Analysis of CNC machining technology in production of plaster moulds

Abstract

The present paper continues the further application of machining techniques in the ceramics industry with the aim of optimising company resources in new competitive markets. The work is focused on plaster model and mould generation by computer based geometric design, machine tool path creation, and subsequent production through CNC machining using a robotic machining centre. Many constraints were identified related specifically to the machining of plaster used in the manufacture of ceramic ware. Because of the limited information, since most machining investigations have only considered metal machining or fired ceramics, a large number of machining experiments were conducted. It is concluded that substantial advantages are gained through the use of this new approach for ceramic production processes, and the subjects for follow on research are defined.     

Fabrication of coloured zirconia ceramics by infiltrating water debound injection moulded green body

Abstract

Abstract

The authors developed a new technique combining ceramic injection moulding and liquid precursor infiltration, presenting a new strategy for fabrication of coloured zirconia ceramics. The authors’ strategy includes ceramic injection moulding 3Y‐TZP powder using a water debinding binder system, debinding moulded parts in water and drying, immersing debound parts in solutions containing different colouring ions and then sintering and creating coloured zirconia ceramics. The fabricated coloured ceramic bars exhibit a core shell structure, and the thickness of the coloured shell can be tailored by adjusting immersion time and temperature. Using solutions containing different colouring ions, ceramic bars with various colours can be prepared.     

Ceramics of Ategua (Córdoba, Spain): Mineralogical and petrographic study

This paper is part of research project on the ceramics of Ategua, a village located in the Guadalquivir depression near Córdoba (S. Spain). Ategua is a major archaeological deposit with pre-Roman (pre-colonial, Tartessian and Iberian) ruins that are highly rich in ceramic pieces.This work was conducted on 20 selected pieces found in various archaeological layers spanning the following phases in the period from 900 to 350 B.C. (i.e. the beginning of the Roman republic):

(a) Phase I: pre-colonial Bronze age, from 900 to 859 B.C. in a pre-colonial necropolis.

(b) Phases II–IV: western-style and Final Bronze age, from 750 to 550 B.C.

In order to identify the origin of ceramics and the different types of materials used to produce the ceramic pieces studied, we used various techniques including: X-ray diffraction, scanning electron microscopy with EDS microanalysis and petrographic microscopy (thin section).The materials identified in most of the ceramic pieces from the archaeological phases studied were similar and also present in the geological environment, which supports an autochthonous origin. The presence of metamorphic rock clase, amphiboles and small content of TiO₂ in some of the ceramic simples could suggest its allocthonous origenorigin.This paper reports the first mineral and petrographic data on pre-Roman ceramics from Ategua.     

Bioceramics and their application for dental restoration

Abstract

This review article covers the historical development of ceramics, from the beginnings to the present. Feldspar based ceramic biomaterials for veneering metal frameworks, which are based on the jacket porcelain crown, have firmly established themselves in restorative dentistry since the 1970s. Currently, the development of restorative dental materials that can be used to replace metal represents a major challenge. As a result, this review will focus on the latest materials in this field. These materials include glass ceramics as well as high performance sintered ceramics. Glass ceramics exhibit more favourable optical properties, such as translucency and colour, compared with high performance ceramics, while the latter demonstrate high flexural strength and toughness. Both groups of materials have specialised applications in restorative dentistry and are capable of covering all the indications of dental restorations. The two types of materials, that is, glass ceramics and ceramics, have to be processed in accordance with their properties. As a result, the processing techniques, such as moulding, sintering and machining, will be discussed in detail in addition to the properties of the materials. Additional development possibilities for the materials will be presented on the basis of customer/patient needs and the successful long term use of glass ceramics and ceramics. In this context, it is clear that high performance ceramics and layered composites (consisting of high performance ceramics veneered with glass ceramics) offer the best possible solution for indications in the posterior region of the mouth. In contrast, glass ceramics are used to fabricate inlays and onlays for all parts of the jaw. In addition, glass ceramics can be used to fabricate crowns and small bridges to replace anterior dentition.     

Effect of self-etching ceramic primer on bond strength of zirconia-reinforced lithium silicate ceramics

Abstract

This study evaluated the effect of self-etching ceramic primer (SECP) on shear bond strength (SBS) of zirconia-reinforced lithium silicate (ZLS) ceramics. Two hundred and seventy block-specimens of two types of ZLS ceramics and one type of lithium disilicate (LS) ceramics were prepared. Ninety blocks of each material were divided into three groups (n?=?30), namely group 1: no surface treatment (control), group 2: hydrofluoric acid (HF), silane-based primer (S), and group 3: SECP. Resin cement was applied, and light-cured for build-up. Shear bond strength (SBS) test was used. Half of the bonded specimens (n?=?15) were tested after storage in distilled water for 24?h, whereas the other half were tested after 5000 thermo-cycles. The failure modes were evaluated using scanning electron microscope (SEM). The SBS values for samples treated with SECP and HF?+?S within the respective materials were statistically comparable (p?>?0.05). Thermocycling significantly reduced the SBS (p?<?0.05) for all ceramic materials in groups 2 and 3. Mixed failure followed by adhesive failure were the most common failure modes in groups 2 and 3, whereas pretest failure was only detected in group 1. Considering the limitations of the study, with respect to in vitro bond strength, the SECP is an alternative for the conditioning of internal surface of glass ceramics.     

