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Ceramic
Processing
Ceramic
Processing
Mohamed N. Rahaman
University of Missouri-Rolla, USA
This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted
with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to
publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of
all materials or for the consequences of their use.
No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or
other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any informa-
tion storage or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://
www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA 01923,
978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For orga-
nizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for
identification and explanation without intent to infringe.
Rahaman, M. N. 1950-
Ceramic processing / Mohamed Rahaman.
p. cm.
Includes bibliographical references and index.
ISBN 0-8493-7285-2 (acid-free paper)
1. Ceramics. 2. Ceramic engineering. 3. Polycrystals. 4. Sintering. I. Title.
TP807.R278 2006
666--dc22 2006043889
Contents
Chapter 1 Ceramic Fabrication Processes: An Introductory Overview .......................................1
1.1 Introduction...............................................................................................................................1
1.2 Ceramic Fabrication Processes.................................................................................................2
1.2.1 Gas-Phase Reactions ....................................................................................................2
1.2.1.1 Chemical Vapor Deposition ..........................................................................4
1.2.1.2 Directed Metal Oxidation .............................................................................7
1.2.1.3 Reaction Bonding..........................................................................................8
1.2.1.4 Silicon Nitride ...............................................................................................9
1.2.1.5 Oxides..........................................................................................................10
1.2.1.6 Silicon Carbide............................................................................................11
1.2.2 Liquid Precursor Methods..........................................................................................12
1.2.2.1 Sol–Gel Processing .....................................................................................12
1.2.2.2 Polymer Pyrolysis .......................................................................................15
1.2.2.3 Silicon Carbide............................................................................................15
1.2.2.4 Silicon Nitride .............................................................................................17
1.2.2.5 Boron Nitride and Boron Carbide ..............................................................18
1.2.3 Fabrication from Powders ..........................................................................................19
1.2.3.1 Melt Casting ................................................................................................19
1.2.3.2 Sintering of Compacted Powders ...............................................................20
1.3 Production of Polycrystalline Ceramics from Powders: An Overview.................................21
1.3.1 Powder Synthesis and Powder Characterization........................................................21
1.3.2 Powder Consolidation ................................................................................................22
1.3.3 The Sintering Process.................................................................................................22
1.3.4 Ceramic Microstructures ............................................................................................25
1.4 Case Study in Processing: Fabrication of TiO2 from Powders .............................................28
1.5 Concluding Remarks ..............................................................................................................30
Problems...........................................................................................................................................30
References ........................................................................................................................................32
Problems.........................................................................................................................................187
References ......................................................................................................................................189
Appendix D: Aperture Size of U.S. Standard Wire Mesh Sieves (ASTM E 11:87) ..................459
Appendix E: Densities and Melting Points of Some Elements, Ceramics, and Minerals..........461
Index ..............................................................................................................................................465
7285_book.fm Page v Friday, June 9, 2006 10:28 AM
Preface
The production and application of ceramics are among the oldest technological skills. The field of
ceramic materials has its roots in the more traditional aspects of the subject such as clay-based
ceramics and glasses. During the past few decades, new developments in the use of ceramics in
more advanced technological applications have attracted considerable attention. The discovery of
ceramic superconductors, as well as the use of ceramics for heat-resistant tiles in the space shuttle,
optical fibers, components in high temperature engines, and the electrolyte in solid oxide fuel cells,
has generated considerable interest in the field.
The increasing use of ceramics in more advanced technological applications has resulted in a
heightened demand for improvements in properties and reliability. In recent years, there has been
the realization that such improvements can be achieved only through careful attention to the
fabrication process. The engineering properties of polycrystalline ceramics are controlled by the
microstructure, which, in turn, depends on the processing method used to fabricate the body.
Therefore, the fabrication process governs the production of microstructures with the desired
properties. It is often stated that materials science is a field at the interface between the physical
sciences (physics, chemistry, and mathematics) and engineering (such as electrical, mechanical,
and civil). In this view, the approach to ceramic processing is concerned with the understanding
of fundamentals and the application of the knowledge to the production of microstructures with
useful properties.
This book is concerned primarily with the processing of polycrystalline ceramics. Because of
its importance and widespread use, the fabrication of ceramics by the consolidation and sintering
of powders forms the focus of this book. A brief treatment of the production of ceramics (and
glasses) by the less conventional sol–gel route is also included. The approach is to outline the
fundamental issues of each process and to show how they are applied to the practical fabrication
of ceramics. Each fabrication route involves a number of processing steps, and each step has the
potential for producing microstructural flaws that degrade the properties of the fabricated material.
An important feature of this treatment is the attempt to show the importance of each step as well
as the interconnection between the various steps in the overall fabrication route. Chapter 1 provides
an introductory overview of the various methods that can be used for the production of ceramic
materials. The overview also forms a basis for the more detailed treatment of powder processing
and sol–gel processing, which is discussed later in the book. Chapter 2 to Chapter 9 form a logical
development from the start of the fabrication process to the final fabricated microstructure.
My intention has been to prepare a textbook that is suitable for a one-semester (or two-quarter)
course in ceramic processing at the upper undergraduate level or the introductory graduate level.
A background in the concepts and processing of traditional ceramics, typically obtained in lower-
level undergraduate courses, is assumed. It is hoped that the book will also be useful to researchers
in industry who are involved in the production of ceramics or who would wish to develop a
background in the processing of ceramics.
I wish to thank the many authors and publishers who have allowed me permission to reproduce
their figures in this book. Last but not least, I wish to thank my wife, Vashanti, for her encouragement
and support when I was preoccupied with the completion of this book.
