Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV: Ceramic Engineering and Science Proceedings, Volume 31

240 Pages·2010·13.295 MB·English

Advanced Processing and
Manufacturing Technologies
for Structural and
Multifunctional Materials IV
Advanced Processing and
Manufacturing Technologies
for Structural and
Multifunctional Materials IV
A Collection of Papers Presented at the
34th International Conference on Advanced
Ceramics and Composites
January 24-29, 2010
Daytona Beach, Florida
Edited by
Tatsuki Ohji
Mrityunjay Singh
Volume Editors
Sanjay Mathur
Tatsuki Ohji
©WILEY
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Copyright © 2010 by The American Ceramic Society. All rights reserved.
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ISBN 978-0-470-59473-5
Printed in the United States of America.
10 9 8 7 6 5 4 3 21
Contents
Preface ix
Introduction xi
GREEN MANUFACTURING AND SMART PROCESSING
Securing the Supply of Precious and Special Metals—The Need of 3
Closing the Loop
Christian Hagelüken
Mechanical Properties of Cr-Si-N-0 Thin Films Deposited by RF 15
Reactive Unbalanced Magnetron Sputtering
Jun Shirahata, Tetsutaro Ohori, Hiroki Asami, Tsuneo Suzuki,
Tadachika Nakayama, Hisayuki Suematsu, and Koichi Niihara
Room-Temperature Deposition and Magneto-Optical Properties of 23
Transparent Cobalt/Lead Zirconate Titanate (PZT) Nanocomposite
Films by Aerosol Deposition
Jae-Hyuk Park and Jun Akedo
Influence of Dispersant on Rheology of Zirconia-Paraffin Feedstocks 31
and Mechanical Properties of Micro Parts Fabricated via LPIM
Fatih A. Cetinel, Marcus Müller, Joachim Rogner, Werner Bauer, and
Jürgen Hausselt
ADVANCED COMPOSITE MANUFACTURING
Fiber-Reinforced Ceramic Matrix Composites Processed by a 47
Hybrid Process Based on Chemical Vapor Infiltration, Slurry
Impregnation and Spark Plasma Sintering
Jerome Magnant, Rene Pailler, Yann Le Petitcorps, Laurence Maille,
Alain Guette, Jimmy Marine, and Eric Philippe
v
Manufacturing of the CMC Nose Cap for the Expert Spacecraft 59
Christian Zuber, Thomas Reimer, Kornelia Stubicar, Bernhard Heidenreich,
and Hermann Hald
The Nature of Silicon Carbide Phases Developed from Different 73
Carbonaceous Sources and Its Impact on the Microstructure of
C/C-SiC Composites
Andrew Leatherbarrow and Houzheng Wu
Shaping Radiation Curable Colloidal Dispersions—From 85
Polymer/Ceramic Fibers and Microspheres to Gradient Porosity
Ceramic Bulk Materials
Yoram de Hazan, Maciek Wozniak, Judit Heinecke, Gregor Müller,
Veronika Märkl, and Thomas Graule
Melt-Infiltration Processing of Titanium Carbide-Stainless Steel 97
Cermets
Tyler Stewart, R. Bradley Collier, Zoheir N. Farhat, Georges J. Kipouros, and
Kevin P. Plucknett
Oxidation Behavior of Zirconium Diboride-Silicon Carbide 105
Composites
Ipek Akin, Filiz Cinar Sahin, Onuralp Yucel, and Gultekin Goller
RAPID PROCESSING
Nano-Crystalline Yttria Samaria Codoped Zirconia: Comparison 115
of Electrical Conductivity of Microwave and Conventionally
Sintered Samples
Soumyajit Koley, Abhijit Ghosh, Ashok Kumar Sahu, and Ashok Kumar Suri
Spark Plasma Sintering (FAST/SPS) of Novel Materials—Taking 127
the Next Step Forward to Industrial Production
H. U. Kessel, J. Hennicke, R. Kirchner, andT. Kessel
Rapid Manufacturing of Ceramic Parts by Selective Laser Melting 137
Jan Wilkes, Yves-Christian Hagedorn, Sörn Ocylok, Wilhelm Meiners,
and Konrad Wissenbach
JOINING AND MACHINING
Active Metal Brazing and Characterization of Brazed Joints between 151
Silicon Carbide and Metallic Systems