Low temperature cofiring and compatibility with silver electrode of ZnO-SnO2-TiO2-Nb2O5 ceramics with BaCu(B2O5) addition

The effect of BaCu(B₂O₅) (BCB) addition on the sintering temperature and microwave dielectric properties of 2.5ZnO-0.2SnO₂-4.8TiO₂-2.5Nb₂O₅ (ZSTN) has been investigated by the solid-state ceramic route. X-ray diffraction and scanning electron microscopy techniques were used to analysis the structure and microstructure. The microwave dielectric properties were measured by the resonance method. It was found that the addition of BCB can effectively lower the sintering temperature from 1100 °C to 900 °C, and improves the microwave dielectric properties of ZSTN ceramics. The BCB doped ZSTN ceramics can be compatible with Ag electrode, which makes it a promising ceramic for LTCC technology application.     

Basaltic tephra: potential new resource for ceramic industry

Abstract

This preliminary study reveals that basaltic tephra(pumice) is a material suitable for the production of high quality ceramics and also provides important evidence concerning the transfer of the process of manufacture from the laboratory to commercial production. Specifically, the shapes of pores and the uniformity of the pore size frequency distributions in the basaltic ceramic preparations are the major textural properties controlling compressive strength, whereas the contents and textures of fibrous minerals occupying the pores appear to be less significant in determining the physical properties of these ceramics.     

Dielectric,Mechanical, and Thermal Properties of Low-Permittivity Polymer–Ceramic Composites for Microelectronic Applications

A new low-permittivity polymer–ceramic composite for packaging applications has been developed. The ceramic-reinforced polyethylene and polystyrene composites were prepared by melt mixing and hot molding techniques. Low-loss, low-permittivity Li₂MgSiO₄ (LMS) ceramics prepared by the solid-state ceramic route were used as the filler to improve the dielectric properties of the composites. The relative permittivity and dielectric loss were increased with the increase in the ceramic loading at radio and microwave frequencies. The mechanical properties and thermal conductivity of the Li₂MgSiO₄-reinforced polymer–ceramic composite were also investigated. The stability of the relative permittivity of polymer–ceramic composites with temperature and frequency was investigated. The experimentally observed relative permittivity, thermal expansion, and thermal conductivity were compared with theoretical models.     

Effects of fine grains and sintering additives on stereolithography additive manufactured Al2O3 ceramic

Al₂O₃ ceramics are fabricated by stereolithography based additive manufacturing in present reports. To improve the densification and performance of Al₂O₃ ceramic, the introduction of fine grains or sintering additives has been studied by traditional fabrication techniques. However, no research has focused on the effects of adding fine grains and sintering additives on the stereolithography additive manufactured Al₂O₃ ceramic. In this study, both fine grains and sintering additives were added firstly, and then the effects of fine grains and sintering additives on the relative density, microstructure, mechanical properties, and physical properties of the stereolithography additive manufactured Al₂O₃ ceramics were investigated. Finally, defect-free Al₂O₃ ceramic lattice structures with high precise and high compressive strength were manufactured.     

Ba0.6Sr0.4TiO3–MgO ceramics from ceramic powders prepared by improved aqueous gelcasting-assisted solid-state method

Based on aqueous gelcasting-assisted solid-state method (AGASSM), improved aqueous gelcasting-assisted solid-state method (IAGASSM) was proposed to prepare the 45 wt% Ba_0.6Sr_0.4TiO₃–55 wt% MgO (BSTM) ceramic powders. It is found that the BSTM ceramic powders prepared by IAGASSM are the most uniform with the smallest particles (D_av = 0.83 μm) than those prepared by solid-state method (SSM) and AGASSM. The phase compositions of the BSTM ceramic powders and ceramics from the prepared ceramic powders are the same whatever ceramic powder preparation method is adopted. Compared with SSM and AGASSM, the BSTM green samples and ceramics from ceramic powders prepared by IAGASSM are the most uniform. Furthermore, it is found that adopting IAGASSM to prepare ceramic powders could not only improve the dielectric properties of the BSTM ceramics considerably, but also decrease their sintering temperature.     

