Courses - Introduction to Ceramic Processing
June 3-5, 2013 (2.5 days - ends at noon on Wednesday)
Managers, engineers, and scientists who will benefit from a better understanding of the critical role suspension and rheology control plays in the processing of ceramics as well as the basic concepts of colloidal behavior. The class will focus on wet powder processing, addressing advanced technical ceramic materials as well as the traditional clay-based systems. Lab sessions are built into the afternoon schedule to allow first-hand observation of the principles discussed in the lectures. Participants are encouraged to bring examples of defects for discussion.
This two and a half day course will address the concerns of ceramic processing from a comprehensive perspective, which necessarily has a major component in the colloidal properties of particles in suspension and their impact on the rheology of those suspensions. Lecture topics will begin with a broad discussion of defects in ceramic manufacturing, and how those defects are generally rooted in the processing and fabrication stage, even though they show up as cracking or warping during drying and/or sintering. The course will then progress to discussion of raw materials and powder characterization, and then to processing including the use of dispersants, role of mixing, impact of specific gravity, use of polymeric additives, and contribution of time (aging) on viscosity and performance of particle suspensions. Different rheological properties including dilatancy and thixotropy will be addressed through the use of practical examples. Recommendations for characterization and monitoring equipment will also be provided. The course will culminate with discussions illustrating how the processing contributes to the final microstructure and phase evolution in a heat treated ceramic component. Case studies and suggestions for additional reading will be presented throughout the course as appropriate. Course notes will be provided in a PowerPoint format both in a printed version (for use during the course) and an electronic version that includes articles and other reference material.
A sequential outline will be used beginning with an introduction to ceramic processing. The course will then logically progress through defects, raw material characterization, colloidal behavior, use of polymeric additives, mixing, definitions of viscosity and rheological properties, rheological process control diagrams, dilatancy and plasticity, aging, consolidation and forming. Drying, sintering and densification, and microstructure and phase evolution will also be briefly discussed as these processes are affected by processing.
Dr. William M. Carty is John F. McMahon Professor and Chair of Ceramic Engineering, in the Kazuo Inamori School of Engineering at Alfred University. Dr. Carty teaches both engineering courses in Ceramic Processing, Refractories, and Science of Whitewares and teaches Ceramic Science for the Artist. His research interests are in ceramic processing of traditional and advanced ceramic materials, microstructure tailoring and evolution, and the identification of defects and their elimination. He received the B.S. and M.S. in Ceramic Engineering from the University of Missouri-Rolla and the Ph.D. in Materials Science and Engineering from the University of Washington (Seattle). He joined the faculty at Alfred University in 1993.