Bryan P. Coddington, Rajiv Asthana, Michael C. Halbig, and Mrityunjay Singh
Joining of Silicon Nitride with Glass or Powder under Mechanical 163
Pressure
Naoki Kondo, Hideki Hyuga, Takaaki Nagaoka, and Hideki Kita
vi · Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV
Fabrication of Thermodynamic Crystals by Structural Joining 169
Soshu Kirihara, Yasunori Uehara, and Youhei Takinami
Effect of Various Factors on Interface Formation in Magnetic 175
Pressure Seam Welding
Hisashi Serizawa, Isao Shibahara, Sherif Rashed, Hidekazu Murakawa, and
Shinji Kumai
Production Environment Laser Assisted Machining of Silicon Nitride 183
Federico Sciammarella, Joe Santner, Jeff Staes, Richard Roberts,
Frank Pfefferkorn, Stephen T. Gonczy, Stefan Kyselica, and Ricardo Deleon
NET SHAPE FORMING
Gelcasting of High Performance Carbide Ceramics with Larger 197
Size/Complex Shape
Dongliang Jiang
Processing of Complex-Shaped Micro Parts by Reaction-Bonding 213
and Sintering of Silicon Nitride
M. Müller, W. Bauer, R. Knitter, and J. Rogner
Thermoplastic Ceramic Injection Molding of Zirconia Toughened 223
Alumina Components
F. Kern, M. Abou El-Ezz, and R. Gadow
Fabrication of Alumina Dental Crown Model with Biomimetic 239
Structure by Using Stereolithography
Mitsuyori Suwa, Soshu Kirihara, and Taiji Sohmura
Author Index 247
Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV · vii
Preface
The Fourth International Symposium on Advanced Processing and Manufacturing
Technologies for Structural and Multifunctional Materials and Systems (APMT)
was held during the 34th International Conference on Advanced Ceramics and
Composites, in Daytona Beach, FL, January 24-29, 2010. The aim of this interna-
tional symposium was to discuss global advances in the research and development
of advanced processing and manufacturing technologies for a wide variety of non-
oxide and oxide based structural ceramics, particulate and fiber reinforced compos-
ites, and multifunctional materials. A total of 96 papers, including invited talks, oral
presentations, and posters, were presented from more than 10 countries (USA,
Japan, Germany, France, Italy, Slovenia, Serbia, Belgium, Turkey, Sweden, Cana-
da, China, Korea, India and Israel). The speakers represented universities, industry,
and research laboratories.
This issue contains 25 invited and contributed papers, all peer reviewed accord-
ing to the American Ceramic Society Review Process. The latest developments in
processing and manufacturing technologies are covered, including green manufac-
turing, smart processing, advanced composite manufacturing, rapid processing,
joining, machining, and net shape forming technologies. These papers discuss the
most important aspects necessary for understanding and further development of
processing and manufacturing of ceramic materials and systems.
The editors wish to extend their gratitude and appreciation to all the authors for
their cooperation and contributions, to all the participants and session chairs for
their time and efforts, and to all the reviewers for their valuable comments and sug-
gestions. Financial support from the Engineering Ceramic Division and the Ameri-
can Ceramic Society is gratefully acknowledged. Thanks are due to the staff of the
meetings and publication departments of the American Ceramic Society for their
invaluable assistance.
We hope that this issue will serve as a useful reference for the researchers and
ix
technologists working in the field of interested in processing and manufacturing of
ceramic materials and systems.