Room temperature R-curve and stable crack growth behaviour of ZrB2–SiC ceramic composites

ABSTRACT

R-curve and controlled stable crack growth behaviour of ZrB₂–17vol.-%SiC and ZrB₂–45vol.-%SiC ceramic composites was studied on V-notched samples using four-point bending at room temperature. The rising K_1R behaviour was determined as a function of the crack extension Δa with a crack bridging mechanism being dominant in such behaviour. Significant differences in crack growth rates were found within the same composition of ceramics simply as the crack length varied during crack growth processes. These differences are indicative of the significant influence of microstructural parameters of the ceramics on crack propagation. The peculiarities of stress intensity factor K₁ and the crack growth-specific behaviour in ZrB₂–SiC particulate ceramic composites are discussed.     

R&D OPPORTUNITES IN DRYING OF ADVANCED ELECTRO-CERAMICS

ABSTRACT

This article presents an inaoduction to the various drying processes operational in the ceramic processing industry, with special emphasis on electro ceramics. An attempt is made to arouse the interest of drying specialists in fields other than ceramics to participate in a concentrated group effort to solve a number of existing problems related to ceramics drying. The importance of materials education is highlighted by referring to a few examples depicting the effect of the drying process on the final product quality. It is argued that with more research, conventional processes like spray drying, rotary drum drying, etc. can be improved or replaced with alternative processes like freeze drying, microwave drying, infrared drying and vibrated fluidized bed drying.     

Transparent ultrafine Yb3+:Y2O3 laser ceramics fabricated by spark plasma sintering

Conventional ceramic processing techniques do not produce ultrafine‐grained materials. However, since the mechanical and optical properties are highly dependent on the grain size, advanced processing techniques are needed to obtain ceramics with a grain size smaller than the wavelength of visible light for new laser sources. As an empirical study for lasing from an ultrafine‐grained ceramics, transparent Yb³⁺:Y₂O₃ ceramics with several doping concentrations were fabricated by spark plasma sintering (SPS) and their microstructures were analyzed, along with optical and spectroscopic properties. Laser oscillation was verified for 10 at.% Yb³⁺:Y₂O₃ ceramics. The laser ceramics in our study were sintered without sintering additives, and the SPS produced an ultrafine microstructure with an average grain size of 261 nm, which is about one order of magnitude smaller than that of ceramics sintered by conventional techniques. A load was applied during heating to enhance densification, and an in‐line transmittance near the theoretical value was obtained. An analysis of the crystal structure confirmed that the Yb³⁺:Y₂O₃ ceramics were in a solid solution. To the best of our knowledge, this study is the first report verifying the lasing properties of not only ultrafine‐grained but also Yb‐doped ceramics obtained by SPS.     

High-performance ceramic parts with complex shape prepared by selective laser sintering: a review

ABSTRACT

Selective laser sintering (SLS) is an additive manufacturing technology which has shown great advantages in direct formation of the polymer, metal and their composites. However, ceramic parts prepared by the SLS still exhibit some fatal defects, including low density and poor mechanical properties. In this respect, recent advances for preparing ceramics have improved the final density and performance by adopting post-processing methods. In this review, three commonly used powder preparation approaches (i.e. mechanical mixing, solvent evaporation and dissolution-precipitation process) and two powder sintering mechanisms for the SLS are introduced. Porous ceramic parts are prepared directly through the SLS by virtue of their high porosity. And dense, high-performance Al₂O₃, ZrO₂, kaolin and SiC ceramic parts with complex shape are prepared by introducing CIP technology into the SLS, indicating that the hybrid technology could be the promising route for preparing high-performance ceramic parts used in various fields.     

Preparation of Dense Ceramics Based on Silicon Nitride Nanopowders

Synthesis of ceramics from silicon nitride nanopowders using hot-pressing and pressure-assisted and microwave (MW) sintering techniques has been studied. Dense ceramics with improved physicomechanical characteristics can be prepared on condition that most of the oxygen in the form of silicon monoxide (contained at 5 – 8 wt.% in the precursor powders) has been removed from the material. In ceramics treated by the three sintering technologies, an extensive grain growth is observed. The microstructure of these materials was more disperse in comparison with that of ceramic prepared from conventional -Si₃N₄ powders synthesized in a furnace. This provides a route towards preparing nanopowder-based ceramics with a 25 – 30% increase in strength in comparison to ceramics of the same density prepared from conventional powders.     