7285_book.fm Page ix Friday, June 9, 2006 10:28 AM
The Author
Mohamed N. Rahaman is professor of ceramics in the department of materials science and
engineering, University of Missouri-Rolla. He earned a B.A. (Hons.) and an M.A. from the
University of Cambridge, England, and a Ph.D. from the University of Sheffield, England. Prior
to joining the University of Missouri in 1986, Dr. Rahaman held positions at the University of
Leeds, England; the University of the West Indies, Trinidad; and the Lawrence Berkeley National
Laboratory, Berkeley, California. Dr. Rahaman is the author of two books, and the author or coauthor
of over 125 publications, most of them in the area of processing and sintering of ceramics.
7285_C001.fm Page 1 Thursday, June 22, 2006 12:34 PM
1 Ceramic Fabrication
Processes: An Introductory
Overview
1.1 INTRODUCTION
The subject of ceramics covers a wide range of materials. Recent attempts have been made to
divide it into two parts: traditional ceramics and advanced ceramics. The usage of the term advanced
has, however, not received general acceptance and other forms, including technical, special, fine
and engineering will also be encountered. Traditional ceramics bear a close relationship to those
materials that have been developed since the time of the earliest civilizations. They are pottery,
structural clay products, and clay-based refractories, with which we may also group cements,
concretes, and glasses. Whereas traditional ceramics still represent a major part of the ceramics
industry, the interest in recent years has focused on advanced ceramics, ceramics that, with minor
exceptions, have been developed within the last 50 years or so. Advanced ceramics include ceramics
for electrical, magnetic, electronic, and optical applications (sometimes referred to as functional
ceramics) and ceramics for structural applications at ambient as well as at elevated temperatures
(structural ceramics). Although the distinction between traditional and advanced ceramics may be
referred to in this book occasionally for convenience, we do not wish to overemphasize it. There
is much to be gained through continued interaction between the traditional and the advanced sectors.
Chemically, with the exception of carbon, ceramics are nonmetallic, inorganic compounds.
Examples are the silicates such as kaolinite (Al2Si2O5(OH)4) and mullite (Al6Si2O13); simple oxides
such as alumina (Al2O3) and zirconia (ZrO2); complex oxides other than the silicates such as barium
titanate (BaTiO3) and the superconducting material YBa2Cu3O6+δ (0 ≤ δ ≤ 1). In addition, there are
nonoxides, including carbides, such as silicon carbide (SiC) and boron carbide (B4C); nitrides such
as silicon nitride (Si3N4), and boron nitride (BN); borides such titanium diboride (TiB2); silicides
such as molybdenum disilicide (MoSi2); and halides such as lithium fluoride (LiF). There are also
compounds based on nitride-oxide or oxynitride systems (e.g., β′-sialons with the general formula
Si6–zAlzN8–zOz where 0 < z < ∼4).
Structurally, all materials are either crystalline or amorphous (also referred to as glassy). The
difficulty and expense of growing single crystals means that, normally, crystalline ceramics (and
metals) are actually polycrystalline; they are made up of a large number of small crystals, or grains,
separated from one another by grain boundaries. In ceramics as well as in metals, we are concerned
with two types of structure, both of which have a profound effect on properties. The first type of
structure is at the atomic scale: the type of bonding and the crystal structure (for a crystalline
ceramic) or the amorphous structure (if it is glassy). The second type of structure is at a larger
scale: the microstructure, which refers to the nature, quantity, and distribution of the structural
elements or phases in the ceramic (e.g., crystals, glass, and porosity).
It is sometimes useful to distinguish between the intrinsic properties of a material and the
properties that depend on the microstructure. The intrinsic properties are determined by the structure
at the atomic scale and are properties that are not susceptible to significant change by modification
1
7285_C001.fm Page 2 Thursday, June 22, 2006 12:34 PM
2 Ceramic Processing
of the microstructure. These properties include the melting point, elastic modulus, and coefficient
of thermal expansion, and factors such as whether or not the material is brittle, magnetic, ferro-
electric, or semiconducting. In contrast, many of the properties critical to the engineering applica-
tions of materials are strongly dependent on the microstructure (e.g., mechanical strength, dielectric
constant, and electrical conductivity).
Intrinsically, ceramics usually have high melting points and are therefore generally described
as refractory. They are also usually hard, brittle, and chemically inert. This chemical inertness is
usually taken for granted, for example, in ceramic and glass tableware and in the bricks, mortar,
and glass of our houses. However, when used at high temperatures, as in the chemical and
metallurgical industries, this chemical inertness is severely tried. The electrical, magnetic, and
dielectric behaviors cover a wide range, for example, in the case of electrical behavior, from
insulators to conductors. The applications of ceramics are many. Usually, for a given application
one property may be of particular importance but, in fact, all relevant properties need to be
considered. We are, therefore, usually interested in combinations of properties. For traditional
ceramics and glasses, familiar applications include structural building materials (e.g., bricks and
roofing tile); refractories for furnace linings, tableware, and sanitaryware; electrical insulation (e.g.,
electrical porcelain and steatite); glass containers; and glasses for building and transportation
vehicles. The applications for which advanced ceramics have been developed or proposed are
already very diverse, and this area is expected to continue to grow at a reasonable rate. Table 1.1
illustrates some of the applications for advanced ceramics [1].
The important relationships between chemical composition, atomic structure, fabrication,
microstructure, and properties of polycrystalline ceramics are illustrated in Figure 1.1. The intrinsic
properties must be considered at the time of materials selection. For example, the phenomenon of
ferroelectricity originates in the perovskite crystal structure of which BaTiO3 is a good example.
For the production of a ferroelectric material, we may therefore wish to select BaTiO3. The role
of the fabrication process, then, is to produce microstructures with the desired engineering prop-
erties. For example, the measured dielectric constant of the fabricated BaTiO3 will depend signif-
icantly on the microstructure (grain size, porosity, and the presence of any secondary phases).
Normally, the overall fabrication method can be divided into a few or several discrete steps,
depending on the complexity of the method. Although there is no generally accepted terminology,
we will refer to these discrete steps as processing steps. The fabrication of a ceramic body, therefore,
involves a number of processing steps. In the next section, we examine, in general terms, some of
the commonly used methods for the fabrication of ceramics.