TATSUKI OHJI, Nagoya, Japan
MRITYUNJAY SINGH, Cleveland, USA
x · Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV
Introduction
This CESP issue represents papers that were submitted and approved for the pro-
ceedings of the 34th International Conference on Advanced Ceramics and Compos-
ites (ICACC), held January 24-29, 2010 in Daytona Beach, Florida. ICACC is the
most prominent international meeting in the area of advanced structural, functional,
and nanoscopic ceramics, composites, and other emerging ceramic materials and
technologies. This prestigious conference has been organized by The American Ce-
ramic Society's (ACerS) Engineering Ceramics Division (ECD) since 1977.
The conference was organized into the following symposia and focused ses-
sions:
Symposium 1 Mechanical Behavior and Performance of Ceramics and
Composites
Symposium 2 Advanced Ceramic Coatings for Structural, Environmental,
and Functional Applications
Symposium 3 7th International Symposium on Solid Oxide Fuel Cells
(SOFC): Materials, Science, and Technology
Symposium 4 Armor Ceramics
Symposium 5 Next Generation Bioceramics
Symposium 6 International Symposium on Ceramics for Electric Energy
Generation, Storage, and Distribution
Symposium 7 4th International Symposium on Nanostructured Materials and
Nanocomposites: Development and Applications
Symposium 8 4th International Symposium on Advanced Processing and
Manufacturing Technologies (APMT) for Structural and
Multifunctional Materials and Systems
Symposium 9 Porous Ceramics: Novel Developments and Applications
Symposium 10 Thermal Management Materials and Technologies
Symposium 11 Advanced Sensor Technology, Developments and
Applications
XI
Focused Session 1 Geopolymers and other Inorganic Polymers
Focused Session 2 Global Mineral Resources for Strategic and Emerging
Technologies
Focused Session 3 Computational Design, Modeling, Simulation and
Characterization of Ceramics and Composites
Focused Session 4 Nanolaminated Ternary Carbides and Nitrides (MAX Phases)
The conference proceedings are published into 9 issues of the 2010 Ceramic En-
gineering and Science Proceedings (CESP); Volume 31, Issues 2-10, 2010 as out-
lined below:
• Mechanical Properties and Performance of Engineering Ceramics and Com-
posites V, CESP Volume 31, Issue 2 (includes papers from Symposium 1)
• Advanced Ceramic Coatings and Interfaces V, Volume 31, Issue 3 (includes
papers from Symposium 2)
• Advances in Solid Oxide Fuel Cells VI, CESP Volume 31, Issue 4 (includes
papers from Symposium 3)
• Advances in Ceramic Armor VI, CESP Volume 31, Issue 5 (includes papers
from Symposium 4)
• Advances in Bioceramics and Porous Ceramics III, CESP Volume 31, Issue 6
(includes papers from Symposia 5 and 9)
• Nanostrucrured Materials and Nanotechnology IV, CESP Volume 31, Issue 7
(includes papers from Symposium 7)
• Advanced Processing and Manufacturing Technologies for Structural and
Multifunctional Materials IV, CESP Volume 31, Issue 8 (includes papers
from Symposium 8)
• Advanced Materials for Sustainable Developments, CESP Volume 31, Issue
9 (includes papers from Symposia 6, 10, and 11)
• Strategic Materials and Computational Design, CESP Volume 31, Issue 10
(includes papers from Focused Sessions 1, 3 and 4)
The organization of the Daytona Beach meeting and the publication of these pro-
ceedings were possible thanks to the professional staff of ACerS and the tireless
dedication of many ECD members. We would especially like to express our sincere
thanks to the symposia organizers, session chairs, presenters and conference atten-
dees, for their efforts and enthusiastic participation in the vibrant and cutting-edge
conference.
ACerS and the ECD invite you to attend the 35th International Conference on
Advanced Ceramics and Composites (http://www.ceramics.org/icacc-ll) January
23-28, 2011 in Daytona Beach, Florida.
Sanjay Mathur and Tatsuki Ohji, Volume Editors
July 2010
xii · Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV