Technovation 21 (2001) 6165www.elsevier.com/locate/technovation

Industrial viewpoint

Application trend in advanced ceramic technologiesYahong Liang *, Sourin P. Dutta

Industrial and Manufacturing Systems Engineering, Faculty of Engineering, University of Windsor, Windsor, Ontario N9B 3P4, CanadaReceived 2 February 2000; accepted 28 February 2000

Abstract

Advanced ceramics and processes have found potential applications in many fields ranging from heat engines to communicationand energy transmission. In this paper, the evolution of ceramic technology is introduced, and an Advanced Ceramics ApplicationTree is developed to illustrate current and future potential application areas. 2000 Elsevier Science Ltd. All rights reserved.

Keywords: Advanced Ceramics Application Tree; Durability; Reliability; High performance/weight rate; High-temperature strength

1. The evolution of ceramics technology

With technological progress, natural materials becomeinsufficient to meet increasing demands on product capa-bilities and functions. In ancient times, human beingsused fire to synthesize new materials to improve orchange the properties of naturally available materials.The invention of the furnace propelled revolutionaryadvances in metallurgy, glass and ceramics technology.The advance of ceramics technology drew on experiencefrom metallurgical technologies. In the nineteenth andtwentieth centuries, there appeared in the marketplace awide variety of new types of building materials withsuperior durability, strength, and other properties. Theseincluded brick, tile piping for drainage systems androofing, sanitary ware and refractory (high-temperature)insulation materials which served as furnace linings forglass, steel, and other industries dependant on high-tem-perature processing of new materials.

There are many combinations of metallic and nonmet-allic atoms that can combine to form ceramic compo-nents, and also several structural arrangements are usu-ally possible for each combination of atoms. This ledscientists to invent many new ceramic materials to meetincreasing requirements and demands in various appli-cation areas. Advanced furnaces and heat engines played

* Corresponding author. Tel.: +1-519-253-3000 ext. 2614; fax: +1-519-973-7062.

E-mail address: liang2@server.uwindsor.ca (Y. Liang).

0166-4972/01/$ - see front matter 2000 Elsevier Science Ltd. All rights reserved.PII: S0166- 49 72 (00)00 01 9- 5

important roles in the success of the industrial revol-ution, while ceramic materials were essential for thermalinsulation of various types of furnaces and engines. Elec-trically insulating ceramic materials were developed aselectrical and electronic technologies matured. As higherand higher frequencies and voltages were used, thedemand on ceramic dielectrics became more stringent.Also, new specifications for the magnetic and opticalproperties of ceramics were developed as a part of thenew electronic and electrooptical technology revolution(Musikant, 1991).

2. Industrial research and applications in advancedceramic technology

Advanced materials are recognized to be crucial tothe growth, prosperity, and sustained profit-ability of anyindustry. The National Research Council in the USAinvestigated eight major US industries that employedseven million people and had sales of 1.4 trillion USdollars in 1987, to examine the role of materials in futuretechnology strategies. The result shows a generic needfor lighter, stronger, more corrosion-resistant materialscapable of withstanding high temperatures (Richlen,1990). Ceramic materials are the leading candidates formeeting these requirements.

There has been great interest shown in advanced orhigh technology ceramic materials among scientists, pol-icymakers, and corporations in recent years. Varieties ofceramic materials, which hold remarkable properties

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able to meet the need for high end applications, haveappeared. Advanced ceramic materials include: oxides,carbides, nitrides, borides, silicates and glass ceramicsand composite materials-polymer matrix (PMC), metalmatrix (MMC), ceramic matrix (CMC), and carboncar-bon (CCC) materials. The most commonly used are alu-mina, zirconia, silicon carbide, silicon nitride, sialon, fer-rites and titanates. Substitutions of ceramic componentsfor traditional parts in many applications result in sub-stantial productivity improvements and high perform-ance.

For some time, ceramic engine parts have been underactive development by major automobile manufacturersand the major component suppliers. Engineers atKyocera Corp. (Kyoto, Japan) report that silicon nitrideceramic glow plugs will give a diesel passenger car thesame fast, cold engine starting action as a gasolineengine car. The US Department of Energy Office ofTransportation Technologies has made sustained effortsfocusing on emerging customer needs. Some of themajor objectives of ceramic technology programs are:development of alternative fuels, manufacturing gas-tur-bine components, advanced silicon nitride fabricationand forming techniques, life-prediction development,mechanical property characterization, nondestructiveexamination and joining in advanced light-duty vehicles,as well as research and development on critical techno-logies that will enable trucks and other heavy vehiclesto fully exploit energy efficiency and alternative fuelcapabilities of the diesel engines, while simultaneouslyreducing highway vehicle emissions. The key goal is thedevelopment of cost-effective, high-efficiency, com-pression ignition diesel engines capable of using alterna-tive fuels (Wyrick, 1996). In Japan, a few parts arealready in commercial production, albeit in limited vol-ume. Table 1 provides examples of MMC products com-mercialized in Japan. Increased use of ceramic materials

Table 1Examples of MMC products commercialized in Japan (Kevorkijan, 1998)a

Product (composite part) Matrix Main property Reinforcement

Top ring grove of piston for diesel JIS AC8A Wear resistance Alumina /sillica short fiberengine (Toyota)Piston head of diesel engine (Izumi High-temperature tensile strengthJIS AC8A SiC whiskersIndustries) and thermal fatigue

High-temperature tensile strengthPiston head of outboard engine (Suzuki) JIS AC9A SiC whiskersand thermal fatigue

Bicycle frame (Kobe Steel) 6061 Tensile strength SiC whiskersJoint of structural material for artificial Tensile strength and elastic6061 SiC whiskerssatellite (Mitsubishi Electric) modulusBore surface of cylinder block (Honda) JIS ADC12 Wear resistance SiC whiskersConnecting rod (Honda) JIS AC4D Tensile strength alumina and carbon fibersCrankshaft damper pulley (Toyota) JIS AC8A Creep Stainless fiberVane for rotary compressor (Sanyo Al17%Si Wear resistance SiC whiskersElectric)

a Source: Government Industrial Research Institute, Nagoya

for commercial applications presents a host of challengesto both manufacturers and their material suppliers. Theseinclude significant cost, reliability, low volume demandand manufacturing problems. As we all know from com-mon experience, ceramics are brittle and are susceptibleto mechanical stresses or those induced by thermalshock. The fracture occurs because the stresses inducedby the thermal gradients in the structure exceed thestrength of the materials. Relatively high costs are asso-ciated with new ceramic materials (Kevorkijan, 1998).

In addition to high material cost, ceramic design, pro-cess technology and machining technology need todevelop significantly to achieve cost effective levels ofhigh volume production. Because of the high hardnessand low toughness of ceramic materials, diamond grind-ing is often the method of choice in machining suchmaterials. This results in high cost of machining tools,limitation on the types of shapes and materials that couldbe machined, lack of knowledge of control and evalu-ation of new machining and so on. Other drawbacks ofthe technology application come from lack of designdata and experience, doubts about recyclability, etc. Pro-gress in certain key technologies are needed to enableceramics to be adapted for heat engine applications.There are several research projects aimed at thereduction of various costs required for commercialimplementation. Machining projects supported by theUS Department of Energy (DOE) Office of Transpor-tation Technologies include innovative grinding-wheeldesign; high-speed grinding methods; high-speed center-less grinding spindle; machine-tool stiffness effects onpart quality; grindability test for ceramics; laser-light-scattering and dye-penetrating inspection; surface qualityand performance assessment (Allor and Jahanmir, 1996).

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Fig. 1. Advanced ceramics application tree.

3. Advanced ceramics application tree

The ceramics industry is a very large internationalindustry with sales amounting to around $100 bn/year(Campbell, 1997). The technology of ceramics is a rap-

idly developing applied science in todays world. Tech-nological advances result from unexpected material dis-coveries. On the other hand, the new technology candrive the development of new ceramics. Currently manynew classes of materials have been devised to satisfy

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Table 2Current and future products for advanced ceramics

Mechanical Engineering Aerospace Automotive Defense industry

Cutting tools and dies Fuel systems and valves Heat engines Tank power trainsAbrasives Power units Catalytic converters Submarine shaft sealsPrecise instrument parts Low weight components Drivetrain components Improved armorsMolten metal filter Fuel cells Turbines Propulsion systemsTurbine engine components Thermal protection systems Fixed boundary recuperators Ground support vehiclesLow weight components for rotary Turbine engine components Fuel injection components Military weapon systemsequipment

Military aircraft (airframe andWearing parts Combustors Turbocharger rotorsengine)

Bearings Bearings Low heat rejection diesels Wear-resistant precision bearingsSeals Seals Waterpump sealsSolid lubricants Structures

Biological, Chemical processing Electrical, Magnetic Engineering Nuclear industryengineering

Artificial teeth, bones and joints Memory element Nuclear fuelCatalysts and igniters Resistance heating element Nuclear fuel claddingHeart valves Varistor sensor Control materialsHeat exchanger Integrated circuit substrate Moderating materialsReformers Multilayer capacitors Reactor mining

Advanced multilayer integratedRecuperators packagesRefractoriesNozzles

Oil industry Electric power generation Optical Engineering Thermal Engineering

Bearings Bearings Laser diode Electrode materialsFlow control valves Ceramic gas turbines Optical communication cable Heat sink for electronic parts

Heat resistant translucent High-temperature industrialPumps High temperature components porcelain furnace liningRefinery heater Fuel cells (solid oxide) Light emitting diodeBlast sleeves Filters

various new applications. Advanced ceramics offernumerous enhancements in performance, durability,reliability, hardness, high mechanical strength at hightemperature, stiffness, low density, optical conductivity,electrical insulation and conductivity, thermal insulationand conductivity, radiation resistance, and so on. Cer-amic technologies have been widely used for aircraft andaerospace applications, wear-resistant parts, bioceramics,cutting tools, advanced optics, superconductivity,nuclear reactors, etc. In most of these applications,improved materials based on ceramics were purposefullysought after. These applications dramatically change oraffect the environment in which we live. Not only dowe have economic and material issues to deal with, butalso, unforeseeable changes in economic factors and thepolitical environment will play significant roles in theneeds for improved components and devices, as well asaffect our ability to apply resources towards research anddevelopment needed to bring new materials to the mar-ketplace (Freiman and Onoda, 1997).

Ceramics application could be categorized as struc-

tural ceramics, electrical ceramics, ceramic composites,and ceramic coatings. These materials are emerging asthe leading class of materials needed to be improved toexplore further potential applications. An Advanced Cer-amics Application Tree, which classifies its current andpotential application areas and related advantageousproperties, has been developed and is shown in Fig. 1.Current and future advanced ceramic products derivedfrom the application tree are indicated in Table 2.

Today, advanced ceramics have been widely used inwearing parts, seals, low weight components and fuelcells in transportation sectors, to reduce the weight ofproduct, increase performance especially at high tem-peratures, prolong the life cycle of a product andimprove the efficiency of combustion. As advances inceramic technology offer potential and immediateopportunities, these materials will translate into greatermarket shares in transportation sectors. On the otherhand, future application is still very limited if no break-throughs are achieved in fundamental and appliedresearch.

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4. Concluding remarks

Advanced material science and engineering appli-cations have received increasing attention from manu-facturing industries. In this paper, the evolution of cer-amics technology is highlighted. Advanced ceramics andprocesses have substituted the traditional processes andraw materials in many fields because of their outstandingproperties. An Advanced Ceramics Application Tree isdeveloped to identify possible future applications foradvanced ceramics.

References

Allor, R., Jahanmir, S., 1996. Current problems and future directionsfor ceramic machining. The American Ceramic Society Bulletin 75(7), 4043.

Campbell, J., 1997. Opportunities for ceramic industry. British Cer-amic Transactions 96 (6), 237246.

Freiman, S.W. and Onoda, G.Y.Jr., 1997. Advanced ceramics in theUS for the 21st century: prospects and challenges. Proceedings of1997 21st Annual Conference on Composites, Advanced Ceramics,

Materials, and Structures, vol. 18, no. 3A, Jan. 1216. Cocoa beach,FL, USA., 2127.

Kevorkijan, M.V., 1998. MMCs for automotive applications. TheAmerican Ceramic Society Bulletin, Dec. 5354.

Musikant, S., 1991. What every engineer should know about ceramics.Dekker, New York.

Richlen, S., 1990. Opportunities for the industrial application of con-tinuous fiber ceramic composites. Ceramic Engineering andScience Proceedings 11 (7/8), 576577.

Wyrick, J., 1996. DOE office of transportation technologies focus oncustom needs. Ceramic Technology Newsletter, SpringSummer.

Yahong Liang received her BEng and MSc from Tianjin University, Tian-jin, PRCHINA. She is currently a candidate for a PhD degree in the Uni-versity of Windsor. Her current research interests include Management ofTechnology, Technology Evaluation and Forecasting, Strategic Planningand Justification for Advanced Manufacturing Technology, Neural Net-works, Fuzzy Logic, and Decision Support Systems.

Dr Sourin P. Dutta is Professor and Chair of the Industrial and Manufac-turing Systems Engineering program in the Faculty of Engineering at theUniversity of Windsor in Canada. His research interests include Manage-ment of Technology, Modeling of Heterarchical Manufacturing Systemsand Ergonomics. He has over 100 publications in peer reviews journalsand conference proceedings and has authored five book chapters to date.He is on the editorial board of the International Journal of Industrial Engin-eering and Occupational Ergonomics.