TABLE 1.1
Application of Advanced Ceramics Classified by Function
Function Ceramic Application
Electric Insulation materials (Al2O3, BeO, MgO) Integrated circuit substrate, package, wiring substrate, resistor
substrate, electronics interconnection substrate
Ferroelectric materials (BaTiO3, Ceramic capacitor
SrTiO3)
Piezoelectric materials (PZT) Vibrator, oscillator, filter, etc.
Transducer, ultrasonic humidifier, piezoelectric spark generator,
etc.
Semiconductor materials (BaTiO3, SiC, NTC thermistor: temperature sensor, temperature compensation,
ZnO–Bi2O3, V2O5 and other transition etc.
metal oxides) PTC thermistor: heater element, switch, temperature
compensation, etc.
CTR thermistor: heat sensor element
Thick film sensor: infrared sensor
Varistor: noise elimination, surge current absorber, lightning
arrestor, etc.
Sintered CdS material: solar cell
SiC heater: electric furnace heater, miniature heater, etc.
Ion-conducting materials (β-Al2O3, Solid electrolyte for sodium battery
ZrO2) ZrO2 ceramics: oxygen sensor, pH meter, fuel cells
Magnetic Soft ferrite Magnetic recording head, temperature sensor, etc.
Hard ferrite Ferrite magnet, fractional horse power motors, etc.
Optical Translucent alumina High-pressure sodium vapor lamp
Translucent Mg–Al spinel, mullite, etc. Lighting tube, special-purpose lamp, infrared transmission
window materials
Translucent Y2O3–ThO2 ceramics Laser materials
PLZT ceramics Light memory element, video display and storage system, light
modulation element, light shutter, light valve
Chemical Gas sensor (ZnO, Fe2O3, SnO2) Gas leakage alarm, automatic ventilation alarm, hydrocarbon,
fluorocarbon detectors, etc.
Humidity sensor (MgCr2O4–TiO2) Cooking control element in microwave oven, etc.
Catalyst carrier (cordierite) Catalyst carrier for emission control
Organic catalysts Enzyme carrier, zeolites
Electrodes (titanates, sulfides, borides) Electrowinning aluminum, photochemical processes, chlorine
production
Thermal ZrO2, TiO2 Infrared radiator
Mechanical Cutting tools (Al2O3, TiC, TiN, others) Ceramic tool, sintered CBN; cermet tool, artificial diamond;
nitride tool
Wear-resistant materials (Al2O3, ZrO2) Mechanical seal, ceramic liner, bearings, thread guide, pressure
sensors
Heat-resistant materials (SiC, Al2O3, Ceramic engine, turbine blade, heat exchangers, welding burner
Si3N4, others) nozzle, high-frequency combustion crucibles)
Biological Al2O3, MgO-stabilized ZrO2, Artificial tooth root, bone, and joint implantation.
hydroxyapatite, bioactive glass
Nuclear UO2, UO2–PuO2 Nuclear fuels
C, SiC, B4C Cladding materials
SiC, Al2O3, C, B4C Shielding materials
Source: Kenney, G.B. and Bowen, H.K., High tech ceramics in Japan: current and future markets, Am. Ceram. Soc. Bull.,
62, 590, 1983. With permission.
7285_C001.fm Page 4 Thursday, June 22, 2006 12:34 PM
4 Ceramic Processing
Chemical
composition
Ceramic
(Intrinsic)
fabrication
Microstructure Properties
TABLE 1.2
Common Ceramic Fabrication Methods
Starting Materials Method Product
as reaction bonding (or reaction forming) has been used mainly for the production of Si3N4 but is
now also being applied to the production of oxide ceramics. Reaction bonding (by a solid–liquid
reaction) is also an important fabrication route for SiC.
Chemical vapor deposition (CVD) is a process by which reactive molecules in the gas phase are
transported to a surface at which they chemically react and form a solid film [2–9]. It is a well-
established technique that can be used to deposit all classes of materials, including metals, ceramics,
and semiconductors, for a variety of applications. Large areas can be coated, and the process is
amenable to mass production. Thick films or even monolithic bodies can also be produced by
basically prolonging the deposition process so that the desired thickness is achieved. Table 1.3
shows some of the important reactions used for the fabrication of ceramics, together with the
temperature range of the reactions and the applications of the fabricated articles.
The apparatus used for CVD depends on the reaction being used, the reaction temperature, and
the configuration of the substrate. Figure 1.2 shows examples of reactors for the deposition of films
on substrates such as Si wafers. The general objective for any design is to provide uniform exposure
of the substrate to the reactant gases. CVD has a number of process variables that must be
manipulated to produce a deposit with the desired properties. These variables include the flow rate
of the reactant gases, the nature and flow rate of any carrier gases, the pressure in the reaction
vessel, and the temperature of the substrate. Substrate heating is required in CVD reactors because
the films are produced preferably by endothermic reactions. The temperature of the substrate
influences the deposition rate and is the main factor controlling the structure of the deposit. In
general, high temperatures will yield crystalline deposits whereas low temperatures result in amor-
phous materials. Between these two extremes a polycrystalline deposit will be formed.
7285_C001.fm Page 5 Thursday, June 22, 2006 12:34 PM
TABLE 1.3
Some Important CVD Reactions for the Fabrication of Ceramics
Temperature
Reaction (°°C) Application
Silicon
Quartz wafers
bell jar
Induction
coil or
heaters
Exhaust Exhaust
Radiant Quartz bell jar
Gas inlet heaters
Exhaust
(a) (b)
Three-zone
Gas temperature
control control
(c) (d)
FIGURE 1.2 Typical reactors used in chemical vapor deposition: (a) pancake reactor; (b) barrel reactor; (c)
horizontal reactor; (d) low-pressure (LPCVD) reactor. (From Jensen, K.F., Modeling of chemical vapor dep-
osition reactors for the fabrication of microelectronic devices, Am. Chem. Soc. Symp. Series, 237, 197, 1984.)
