ADVANCED MATERIALS AND COMPOSITES: FROM POWDER TO PART

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ADVANCED MATERIALS AND COMPOSITES: FROM POWDER TO PART

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1. ADVANCED MATERIALS AND COMPOSITES: FROM POWDER TO PART Assoc. Prof. Dr. Alpagut KARA

2. MANUFACTURE

3. MANUFACTURE

4. MANUFACTURE - Raw materials and additives

5. MANUFACTURE - Raw materials and additives

6. There are two possibilities: a) The ceramic manufacturer acquires the necessary raw materials and carries out all further processing tasks. Specific preparations of unfired material are required for the different forming processes:

7. MANUFACTURE - Body preparation

8. Methods of shaping ceramic parts can be divided into the following basic types: pressing (0 – 15 % moisture) plastic forming (15-25 % moisture) casting (> 25 % moisture), and others.

9. MANUFACTURE – Forming ? Dry pressing

10. MANUFACTURE – Forming ? Isostatic pressing

11. Allows the manufacture of parts with complex geometries such as screw threads, side holes, recesses and undercuts. The unfired material used for this purpose usually has moisture levels in the range of 10 to 15%. Compressing with a single axis makes these materials able to flow freely, so that relatively even compression can be achieved. The disadvantage of this, however, is that wet pressing materials can accept only low compressive strains. This also means that the degree of compression is limited. It depends heavily on the moisture content of the unfired material, and is lower than in the case of dry pressed parts. MANUFACTURE – Forming ? Wet pressing

12. MANUFACTURE – Forming ? Extrusion

13. Principally suited to the mass production of complex products. It is limited by relatively high die costs and the complex burnout of organic additives. The conveying capacity ("shot weight") of large injection moulding machines is typically up to about 70g. Generally, the part should be designed so that thicknesses are as consistent as possible, having an upper limit of approx. 12 mm. MANUFACTURE – Forming ? Injection Moulding

14. A simple method for the manufacture of prototypes, parts with complex geometries and relatively large items. It can be used to manufacture both thin-walled and solid objects. Ceramic slip casting involves a stable suspension, referred to as the slip, being poured into a porous, absorbent plaster mould. Extraction of the suspending liquid causes a layer of particles to develop on the mould wall. This layer develops, in solid casting, to create the fully molded body. In the case of hollow casting, the superfluous slip is poured out once the desired wall thickness has been achieved. MANUFACTURE – Forming ? Slip Casting

15. MANUFACTURE – Forming ? Tape Casting

16. MANUFACTURE

18. FROM FORMING TO FIRING

19. FIRING

20. FIRING

21. FIRING

22. DIMENSIONS & SHRINKAGE

23. DIMENSIONS & SHRINKAGE

24. MACHINING

25. MACHINING – Green machining

26. MACHINING – White machining

27. FINAL MACHINING – Hard machining

28. FINAL MACHINING – Possible finishing processes

29. Ground Surfaces

30. Ground Surfaces

31. HONED SURFACES

32. LAPPED SURFACES

33. LAPPED SURFACES - Model of material removal by lapping

34. POLISHED SURFACES

35. CERAMIC COATINGS

36. CERAMIC COATINGS

37. CERAMIC COATINGS

38. CERAMIC COATINGS

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