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MATERIALS
MATERIALS SCIENCE
NON-METALLIC MATERIALS
1. CERAMICS
2. REFRACTORIES
3. GLASSES
4. POLYMERS
CERAMICS
DEFINITION
Refractories,
CERAMICS
Ceramic processing
i.
(rc/ra) stability
range
Geometry
0.155
0.225
0.414
( octahedral)
12
0.732
1.0
rc/ra = 1
( cubic)
FCC or HCP
bonded
bonding
PROPERTIES
Lower density
High melting temperature
Lower thermal conductivity
Low thermal expansion
PROPERTIES
Poor electrical conductivity
Good dielectrics
High hardness and brittle
Good inertness towards chemicals
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PROCESSING
Powder preparation
Shape forming process
Densification or sintering
Final machining
FORMING PROCESS
1. Die pressing
2. Isostatic pressing
3. Extrusion
4. Slip casting
5. Injection moulding
DIE PRESSING
Power mixed with organic binders
Filled into the die
Pressure is applied unidirectional
Inexpensive method
DIE PRESSING
Plunger
Powder
Die
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ISOSTATIC PRESSING
Powder mix is loaded into the rubber
mould
Pressed in a hydrostatic moulding
chamber
Density variation is avoided
ISOSTATIC PRESSING
Inlet
Powder
Rubber Mould
Oil
Outlet
EXTRUSION
Stiff plastic mix (powder+binder) is
extruded through an orifice
Used for making materials having an
axis normal to a fixed cross section
EXTRUSION
Extruded
Component
Piston
Powder
mix
Orifice
SLIP CASTING
Slip (is a suspension of particle in a liquid
medium) is poured into a plaster - of parries mould
After the
released
SLIP CASTING
Solid Mass
Slip
Plaster Mould
INJECTION MOULDING
Plastic mix ( power+ thermoplastic
polymer) is preheated in the barrel of
the injection moulding machine.
The viscous material is forced
through an orifice into a shaped tool
cavity.
INJECTION MOULDING
Piston
Orifice
Powder
mix
Tool Cavity
REFRACTORIES
DEFINITION
Refractories are heat resistant
materials
with
high
melting
temperature,
they
are
oxides,
carbides of Si, Al, Zr, Mg, etc
Examples: SiO2, MgO, CaO, ZrO2,
SiC.
REFRACTORIES
Acid refractories
Basic refractories
Neutral refractories
REFRACTORIES
Acid refractories
The refractories which
attacked by acid slags.
are
not
REFRACTORIES
Basic refractories
The refractories which
attacked by basic slags.
Examples:
Magnesite,
Chrome magnesite, etc
are
not
Dolomite,
REFRACTORIES
Neutral refractories
The refractories which are
attacked by acid or basic slags.
not
REFRACTORIES
FIRE CLAY REFRACTORIES
Raw material is fire clay (grayish or
blackish in colour)
all
places
of
ordinary
GLASSES(INORGANIC)
DEFINITION
Glass
is
a
noncrystalline,
metastable material, lacks long range
order, which has hardened and
become rigid without crystallizing.
Example of inorganic glasses: Soda
lime glass, fused silica, etc.
GLASSES(INORGANIC)
Glass transition temperature
Glass composition
Specific Volume
Liquid
Glass
Crystal
Tg
Tm Temperature
GLASS COMPOSITIONS
Most of the glasses have:
GLASS COMPOSITIONS
According to properties oxides are
divided into three types:
Glass (Network) formers
Network modifiers
intermediates
GLASS COMPOSITIONS
GLASS FORMERS
These
oxides
forms
three
dimensional network using its
triangular or tetrahedral units.
GLASS COMPOSITIONS
NETWORK MODIFIERS
Oxides incapable of forming a three
dimensional network, but break up
the network structure, thus lowers Tm
and Tg.
Example: Na2O, CaO, Y2O3, etc.
