Ceramics Science and Technology, 4 Volume Set

543 Pages·2008·0.78 MB·English

by  Riedel

R Edited by Ralf Riedel and I-Wei Chen
i
e
A d
lthough ceramics have been known to mankind literally for millen-
e
nia, research has never ceased. Apart from the classic uses as a bulk l

material in pottery, construction, and decoration, the latter half of the ·
Ceramics Science
C
twentieth century saw an explosive growth of application fi elds, such as
h
electrical and thermal insulators, wear-resistant bearings, surface coat-
e
ings, lightweight armour, and aerospace materials. In addition to plain, n
hard solids, modern ceramics come in many new guises such as fabrics,
(
ultrathin fi lms, microstructures and hybrid composites. E and Technology
d
Built on the solid foundations laid down by the 20-volume series
s
Materials Science and Technology, Ceramics Science and Technology picks .
)
out this exciting material class and illuminates it from all sides.
Materials scientists, engineers, chemists, biochemists, physicists and
medical researchers alike will fi nd this work a treasure trove for a wide
range of ceramics knowledge from theory and fundamentals to practical
Volume 4
approaches and problem solutions.
Applications
Ralf Riedel has been a professor at the Institute of Materials Science at the Darmstadt Univer-
4
sity of Technology in Darmstadt since 1993. He received a Diploma degree in chemistry in 1984
and he fi nished his dissertation in Inorganic Chemistry in 1986 at the University of Stuttgart.
After postdoctoral research at the Max-Planck-Institute for Metals Research and the Institute
of Inorganic Chemistry at the University of Stuttgart he completed his habilitation in the fi eld
of Inorganic Chemistry in 1992. Prof. Riedel is Fellow of the American Ceramic Society and was aC
awarded with the Dionyz Stur Gold Medal for merits in natural sciences. He is a member of the ne
World Academy of Ceramics and Guest Professor at the Jiangsu University in Zhenjiang, China. dr
In 2006 he received an honorary doctorate from the Slovak Academy of Sciences, Bratislava, Slo- a
Tm
vakia. In 2009 he was awarded with an honorary professorship at the Tianjin University in China. e
He published more than 300 papers and patents and he is widely known for his research in the cic
fi eld of polymer derived ceramics and on ultra high pressure synthesis of new materials. hs
n
S
o
c
I-Wei Chen has been Skirkanich Professor of Materials Innovation at the University of Pennsyl- l
oi
vania since 1997, where he also gained his master‘s degree in 1975. He received his bachelor‘s e
g
n
degree in physics from Tsinghua University, Taiwan, in 1972, and earned his doctorate in metal- y
c
lurgy from the Massachusetts Institute of Technology in 1980. He taught at the University of
e
Michigan (Materials) during 1986 – 1997 and MIT (Nuclear Engineering ; Materials) during
1980 – 1986. He began ceramic research studying martensitic transformations in zirconia nano
crystals, which led to work on transformation plasticity, superplasticity, fatigue, grain growth
and sintering in various oxides and nitrides. He is currently interested in solid oxide fuel cells,
nanotechnology of resistance memory and ferroelectrics, and nanoparticle-based medical imag-
ing and drug delivery. A Fellow of American Ceramic Society (1991) and recipient of its Ross
Coffi n Purdy Award (1994), Edward C. Henry Award (1999) and Sosman Award (2006),
he authored over 90 papers in the Journal of the American Ceramic Society (1986 – 2006).
He also received Humboldt Research Award for Senior U.S. Scientists (1997).