Highly dense 0.3CaCeNbWO8-0.7LaMnO3 composite ceramics fabricated by cold sintering process

The cold sintering process (CSP) has been used for fabricating functional ceramics at a low sintering temperature. In this study, highly dense 0.3CaCeNbWO₈-0.7LaMnO₃ composite ceramics have been successfully fabricated by CSP. The phase structure, microstructure, and electrical properties of composite ceramics have been investigated. The composite ceramic is mainly composed of a tetragonal CaCeNbWO₈ phase with scheelite structure and an orthorhombic LaMnO₃ phase with perovskite structure. The relative density of composite ceramic is 94.5%, and is higher than that of single phase ceramic. The resistivity of composite ceramic exhibits negative temperature coefficient characteristics, with an aging coefficient less than 2%. Such a sintering methodology is of great significance, since it provides a feasible idea for preparing composite ceramics.     

Deficient or excessive CuO-TiO2 phase influence on dielectric properties of CaCu3Ti4O12 ceramics

The influence of the CuO–TiO₂ phase (CT) on dielectric properties of the CCTO ceramic was investigated. CaCu_XTi_YO₁₂ (CC_XT_YO) powders were prepared based on the coprecipitated method, where 2.70 ≤ x ≤ 3.30 and 3.25 ≤ y ≤ 4.75. XRD patterns confirmed the presence of CCTO and also the secondary phases as CuO, TiO₂, and CaTiO₃ for each sample and aided in its quantification. Scanning Electron Microscopy (SEM) shows secondary phases evolution in the grain boundaries, and its influence on size and morphology of the grains. Impedance spectroscopy measurements showed that the ceramics with lower amount of CuO and TiO₂ phases (CT/deficient ceramics) exhibited the highest ε′ values (2.1 × 10⁴ at 1 kHz for CC_2.9T_3.75O ceramic). Also, CT/deficient ceramics showed lower tanδ values (0.090 at 1 kHz for CC_2.9T_3.75O ceramic) than ceramics prepared with excessive CuO–TiO₂ phase (0.241 at 1 kHz for CC_3.1T_4.25O ceramics). The deficiency of CuO and TiO₂ phases associated with high percentage of CCTO and CaTiO₃ phases resulted in ceramics with the higher ε′ values.     

A novel formula for the quality factor calculation for the multiphase microwave dielectric ceramic mixtures

Microwave dielectric ceramics are pillar materials in the microwave applications, for example, resonators. However, because most ceramics possess non-zero temperature coefficients, two or more ceramics, with temperature coefficient of opposite signs, are always mixed as a multiple phase system to obtain a zero temperature coefficient ceramic. While the dielectric constant can be calculated by the Maxwell-Wagner based formula, the quality factor (Q) is usually hard to be precisely calculated by the conventional method. In this paper, basing on the classical dispersion theory, we derive a new formula for the Q calculation for the ceramic mixtures. The deviation between the calculated and reported Q, of several typical ceramic systems, is around ±5%, for the example of two phases ceramic mixtures.     

Microstructure and Strength of Ceramics Prepared from Powders Synthesized Via Simultaneous and Sequential Deposition Routes

Sol-gel techniques for simultaneous and sequential deposition of precursor powders for preparation of ceramics in the ZrO₂ – Al₂O₃ – CeO₂ system are described. The phase composition of ceramics varies with the method of powder deposition. The intracrystallite arrangement pattern of the secondary phase in the system obtained via simultaneous deposition route provides the base for a ceramic that is superior in strength characteristics to ceramic prepared from ZrO₂ – Al₂O₃ powders deposited via sequential route.     

Effects of hafnium content on microstructures and properties of newly developed (Ti,Hf)(C,N) ceramics

In this study, novel (Ti,Hf)(C,N) ceramics with varying hafnium contents were fabricated via carbothermal reduction–nitridation and subsequent spark plasma sintering. The influence of Hf addition on the mechanical properties, wear properties, and corrosion resistance of the (Ti,Hf)(C,N) ceramics was systematically studied. The introduction of Hf promoted the sintering densification of the ceramics in the sintering process. The prepared (Ti,Hf)(C,N) ceramics exhibited excellent mechanical and wear properties owing to refinement and solution-strengthening mechanisms. The (Ti_0.9,Hf_0.1)(C_0.5,N_0.5) ceramic demonstrated higher Vickers hardness and fracture toughness, measuring 1997 HV5 and 4.28 MPa m^1/2, respectively, compared to the pure Ti(C_0.5,N_0.5) ceramic which exhibited values of 1635 HV5 and 3.94 MPa MPa m^1/2. The wear scar depth of the (Ti_0.9,Hf_0.1)(C_0.5,N_0.5) ceramic sample was 57.36% to that of the Ti(C_0.5,N_0.5) ceramic. Additionally, the addition of Hf improved the corrosion resistance of (Ti,Hf)(C,N) ceramics in a 0.5 M NaOH solution. The potential applications of (Ti,Hf)(C,N) ceramics include machining tools and wear-resistant parts.