powder form

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Processing of SuperconductorsProcessing of Superconductors

• Prepare powder: mix it by grinding in ballPrepare powder: mix it by grinding in ball mill to grain size 0.5 to 10 μm

• Form powder to desired shape• Form powder to desired shape• Heat treat the product

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FIGURE 18.15 Schematic illustration of the powder-in-tube process.p p

Page 23: Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi ...adfisher/3941/Ch18_Ceramics... · Ceramics, Glasses,Ceramics, Glasses, Superconductors Pi dEi tProcessing and Equipment

SummarySummary• Ceramic products made by casting, plastic forming, p y g p g

pressing; then dried & fired• Glass products made by several shaping processes

similar to those for ceramics, plasticssimilar to those for ceramics, plastics• Continuous glass processing methods: Drawing, Rolling,

FloatingDi t l i th d Bl i P i• Discrete glass processing methods: Blowing, Pressing, Centrifugal casting

• Design considerations: low tensile strength, low g gtoughness, sensitivity to defects, warping, cracking

• Manufacturing superconductors difficult: brittleness, anisotropyanisotropy