Volume 4 of 4
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RalfRiedelandI-WeiChen
CeramicsScienceand
Technology
RelatedTitles
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Edited by Ralf Riedel and I-Wei Chen
Ceramics Science and Technology
Volume 4: Applications
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V
Contents
Preface XV
ListofContributors XVII
PartOne StructuralApplications 1
1 OxidationandCorrosionofCeramics 3
ElizabethJ.OpilaandNathanS.Jacobson
1.1 Introduction 3
1.2 Silica-FormingCeramics 4
1.2.1 IdealOxidationBehaviorofSilica-FormingCeramics 4
1.2.1.1 StructureofSilicaandTransportofOxygeninSilica 4
1.2.1.2 OxidationofSiliconinDryOxygen 5
1.2.1.3 OxidationofSiliconCarbideinDryOxygen 7
1.2.1.4 OxidationofSiliconNitrideinDryOxygen 9
1.2.2 SiCOxidation:DeviationsfromNortonPermeation 11
1.2.2.1 CrystallizationoftheSilicaScale:EffectonSiCOxidation 11
1.2.2.2 IonicExchangewiththeSilicaNetwork:EffectonSiCOxidation 12
1.2.2.3 EffectsofLow-LevelImpuritiesonSiCOxidation 12
1.2.3 OxidationofSilica-FormersinthePresenceofLow-Level
Impurities 13
1.2.3.1 EffectofAlkali-MetalImpuritiesontheOxidationofSilica-Formers 13
1.2.3.2 EffectofAluminumImpuritiesonSilica-Formers 14
1.2.4 AdditiveEffectsontheOxidationofSilica-Formers 14
1.2.4.1 AlandBAdditionstoSiC:EffectonOxidationRates 15
1.2.4.2 EffectofSinteringAdditivesontheOxidationofSiliconNitride 15
1.2.5 Deposit-InducedCorrosionofSilicon-BasedCeramics 16
1.2.6 TemperatureCycling 24
1.2.7 OxidationofSilica-FormersinOtherOxidants 25
1.2.7.1 OxidationofSilica-FormersinOtherOxidants:H O 26
2
1.2.7.2 OxidationofSilicaFormersinOtherOxidants:Carbon
Dioxide(CO2) 36
1.2.7.3 OxidationofSilicaFormersinOtherOxidants:DissociatedOxygen 37
1.2.8 ActiveOxidationofSilicaFormers 38
j
VI Contents
1.2.9 UpperTemperatureLimitforSilica-FormingMaterials 45
1.2.10 OxidationofPolymer-DerivedSi-BasedCeramics 46
1.2.11 OxidationofSiC-BasedComposites 48
1.2.11.1 OxidationofCarbon 48
1.2.11.2 OxidationofBoronNitride 49
1.2.11.3 OxidationofSiC/C/SiCandC/C/SiCComposites 49
1.2.11.4 OxidationofSiC/BN/SiCComposites 51
1.2.11.5 ImprovedOxidation-ResistantSiCComposites 53
1.2.11.6 Oxidation-ResistantCoatingsandAdditivesforSiC-Based
Composites 55
1.2.12 EnvironmentalBarrierCoatingsforSilicon-BasedCeramics
andComposites 55
1.3 Alumina-FormingCeramics 57
1.3.1 OxidationofAlN 58
1.3.1.1 OnsetofAlNOxidation 58
1.3.1.2 EarlyStagesofAlNOxidation 58
1.3.1.3 OxidationKineticsofAlN 59
1.3.1.4 OxidationofAlNinWaterVapor 61
1.3.1.5 EffectofOxygenandNitrogenPartialPressureon
OxidationofAlN 62
1.3.1.6 EffectofSinteringAdditivesontheOxidationofAlN 62
1.3.2 OxidationofAl4C3 63
1.4 Ultrahigh-TemperatureCeramics 64
1.4.1 OxidationofZirconiumandHafnium 65
1.4.2 OxidationofZrB2andHfB2 65
1.4.2.1 EffectofAdditivesonZrB andHfB Oxidation
2 2
Rates 67
1.4.3 OxidationofZrCandHfC 74
1.4.4 OxidationofZrNandHfN 77
1.4.5 OxidationofTaCandTa2C 78
1.4.6 OxidationofUHTCCompositeMaterials 79
1.5 OxideCeramicDegradationMechanisms 80
1.5.1 OxideCeramicDegradationinWaterVapor 80
1.5.2 OxideCorrosion 81
1.6 ConcludingRemarks 83
References 83
2 ThermalBarrierCoatings 95
RobertVaßen
2.1 Introduction 95
2.2 ManufacturingRoutes 97
2.2.1 ElectronBeam-PhysicalVaporDeposition(EB-PVD) 97
2.2.2 AtmosphericPlasmaSpraying(APS) 98
2.2.2.1 GeneralRemarks 98
j
Contents VII