7285_C001.fm Page 6 Thursday, June 22, 2006 12:34 PM
6 Ceramic Processing
Microwaves
(2.45 GHz)
Substrate
Pressure gage
To pumps
FIGURE 1.3 Schematic diagram of microwave-plasma-assisted chemical vapor deposition (MPACVD) dia-
mond growth system. (From Spear, K.E., Diamond — ceramic coating of the future, J. Am. Ceram. Soc., 72,
171, 1989. With permission.)
The pressure in the reaction vessel influences the concentration of the reactant gases, the
diffusion of reactants toward the substrate, and the diffusion of the products away from the surface.
The higher diffusivity at lower pressure leads to the formation of films with better uniformity, so
most CVD reactors are operated in the pressure range of 1 to 15 kPa. The reactant gases, also
referred to as precursor molecules, are chosen to react and produce a specific film. Properties
necessary for a good precursor include thermal stability at its vaporization temperature and sufficient
vapor pressure (at least ∼125 Pa) at a reasonable temperature (∼300°C) for effective gas-phase
delivery to the growth surface. In addition, the molecules must be obtainable at high purity and
must not undergo parasitic or side reactions which would lead to contamination or degradation of
the film [10]. Examples of the classes of precursor molecules (e.g., hydrides, halides, carbonyls,
hydrocarbons, and organometallics) and the types of chemical reaction (pyrolysis, oxidation/hydrol-
ysis, reduction, carbidization/nitridation, and disproportionation) are summarized in Table 1.3.
CVD technology has been attracting much interest recently for the production of diamond films
or coatings [11]. The diamond has several attractive properties but, in the past, high pressures and
high temperatures were required to produce synthetic diamond. In contrast, a plasma-assisted CVD
process allows the production of diamond films at relatively low temperatures and low pressures
(Figure 1.3). The deposition process is complex and is not understood clearly at present. The basic
reaction involves the pyrolysis of a carbon-containing precursor such as methane:
CH 4 (g ) → C(diamond ) + 2 H 2 (g ) (1.1)
The typical process consists of the reactant gas at less than atmospheric pressure and containing
> 95% H2. The gas is activated by passing it through a plasma or past a heated filament (at ∼2000°C)
before deposition on a substrate at 800 to 1000°C.
CVD technology has also been attracting significant interest as a fabrication route for ceramic
composites [12]. For fiber-reinforced ceramics, one approach that has shown considerable promise
is chemical vapor infiltration (CVI). The fibers, preformed into the shape and dimensions of the
finished body, are placed into the reactant gases and held at the desired temperature so that the
deposited material is formed in the interstices between the fibers. Significant effort has been devoted
to SiC matrix composites reinforced with SiC or C fibers. The SiC matrix is typically deposited
7285_C001.fm Page 7 Thursday, June 22, 2006 12:34 PM
Hot surface
Fibrous
Graphite Cold surface preform
holder
Reactant
gases
FIGURE 1.4 Schematic diagram of chemical vapor infiltration process exploiting forced flow of the infiltrating
gas. (From Stinton, D.P., Besmann, T.M., and Lowder, R.A., Advanced ceramics by chemical vapor deposition
techniques, Am. Ceram. Soc. Bull., 67, 350, 1988. With permission.)
Fabrication routes involving reactions between a gas and a liquid are generally impractical for the
production of ceramic bodies because the reaction product usually forms a solid protective coating,
7285_C001.fm Page 8 Thursday, June 22, 2006 12:34 PM
8 Ceramic Processing
Vapor-phase Vapor-phase
oxidant oxidant Filter
Reaction
Filter with
product
reaction product
Molten Molten matrix
metal metal
Refractory Refractory
container container
(a) (b)
FIGURE 1.5 Schematic diagram of (a) the formation of a matrix of oxide and unreacted metal by directed
oxidation of molten metal and (b) oxidation in the presence of a filler (From Newkirk, M.S. et al., Preparation
of Lanxide™ ceramic matrix composites: matrix formation by directed metal oxidation, Ceram. Eng. Sci.,
Proc., 8, 879, 1987. With permission.)
thereby separating the reactants and effectively stopping the reaction. However, a novel method
employing directed oxidation of a molten metal by a gas has been developed by the Lanxide
Corporation for the production of porous and dense materials, as well as composites [14–19]. Figure
1.5 shows a schematic of the reaction process. In Figure 1.5a, a molten metal (e.g., an Al alloy) is
being oxidized by a gas (e.g., air). If the temperature is in the range of 900 to 1350°C, and the Al
alloy contains a few percent of Mg and a group IVA element (e.g., Si, Ge, Sn, or Pb), the oxide
coating is no longer protective. Instead, it contains small pores through which molten metal is
drawn up to the top surface of the film, thereby continuing the oxidation process. As long as the
molten metal and the oxidizing gas are available to sustain the process, and the temperature is
maintained, the reaction product continues to grow at a rate of a few centimeters per day until the
desired thickness is obtained. The material produced in this way consists of two phases: the
oxidation product (e.g., Al2O3) that is continuous and interconnected, and unreacted metal (Al
alloy). The amount of unreacted metal (typically 5 to 30 vol%) depends on the starting materials
and processing parameters (e.g., the temperature).
For the production of composites, a filler material (e.g., particles, platelets, or fibers) is shaped
into a preform of the size and shape desired of the product. The filler and the metal alloy are then
heated to the growth temperature in which the oxidation process occurs outward from the metal
surface and into the preform (Figure 1.5b), so that the oxidation product becomes the matrix of
the composite. A micrograph of a SiC fiber preform that has been filled with an Al2O3/Al matrix
by directed oxidation of molten aluminum is shown in Figure 1.6.