GLASS COMPOSITIONS
INTERMEDIATES
Oxides doesn't form glass by itself
but incorporated in the network
structure of the glass formers.
Example: Pb2O, Al2O3, BeO, TiO2, etc.
GLASS COMPOSITIONS
TYPICAL GLASS COMPOSITION
1. Fused silica ( 99%SiO2)
2. Window glass ( 72%SiO2, 1%Al2O3,
10% CaO, 14%Na2O, 2%MgO)
3. Optical flint (50%SiO2, 1%Na2O,
19%PbO, 8%K2O, 13%BaO)
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POLYMERS
DEFINITION
POLYMERIZATION MECHANISMS
DEGREE OF POLYMERIZATION
TYPES OF POLYMERS
POLYMERS
DEFINITION
Polymers are organic materials,
with long chain molecules, having
carbon as the common element in
their makeup.
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POLYMERS
POLYMERIZATION MECHANISMS
Addition polymerization
Condensation polymerization
ADDITION POLYMERIZATION
Addition polymerization is produced
by covalently joining the individual
molecules,
producing
chains
without changing the chemistry of
the reactants.
No byproduct is produced.
ADDITION POLYMERIZATION
STEPS IN ADDITION POLYMERIZATION
Initiation
Chain propagation
Termination
ADDITION POLYMERIZATION
Reaction is initiated
pressure or a catalyst.
by
heat,
Polymerization is terminated by
collision between the active ends of
two chains or by addition of
terminator (i.e, free radicals from
catalyst)
ADDITION POLYMERIZATION
Chain length is controlled by the
amount of initiator (for small amount
of initiator longer chain length due to
less amount of terminator)
Example: Production of polyethylene
from ethylene ( C2H4)
initiator is Hydrogen peroxide (H2O2)
ADDITION POLYMERIZATION
H
H O O H +C=C
H
Ethylene Molecule
H
H
H O + H O + C C Mer
H
ADDITION POLYMERIZATION
H
HO + HO CC
H
H H
H H
CC CC CC
H
H H
H H
Initiation of
reaction
Polyethylene
H
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CONDENSATION POLY
Two or more molecules joined by a
chemical reaction that releases a biproduct such as water, alcohol, etc.
This mechanism often involves
different monomers as starting
molecules.
CONDENSATION POLY
Example: Dimethyl terephtalate and
ethylene
glycol
to
produce
Polyethylene
terephthalate
(PET
polymer).
By product
(CH3OH)
is
methyl
alcohol
CONDENSATION POLY
H
HCOC
H
COC H
H
+
H
HO C C OH
H
CONDENSATION POLY
H
HCOC
COC C OH
PET
Polymer
H
HCOH
H
CONDENSATION POLY
The length of the polymer chain
depends on the ease with which the
monomers can diffuse to the end and
undergo condensation reaction.
Chain growth ceases when no more
monomer reach the end of the chain.
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DEGREE OF POLY
Polymers do not have a fixed
molecular weight, instead have a
range.
The average length of a linear
polymer, or average number of
repeat unit in the chain is called
degree of polymerization.
DEGREE OF POLY
Degree of polymerization
Average molecular weight of polymer
Mw fi Mi
DEGREE OF POLY
Number average molecular weight
Mn X i Mi
Mi mean molecular weight of ith
range.
fi weight fraction of the polymer
having chains within ith range.
Xi fraction of the total number of
chains within ith range.
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TYPES OF POLYMERS
THERMO PLASTICS
THERMOSETTING PLASTICS
ELASTOMERS
THERMOPLASTICS
Composed of long chains, may or
may not have branches.
Bonded together by weak Vander
walls bonds between chains.
THERMOPLASTICS
They
can
crystalline.
be
amorphous
or
THERMOSETTING PLASTICS
Composed of long chains molecules
that are strongly cross linked.
Stronger,
but
thermoplastics.
brittle
than
ELASTOMERS
They are known as rubbers.
Have elastic deformation > 200%