Processing is key to the reproducible manufacture of ceramics. The tolerance of a finished ceramic to defects determines the raw materials selected, and the control that must be exercised during processing. More expensive advanced ceramics require higher quality, more expensive raw materials coupled with more carefully controlled manufacturing processes.Ceramic processing is complicated both by the number of steps required in manufacture (Fig. 1), and by requirements to optimize the processing in the different steps. These factors are often opposed. For example, a fine particle size provides improved plasticity for forming and a higher thermodynamic driving force for sintering; however, electrostatic attraction and van der Waals forces promote agglomeration, ie, the formation of weakly bound particle clusters, and caking, making mixing and packing difficult. Submicrometer particles can be more easily mixed and packed in liquids, but the finer interparticle pore structure results in higher forming and drying stresses, as well as longer forming and drying times.Ceramics are basically flaw intolerant materials. Consequently chemical and physical defects can severely degrade properties. Additionally, mistakes are cumulative in ceramic processing and these generally cannot be corrected during sintering and post-sintering processing (as they can be in metals processing, for example). The quality of the product is only as good as the quality of the raw materials used, and the control exercised in each of the process steps.
Raw MaterialsRaw materials for ceramic processing range from relatively impure clay materials (see CLAYS) mined from natural mineral deposits, to ultrahigh purity powders 638 CERAMICS, PROCESSING Vol. 5Kirk-Othmer Encyclopedia of Chemical Technology. Fig. 1. Flow diagram of the steps and processes involved in manufacturing a ceramic.Vol. 5 CERAMICS, PROCESSING CERAMICS, PROCESSING Vol. 5 by chemical synthesis pose some unresolved processing problems in the areas of handling and mixing. Solid State. Ceramic compounds can be formed by reacting constituent oxides and/or thermally decomposed salts at an elevated temperature in a solid-state process described as calcination (2,13-17). For example, spinel [1302-67-6], MgAl 2 O 4 , can be formed by reacting magnesia [1309-48-4], MgO, and alumina [1344-28-1], Al 2 O 3 .Because solid-state diffusion is inherently slow, fine, well-mixed powders are required to ensure that reactions go to completion and that chemical and structural homogeneity are achieved during calcination. Often multiple calcination, grinding, and mixing steps are performed to ensure homogeneity. Purity of the product is limited by the purity of the constituent raw materials, and by the impurities introduced during grinding. Ceramic powders formed by calcination are typically less expensive (<$1=kg) than those formed by liquid or vapor techniques ($$25 À 50=kg), but are also typically less pure and larger in size. Solution Chemistry. Submicrometer particle size, high purity ceramic powders ca...