The term directed metal oxidation is taken to include all reactions in which the metal gives up
or shares its electrons. The method has been used to produce composites with not only matrices
of oxides but also nitrides, borides, carbides, and titanates. Composite systems produced by the
method include matrices of Al2O3/Al, AlN/Al, ZrN/Zr, TiN/Ti, and ZrC/Zr, and fillers of Al2O3,
SiC, BaTiO3, AlN, B4C, TiB2, ZrN, ZrB2, and TiN. A distinct advantage of the method is that
growth of the matrix into the preform involves little or no change in dimensions. The problems
associated with shrinkage during densification in other fabrication routes (e.g., powder processing)
are therefore avoided. Furthermore, large components can be produced readily with good control
of the component dimensions.
The term reaction bonding (or reaction forming) is commonly used to describe fabrication routes
in which a porous solid preform reacts with a gas (or a liquid) to produce the desired chemical
7285_C001.fm Page 9 Thursday, June 22, 2006 12:34 PM
FIGURE 1.6 Optical micrograph of an Al2O3/Al matrix reinforced with SiC fibers produced by directed metal
oxidation (From Newkirk, M.S. et al., Preparation of Lanxide™ ceramic matrix composites: matrix formation
by directed metal oxidation, Ceram. Eng. Sci., Proc., 8, 879, 1987. With permission.)
compound and bonding between the grains. Commonly, the process is accompanied by little or no
shrinkage of the perform, thereby providing the benefit of near-net-shape fabrication. Reaction
bonding is used on a large scale as one of the fabrication routes for Si3N4 and SiC [20,21].
Si3N4 is the most widely known reaction-bonded system involving the reaction between a solid and
a gas phase. In the formation of reaction-bonded Si3N4 (RBSN), Si powder is consolidated by one
of the common ceramic forming methods (e.g., die pressing, isostatic pressing, slip casting, or
injection molding) to form a billet or a shaped article. This is then preheated in argon at ∼1200°C
to develop some strength, after which it can be machined to the required component shape and
dimensions. Finally, the component is heated, usually in N2 gas at atmospheric pressure and at
temperatures in the region of 1250 to 1400°C, when reaction bonding occurs to produce RBSN.
Although the mechanism is fairly complex [22], the overall reaction can be written:
The densities of Si and Si3N4 are 2.33 g/cm3 and 3.18 g/cm3, respectively, so the reaction of
a silicon particle to form Si3N4 involves a volume expansion of 22%. However, very little change
in the external dimensions of the component occurs during the nitridation. This means that the
nitridation occurs by a mechanism in which new mass that has been added to the body expands
into the surrounding pore space. As the pore sizes and the number of pores decrease, the pore
channels close off and the reaction effectively stops. In preforms with relatively high density, pore
channel closure commonly occurs prior to complete reaction. The RBSN has a porosity of 15 to
20% and some residual, unreacted Si. The Si3N4 consists of 60 to 90 wt% of the α-phase, the
remainder being β-Si3N4. Several factors influence the reaction kinetics and the resulting micro-
structure, including the Si particle size, the composition and pressure of the nitriding gas, the
reaction temperature, and impurities in the Si starting powder [22]. Because of the high porosity,
the strength of RBSN is inferior to that of dense Si3N4 produced by other methods (e.g., hot
7285_C001.fm Page 10 Thursday, June 22, 2006 12:34 PM
10 Ceramic Processing
pressing). On the other hand, RBSN bodies with a high degree of dimensional accuracy and with
complex shapes can be prepared fairly readily without the need for expensive machining after
firing.
1.2.1.5 Oxides
A reaction bonding route involving both gas–solid and gas–liquid reactions is the reaction-bonded
aluminum oxide (RBAO) process developed by Claussen and coworkers [23–27]. The RBAO
process utilizes the oxidation of powder mixtures containing a substantial amount of Al (30 to 65
vol%). A mixture of Al (particle size ∼20 μm), α-Al2O3 (0.5 to 1.0 μm), and ZrO2 (∼0.5 μm) is
milled vigorously in an attrition mill, dried and compacted to produce a green article (porosity ≈
30 to 40%). During heat treatment in an oxidizing atmosphere (commonly air), the Al oxidizes to
nanometer-sized γ-Al2O3 crystals below ∼900°C that undergo a phase transformation to α-Al2O3
at temperatures up to ∼11~00°C. The volume expansion (28 vol%) associated with the oxidation
of Al to α-Al2O3 is used to partially compensate for the shrinkage due to sintering, so that dense
RBAO ceramics can be achieved with lower shrinkage than conventionally sintered Al2O3 ceramics.
Figure 1.7 shows a micrograph of a reaction-bonded Al2O3/ZrO2 ceramic produced from a starting
mixture of 45 vol% Al, 35 vol% Al2O3, and 20 vol% ZrO2. Successful application of the RBAO
process depends on several variables, such as the characteristics of the starting powders (e.g.,
particle size and volume fraction of the Al), the milling parameters, the green density of the
compacted mixture, and the heating (oxidation) schedule. ZrO2 is known to aid the microstructure
development during sintering, but its role is not clear. In addition to Al2O3, the RBAO process has
been applied to the fabrication of mullite ceramics [28] and composites [29].
A gas–solid reaction involving the oxidation of a combination of an alkaline earth metal and
another metal has been used recently to produce ceramics containing an alkaline earth element
[30–35]. An unusual feature of most alkaline earth metals is the reduction in solid volume
accompanying oxidation. For example, the molar volume of MgO is 19% smaller than that of
Mg. In contrast, most other metals tend to expand during oxidation. The reduction in volume due
to the oxidation of an alkaline earth metal can be used to offset the volume expansion of
accompanying the oxidation of another metal. In this way, dense ceramics containing an alkaline
earth element can be produced with little change in external dimensions from dense preforms of
metal-bearing precursors.
1 μm
FIGURE 1.7 Scanning electron micrograph showing the microstructure of a reaction-bonded aluminum oxide
(RBAO) sample. The white phase is ZrO2 (∼20 vol%) and the dark phase is Al2O3. (Courtesy of M.P. Harmer.)
