MATSE 423: Ceramic Engineering Processing Laboratory

Homepage: http://kriven.mse.uiuc.edu/

Textbook: J. S. Reed, "Principles of Ceramics Processing," Second Edition, (1995).

References:

1. M. N. Rahaman, "Ceramic Processing and Sintering," Marcel Dekker, Inc. (1995).
2. D. W. Richerson, "Modern Ceramic Engineering," Second Edition, Marcel Dekker Inc., (1992).
3. T. A. Ring, "Fundamentals of Ceramic Powder Processing and Synthesis," Academic Press (1996).
4. J. W. Evans and L. C. DeJonghe, "Production of Inorganic Materials, Macmillan (1991).

Catalogue Description, Pre-requisites and Schedule:

Experiment and demonstrations involving a wide range of modern ceramic processing methods will be conducted to develop fundamental understanding of the relationships between raw materials, processing methods, microstructural development and physical properties. The lab emphasizes the underlying physics and chemistry of processing, as well as designing processing routes to achieve desired material properties. Technical reports and an independent project will be required. 4 hours or 1 unit. 1 lecture/discussion and 4 hours of lab per week plus independent project.

Course Topics:

Powder synthesis
Powder characterization
Rheology of colloidal suspension
Electrophoretic deposition
Slip casting
Pressure filtration
Pressing
Sintering
Grain growth
Glass processing and melting
Glass annealing
Cementitious materials
Project

Course Objectives:

The students should understand the effect of different processing parameters on the microstructure and properties of ceramic bodies. The objective is to teach students the standard techniques for synthesizing and processing of ceramics by completing the following laboratory exercises.

1. Powder synthesis via comminution, ball milling, and chemical synthesis
2. Powder characterization by XRD, SEM, sedigraphy, specific surface area (BET)
3. Wet forming methods focussing on the rheology of particles
4. Wet forming methods focussing on sedimentation, filtration and slip casting
5. Wet forming methods focussing on drying of green bodies
6. Dry forming methods via spray drying and cold pressing
7. Solid state sintering as a function of difference processing parameters
8. Density determination
9. Chemically bonded ceramics as in cements
10. To be able to prepare lucid and complete laboratory reports describing the background, aim, methods, results, discussion, conclusion and references of each experiment.

Course Outcomes:

The students should be able to:
1. Synthesis oxide ceramic powders by conventional techniques (ball milling, attritor milling) and by more modern chemical synthesis using the sol gel method
2. Characterization of powders to determine phase content (XRD), particle sizes and size distribution (sedigraphy), particle morphology (SEM), particle specific surface area
3. Be competent in formulating slurries, binder solutions etc. for wet forming methods
4. Be able to prepare flowable powders via spray drying to form homogeneously mixed granules
5. Form green bodies by dry forming, cold pressing methods
6. Be able to sinter a polycrystalline ceramic and measure the density achieved.
7. Prepare chemically bonded ceramics (e.g. cements) and measure their properties in terms of their processing parameters.

Assessment Tools:

Nine laboratory experiments are conducted by each student during the semester. The final grade is based on the outcome of the experiments and on the quality of the written report.

Contribution of Course to Meeting the Professional Component:

100%

Prepared by:

Waltraud M. Kriven, April 2001