MATSE 421: Ceramic Processing and Microstructure Development

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Textbook: Class notes.

References:

1. Reed, James; Principles of Ceramic Processing 2nd Ed.
2. Evans, J. W./DE Jonghe, Lutgard C.; Production of Inorganic Materials
3. Ring, T. A.; Fundamentals of Ceramic Powder Processing and Synthesis

Catalog Description:

Basic principles and understanding of microstructure development and processing of ceramic materials will be addressed, with an emphasis on structure-property-processing relationships. Knowledge of a variety of processing methodologies and their effects on microstructural development will be gained. Examples of several ceramic components will be illustrated and discussed within this context. Prerequisite: MATSE 320 or consent of instructor. 3 hours, or 3/4 or 1 unit. To receive the additional 1/4 unit credit a term paper is required. 3 hours lecture-discussion/week

Course Topics:

1. Microstructure Development including: solid state sintering, densification vs. coarsening processes, grain boundary mobility mechanisms, porosity evolution (stability/entrapment), viscous densification, liquid phase sintering, constrained sintering.
2. Microstructure Characterization Methods including; microscopy techniques, quantitative image analysis (avg. grain size, distribution).
3. Ceramic Powders and Characterization including: conventional powders, chemically-derived powders, particle size/morphology characterization, surface area characterization, purity analysis, surface chemistry/characterization, and calcination.
4. Colloidal Processing including: interparticle forces, processing additives, spray drying, milling, and rheology
5. Forming Science including: pressing operations (dry, iso-static), slip casting, tape casting, extrusion, injection molding, hot press, HIP, emerging routes (gel-based, SFF methods), and green body characterization methods
6. Presintering Processes including: drying, binder removal

Course Objectives:

1. Develop understanding of microstructural evolution of ceramic materials
2. Develop working knowledge of the unit operations involved in processing ceramic materials
3. Develop ability to select appropriate processing methodologies based on component quantity, cost, and structure-property-processing relationships,
4. Develop knowledge of characterization methods used to determine microstructural features and effect of process variables
5. Develop ability to critically evaluate processing literature through exploration of current research articles

Course Outcomes:

1. Given an unknown ceramic powder be able to characterize its chemical and physical properties sufficient for its synthetic reproduction
2. Given a ceramic component be able to design an appropriate processing methodology for fabricating this sample
3. Design a suitable sintering schedule for heat treating ceramics and understand the effects of existing microstructural features (e.g., porosity, impurities, etc.) on microstructural evolution during this process
4. Familiarization with a wide array of characterization techniques
5. Ability to critically evaluate current literature in the area of ceramic processing

Assessment Tools:

1. Homework problems involving applications of ceramic processing topics
2. Two written exams on course content designed to test the students ability to apply his/her knowledge.
3. Written article summaries in which students must critically evaluate current journal papers published on various course topics

Contribution of Course to Meeting the Professional Component:

100%

Prepared by:

Jennifer Lewis, January, 2001