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to be united; and is there not in all kinds of life, something similar
and common? Hence, when the affections of the soul verge to a
baser nature, while connected with a human body, these
affections, on the dissolution of such a body, become enveloped
as it were, in a brutal nature, and the rational eye, in this case,
clouded with perturbations, is oppressed by the irrational energies
of the brute, and surveys nothing but the dark phantasms of a
degraded imagination. But this doctrine is vindicated by Proclus
with his usual subtilty, in his admirable commentary on the
Timæus, lib. v. p. 329, as follows, “It is usual, says he, to enquire
how souls can descend into brute animals. And some, indeed,
think that there are certain similitudes of men to brutes, which
they call savage lives: for they by no means think it possible that
the rational essence can become the soul of a savage animal. On
the contrary, others allow it may be sent into brutes, because all
souls are of one and the same kind; so that they may become
wolves and panthers, and ichneumons. But true reason, indeed,
asserts that the human soul way be lodged in brutes, yet in such
a manner, as that it may obtain its own proper life, and that the
degraded soul may, as it were, be carried above it, and be bound
to the baser nature, by a propensity and similitude of affection.
And that this is the only mode of insinuation, we have proved by
a multitude of reasons, in our commentaries on the Phædrus. But
if it is requisite to take notice, that this is the opinion of Plato, we
add, that in his politics, he says, that the soul of Thersites
assumed an ape, but not the body of an ape: and in the
Phædrus, that the soul descends into a savage life, but not into a
savage body; for life is conjoined with its proper soul. And in this
place he says it is changed into a brutal nature: for a brutal
nature is not a brutal body, but a brutal life.”
[65] Pericles Lydus, a Stoic philosopher.
[66] Vide Pausan. lib. i. Atticorum, cap. 21. et 20.
[67] He means the Christians.
[68] Proclus was born in the year of Christ 412, on the 6th of
the Ides of February. But, for the sake of the astrologers, I have
subjoined the following figure from the Prolegomena of Fabricius
to this life: and though I am not skilled in the art myself, I am
persuaded, from the arguments of Plotinus, that it contains many
general truths; but when made subservient to particulars, is liable
to great inaccuracy and error. In short, its evidence is wholly of a
physiognomic nature; for such is the admirable order and
connection of things, that throughout the universe, one thing is
signified by another, and wholes are after a manner contained in
their parts. So that the language of the obscure and profound
Heraclitus is perfectly just, when he says, “You must connect the
perfect and the imperfect, the agreeing and the disagreeing, the
consonant and the dissonant, and out of one all things, and out
of all things one.”
And the conclusion will be true, though the major and minor
terms are false; but then these terms are not the causes of the
conclusion, and we have an inference without a proof. In like
manner, if mathematical species are delusive and fictitious, the
conclusions deduced from them as principles, are merely
hypothetical, and not demonstrative.
[76] Aristotle, in his last Analytics. The reader will please to
observe, that the whole force of this nervous, accurate, and
elegant reasoning, is directed against Aristotle; who seems
unfortunately to have considered, with the moderns, that
mathematical species subsist in the soul, by an abstraction from
sensibles. See the preceding Dissertation.
[77] Viz. 1, 2, 4, 8, 3, 9, 27. Concerning which, see lib. iii. of
Proclus’s excellent Commentary on the Timæus.
[78] Plato frequently, both in the Meno and elsewhere, shews
that science is Reminiscence; and I think not without the
strongest reason. For since the soul is immaterial, as we have
demonstrated in the dissertation to this work, she must be truly
immortal, i. e. both a parte ante, & a parte post. That she must
be eternal, indeed, with respect to futurity, if immaterial, is
admitted by all; and we may prove, with Aristotle, in his first book
de Cœlo, that she is immortal, likewise a parte ante, as follows.
Every thing without generation, is incorruptible, and every thing
incorruptible, is without generation: for that which is without
generation, has a necessity of existing infinitely a parte ante
(from the hypothesis); and therefore, if it possesses a capacity of
being destroyed, since there is no greater reason why it should be
corrupted now, rather than in some former period, it is endued
with a capacity of being destroyed and ceasing to be, in every
instant of infinite time, in which it necessarily is. In like manner,
that which is incorruptible, has a necessity of existing infinitely a
parte post; therefore, if it possesses a capacity of being
generated, since there is no greater reason why it should be
generated now rather than afterwards, it possesses a capacity of
being generated, in every instant of time, in which it necessarily
is. If then the soul is essentially immortal, with respect to the
past and future circulations of time; and if she is replete with
forms or ideas of every kind, as we have proved in the
dissertation, she must, from her circulating nature, have been for
ever conversant in alternately possessing and losing the
knowledge of these. Now, the recovery of this knowledge by
science, is called by Plato, reminiscence; and is nothing more
than a renewed contemplation of those divine forms, so familiar
to the soul, before she became involved in the dark vestment of
an earthly body. So that we may say, with the elegant Maximus
Tyrus, (Disser. 28.) “Reminiscence is similar to that which happens
to the corporeal eye, which, though always endued with a power
of vision, yet darkness sometimes obstructs its passage, and
averts it from the perception of things. Art therefore, approaches,
which though it does not give to the eye the power of vision, yet
removes its impediments, and affords a free egress to its rays.
Conceive now, that our rational soul is such a power of
perceiving, which sees and knows the nature of beings. To this
the common calamity of bodies happens, that darkness spreading
round it, hurries away its aspect, blunts its sharpness, and
extinguishes its proper light. Afterwards, the art of reason
approaches, which, like a physician, does not bring or afford it a
new science, but rouses that which it possesses, though very
slender, confused, and unsteady.” Hence, since the soul, by her
immersion in body, is in a dormant state, until she is roused by
science to an exertion of her latent energies; and yet even
previous to this awakening, since she contains the vivid sparks, as
it were, of all knowledge, which only require to be ventilated by
the wings of learning, in order to rekindle the light of ideas, she
may be said in this case to know all things as in a dream, and to
be ignorant of them with respect to vigilant perceptions. Hence
too, we may infer that time does not antecede our essential
knowledge of forms, because we possess it from eternity: but it
precedes our knowledge with respect to a production of these
reasons into perfect energy. I only add, that I would recommend
the liberal English reader, to Mr. Sydenham’s excellent translation
of Plato’s Meno, where he will find a familiar and elegant
demonstration of the doctrine of Reminiscence.