2.2.2.2 ThermallySprayedMCrAlYs(M(cid:2)(cid:2)(cid:2)(cid:2)Ni,Co)Bond
Coatings 99
2.2.3 AtmosphericPlasma-Sprayed(APS)Yttria-StabilizedZirconia(YSZ)
Topcoats 101
2.2.4 NewThermalSprayProcesses 103
2.2.4.1 LiquidFeedstock/SuspensionPlasmaSpraying 103
2.3 YSZ-BasedTBCS 105
2.3.1 SomeBasicPropertiesofYSZ(BulkMaterial) 105
2.3.2 PropertiesofAPSYSZThermalBarrierCoatings 106
2.3.3 PropertyChangesDuringHeatTreatment 107
2.3.4 FailureofYSZ-BasedTBCSystems 109
2.4 NewTBCSystems 110
2.5 Summary 112
Acknowledgments 112
References 112
3 CeramicFiltersandMembranes 117
IngolfVoigt,J€orgAdler,MarcusWeyd,andRalfKriegel
3.1 CeramicsinHotGasFiltration 117
3.1.1 Introduction 117
3.1.2 HotGasCleaninginAdvancedCoal-FiredElectricalPower
Systems 118
3.1.2.1 AdvancedCoal-FiredElectricalPowerSystems 118
3.1.2.2 AshFiltrationFromHotGases 119
3.1.2.3 FilterMaterials 119
3.1.2.4 RigidCandleFilter 121
3.1.2.5 CandleFilterFailingsandFailsafeDevices 123
3.1.2.6 ExperiencewithCandleFiltersinPFBCApplications 124
3.1.2.7 ExperiencewithCandleFiltersinIGCCApplications 124
3.1.2.8 CombinationofFiltrationandCatalyticTreatment 124
3.1.2.9 SummaryofHotGasCleaninginAdvancedCoal-FiredElectrical
PowerSystems 125
3.1.3 ParticulateFiltrationofDieselExhaustGases 125
3.1.3.1 PollutantsinDieselExhaust 126
3.1.3.2 LimitsofPollutantsbyLegislation 126
3.1.3.3 PrinciplesandFunctionoftheDieselParticulateFilter 126
3.1.3.4 ArchitectureofaDPFanditsManufacture 127
3.1.3.5 CeramicMaterialsforDPF 130
3.1.3.6 DPFSummaryandOutlook 132
3.2 CeramicMembranesforLiquidFiltration 132
3.2.1 Introduction 132
3.2.2 MicrofiltrationMembranes 135
3.2.2.1 PreparationofCeramicMicrofiltrationMembranes 135
3.2.2.2 ApplicationofCeramicMicrofiltrationMembranes 136
3.2.3 UltrafiltrationMembranes 137
j
VIII Contents
3.2.3.1 PreparationofCeramicUltrafiltrationMembranes 137
3.2.3.2 ApplicationofCeramicUltrafiltrationMembranes 138
3.2.4 NanofiltrationMembranes 139
3.2.4.1 PreparationofCeramicNanofiltrationMembranes 139
3.2.4.2 ApplicationofCeramicNanofiltrationMembranes 139
3.3 CeramicMembranesforPervaporation/VaporPermeation 142
3.3.1 Introduction 142
3.3.2 MembranesforPervaporation/VaporPermeation 144
3.3.3 DehydrationofIsopropanol 148
3.3.4 DehydrationofEthanol 149
3.4 CeramicMembranesforGasSeparation 151
3.4.1 Introduction 151
3.4.2 MixedIonicElectronicConductingMembranes 152
3.4.3 OxygenSeparationfromAir 155
References 162
4 High-TemperatureEngineeringCeramics 169
RonaldJ.KeransandAllanP.Katz
4.1 Introduction 169
4.2 EngineeringCeramicSystems 170
4.3 TurbineEngineApplications 172
4.4 ApplicationsforRocketPropulsionandHypersonicVehicles 179
4.5 FrictionMaterials 184
4.6 ConcludingRemarks:BarrierstoApplication 186
References 188
5 AdvancedCeramicGlowPlugs 191
TakeshiMitsuoka
5.1 Introduction 191
5.2 GlowPlugs 191
5.3 Metal-TypeGlowPlugs 193
5.4 CeramicGlowPlugs 194
5.5 FabricationProcedureofHeaterElementsforCeramicGlowPlugs 197
5.6 MaterialDesignoftheCeramicHeaterElement 200
5.7 SiliconNitrideCeramics 201
5.8 Conclusions 206
References 206
6 NanosizedandNanostructuredHardandSuperhard
MaterialsandCoatings 207
StanVepr9ek,MaritzaG.J.Vepr9ek-Heijman,andPavelHolub(cid:2)ar9
6.1 Introduction:SmallisStrong 207
6.2 DifferentMechanismsofHardnessEnhancementinCoatings 213
6.3 MechanismsofDecompositionofSolidSolutionandFormationof
Nanostructure 220