[79] Concerning this valuable work, entitled ΙΕΡΟ‘Σ ΛΟΓΟ’Σ,
see the Bibliotheca Græca of Fabricius, vol. i. p. 118 and 462, and
in the commentary of Syrianus on Aristotle’s metaphysics, p. 7,
71, 83, and 108, the reader will find some curious extracts from
this celebrated discourse; particularly in p. 83. Syrianus informs
us, “that he who consults this work will find all the orders both of
Monads and Numbers, without neglecting one, fully celebrated
(ὐμνουμένας.)” There is no doubt, but that Pythagoras and his
disciples concealed the sublimest truths, under the symbols of
numbers; of which he who reads and understands the writings of
the Platonists will be fully convinced. Hence Proclus, in the third
book of his excellent commentary on the Timæus, observes, “that
Plato employed mathematical terms for the sake of mystery and
concealment, as certain veils, by which the penetralia of truth
might be secluded from vulgar inspection, just as the theologists
made fables, but the Pythagoreans symbols, subservient to the
same purpose: for in images we may speculate their exemplars,
and the former afford us the means of access to the latter.”
[80] Concerning this Geometric Number, in the 8th book of
Plato’s Republic, than which Cicero affirms there is nothing more
obscure, see the notes of Bullialdus to Theo. p. 292.
[81] I am sorry to say, that this part of the enemies to pure
geometry and arithmetic, are at the present time very numerous;
conceptions of utility in these sciences, extending no farther than
the sordid purposes of a mere animal life. But surely, if intellect is
a part of our composition, and the noblest part too, there must
be an object of its contemplation; and this, which is no other than
truth in the most exalted sense, must be the most noble and
useful subject of speculation to every rational being.
[82] In the 13th book of his Metaphysics, cap. iii.
[83] In. I. De Partib. Animalium, et in primo Ethic. cap. iii.
[84] See more concerning this in the Dissertation.
[85] Since number is prior to magnitude, the demonstrations
of arithmetic must be more intellectual, but those of geometry
more accommodated to the rational power. And when either
arithmetic or geometry is applied to sensible concerns, the
demonstrations, from the nature of the subjects, must participate
of the obscurity of opinion. If this is the case, a true
mathematician will value those parts of his science most, which
participate most of evidence; and will consider them as degraded,
when applied to the common purposes of life.
[86] This division of the mathematical science, according to
the Pythagoreans, which is nearly coincident with that of Plato, is
blamed by Dr. Barrow in his Mathematical Lectures, p. 15. as
being confined within too narrow limits: and the reason he
assigns for so partial a division, is, “because, in Plato’s time,
others were either not yet invented, or not sufficiently cultivated,
or at least were not yet received into the number of the
mathematical sciences.” But I must beg leave to differ from this
most illustrious mathematician in this affair; and to assert that the
reason of so confined a distribution (as it is conceived by the
moderns) arose from the exalted conceptions these wise men
entertained of the mathematical sciences, which they considered
as so many preludes to the knowledge of divinity, when properly
pursued; but they reckoned them degraded and perverted, when
they became mixed with sensible objects, and were applied to the
common purposes of life.
[87] That is, a right and circular line.
[88] I am afraid there are few in the present day, who do not
consider tactics as one of the most principal parts of
mathematics; and who would not fail to cite, in defence of their
opinions, that great reformer of philosophy, as he is called, Lord
Bacon, commending pursuits which come home to men’s
businesses and bosoms. Indeed, if what is lowest in the true
order of things, and best administers to the vilest part of human
nature, is to have the preference, their opinion is right, and Lord
Bacon is a philosopher!
[89] By this is to be understood the art new called
Perspective: from whence it is evident that this art was not
unknown to the ancients, though it is questioned by the moderns.
[90] From hence it appears, that it is doubtful whether Plato is
the author of the dialogue called Epinomis; and I think it may
with great propriety be questioned. For though it bears evident
marks of high antiquity, and is replete with genuine wisdom, it
does not seem to be perfectly after Plato’s manner; nor to contain
that great depth of thought with which the writings of this
philosopher abound. Fabricius (in his Bibliotheca Græca, lib. i. p.
27.) wonders that Suidas should ascribe this work to a
philosopher who distributed Plato’s laws into twelve books,
because it was an usual opinion; from whence it seems, that
accurate critic had not attended to the present passage.
[91] This proximate conjunction of the mathematical sciences,
which Proclus considers as subordinate to dialectic, seems to
differ from that vertex of science in this, that the former merely
embraces the principles of all science, but the latter comprehends
the universal genera of being, and speculates the principle of all.
[92] In the Meno.
[93] This is certainly the true or philosophical employment of
the mathematical science; for by this means we shall be enabled
to ascend from sense to intellect, and rekindle in the soul that
divine light of truth, which, previous to such an energy, was
buried in the obscurity of a corporeal nature. But by a contrary
process, I mean, by applying mathematical speculations, to
experimental purposes, we shall blind the liberal eye of the soul,
and leave nothing in its stead but the darkness of corporeal
vision, and the phantoms of a degraded imagination.
[94] The design of the present chapter is to prove that the
figures which are the subjects of geometric speculation, do not
subsist in external and sensible matter, but in the receptacle of
imagination, or the matter of the phantasy. And this our
philosopher proves with his usual elegance, subtilty, and depth.
Indeed, it must be evident to every attentive observer, that
sensible figures fall far short of that accuracy and perfection
which are required in geometrical definitions: for there is no
sensible circle perfectly round, since the point from which it is
described is not without parts; and, as Vossius well observes, (de
Mathem. p. 4.) there is not any sphere in the nature of things,
that only touches in a point, for with some part of its superficies it
always touches the subjected plane in a line, as Aristotle shews
Protagoras to have objected against the geometricians. Nor must
we say, with that great mathematician Dr. Barrow, in his
Mathematical Lectures, page 76, “that all imaginable geometrical
figures, are really inherent in every particle of matter, in the
utmost perfection, though not apparent to sense; just as the
effigies of Cæsar lies hid in the unhewn marble, and is no new
thing made by the statuary, but only is discovered and brought to
sight by his workmanship, i. e. by removing the parts of matter
by which it is overshadowed and involved. Which made Michael
Angelus, the most famous carver, say, that sculpture was nothing
but a purgation from things superfluous. For take all that is
superfluous, (says he) from the wood or stone, and the rest will
be the figure you intend. So, if the hand of an angel (at least the
power of God) should think fit to polish any particle of matter,
without vacuity, a spherical superficies would appear to the eyes,
of a figure exactly round; not as created anew, but as unveiled
and laid open from the disguises and covers of its circumjacent
matter.” For this would be giving a perfection to sensible matter,
which it is naturally incapable of receiving: since external body is
essentially full of pores and irregularities, which must eternally
prevent its receiving the accuracy of geometrical body, though
polished by the hand of an angel. Besides, what polishing would
ever produce a point without parts, and a line without breadth?
For though body may be reduced to the greatest exility, it will not
by this means ever pass into an incorporeal nature, and desert its
triple dimension. Since external matter, therefore, is by no means
the receptacle of geometrical figures, they must necessarily reside
in the catoptric matter of the phantasy, where they subsist with
an accuracy sufficient for the energies of this science. It is true,
indeed, that even in the purer matter of imagination, the point
does not appear perfectly impartible, nor the line without latitude:
but then the magnitude of the point, and the breadth of the line
is indefinite, and they are, at the same time, unattended with the
qualities of body, and exhibit to the eye of thought, magnitude
alone. Hence, the figures in the phantasy, are the proper
recipients of that universal, which is the object of geometrical
speculation, and represent, as in a mirror, the participated
subsistence of those vital and immaterial forms which essentially
reside in the soul.
[95] This division is elegantly explained by Ammonius, (in
Porphyr. p. 12.) as follows, “Conceive a seal-ring, which has the
image of some particular person, for instance, of Achilles,
engraved in its seal, and let there be many portions of wax, which
are impressed by the ring. Afterwards conceive that some one
approaches, and perceives all the portions of wax, stamped with
the impression of this one ring, and keeps the impression of the
ring in his mind: the seal engraved in the ring, represents the
universal, prior to the many: the impression in the portions of
wax, the universal in the many: but that which remains in the
intelligence of the beholder, may be called the universal, after and
posterior to the many. The same must we conceive in genera and
species. For that best and most excellent artificer of the world,
possesses within himself the forms and exemplars of all things: so
that in the fabrication of man, he looks back upon the form of
man resident in his essence, and fashions all the rest according to
its exemplar. But if any one should oppose this doctrine, and
assert that the forms of things do not reside with their artificer,
let him attend to the following arguments. The artificer either
knows, or is ignorant of that which he produces: but he who is
ignorant will never produce any thing. For who will attempt to do
that, which he is ignorant how to perform? since he cannot act
from an irrational power like nature, whose operations are not
attended with animadversion. But if he produces any thing by a
certain reason, he must possess a knowledge of every thing
which he produces. If, therefore, it is not impious to assert, that
the operations of the Deity, like those of men, are attended with
knowledge, it is evident that the forms of things must reside in
his essence: but forms are in the demiurgus, like the seal in the
ring; and these forms are said to be prior to the many, and
separated from matter. But the species man, is contained in each
particular man, like the impression of the seal in the wax, and is
said to subsist in the many, without a separation from matter. And
when we behold particular men, and perceive the same form and
effigy in each, that form seared in our soul, is said to be after the
many, and to have a posterior generation: just as we observed in
him, who beheld many seals impressed in the wax from one and
the same ring. And this one, posterior to the many, may be
separated from body, when it is conceived as not inherent in
body, but in the soul: but is incapable of a real separation from its
subject.” We must here, however, observe, that when Ammonius
speaks of the knowledge of the Deity, it must be conceived as far
superior to ours. For he possesses a nature more true than all
essence, and a perception clearer than all knowledge. And as he
produced all things by his unity, so by an ineffable unity of
apprehension, he knows the universality of things.
[96] In lib. vii. Metaphys. 35 & 39.
[97] In lib. iii. de Anima, tex. 20.
[98] That is, geometry first speculates the circle delineated on
paper, or in the dust: but by the medium of the circular figure in
the phantasy, contemplates the circle resident in cogitation; and
by that universal, or circular reason, participated in the circle of
the phantasy, frames its demonstrations.
[99] In his first Analytics, t. 42. See the Dissertation to this
work.
[100] Such as the proportion of the diagonal of a square to its
side; and that of the diameter of a circle, to the periphery.
[101] The gnomons, from which square numbers are
produced, are odd numbers in a natural series from unity, i. e. 1,
3, 5, 7, 9, 11, &c. for these, added to each other continually,
produce square numbers ad infinitum. But these gnomons
continually decrease from the highest, and are at length
terminated by indivisible unity.
[102] This doctrine of ineffable quantities, or such whose
proportion cannot be expressed, is largely and accurately
discussed by Euclid, in the tenth book of his Elements: but its
study is neglected by modern mathematicians, because it is of no
use, that is, because it contributes to nothing mechanical.
[103] This proposition is the 11th of the second book: at least,
the method of dividing a line into extreme and mean proportion,
is immediately deduced from it; which is done by Euclid, in the
30th, of the sixth book. Thus, Euclid shews (11. 2.) how to divide
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