R Edited by Ralf Riedel and I-Wei Chen i e A d lthough ceramics have been known to mankind literally for millen- e nia, research has never ceased. Apart from the classic uses as a bulk l material in pottery, construction, and decoration, the latter half of the · Ceramics Science C twentieth century saw an explosive growth of application fi elds, such as h electrical and thermal insulators, wear-resistant bearings, surface coat- e ings, lightweight armour, and aerospace materials. In addition to plain, n hard solids, modern ceramics come in many new guises such as fabrics, ( ultrathin fi lms, microstructures and hybrid composites. E and Technology d Built on the solid foundations laid down by the 20-volume series s Materials Science and Technology, Ceramics Science and Technology picks . ) out this exciting material class and illuminates it from all sides. Materials scientists, engineers, chemists, biochemists, physicists and medical researchers alike will fi nd this work a treasure trove for a wide range of ceramics knowledge from theory and fundamentals to practical Volume 4 approaches and problem solutions. Applications Ralf Riedel has been a professor at the Institute of Materials Science at the Darmstadt Univer- 4 sity of Technology in Darmstadt since 1993. He received a Diploma degree in chemistry in 1984 and he fi nished his dissertation in Inorganic Chemistry in 1986 at the University of Stuttgart. After postdoctoral research at the Max-Planck-Institute for Metals Research and the Institute of Inorganic Chemistry at the University of Stuttgart he completed his habilitation in the fi eld of Inorganic Chemistry in 1992. Prof. Riedel is Fellow of the American Ceramic Society and was aC awarded with the Dionyz Stur Gold Medal for merits in natural sciences. He is a member of the ne World Academy of Ceramics and Guest Professor at the Jiangsu University in Zhenjiang, China. dr In 2006 he received an honorary doctorate from the Slovak Academy of Sciences, Bratislava, Slo- a Tm vakia. In 2009 he was awarded with an honorary professorship at the Tianjin University in China. e He published more than 300 papers and patents and he is widely known for his research in the cic fi eld of polymer derived ceramics and on ultra high pressure synthesis of new materials. hs n S o c I-Wei Chen has been Skirkanich Professor of Materials Innovation at the University of Pennsyl- l oi vania since 1997, where he also gained his master‘s degree in 1975. He received his bachelor‘s e g n degree in physics from Tsinghua University, Taiwan, in 1972, and earned his doctorate in metal- y c lurgy from the Massachusetts Institute of Technology in 1980. He taught at the University of e Michigan (Materials) during 1986 – 1997 and MIT (Nuclear Engineering ; Materials) during 1980 – 1986. He began ceramic research studying martensitic transformations in zirconia nano crystals, which led to work on transformation plasticity, superplasticity, fatigue, grain growth and sintering in various oxides and nitrides. He is currently interested in solid oxide fuel cells, nanotechnology of resistance memory and ferroelectrics, and nanoparticle-based medical imag- ing and drug delivery. A Fellow of American Ceramic Society (1991) and recipient of its Ross Coffi n Purdy Award (1994), Edward C. Henry Award (1999) and Sosman Award (2006), he authored over 90 papers in the Journal of the American Ceramic Society (1986 – 2006). He also received Humboldt Research Award for Senior U.S. Scientists (1997). Volume 4 of 4 www.wiley-vch.de Editedby RalfRiedelandI-WeiChen CeramicsScienceand Technology RelatedTitles Riedel,R./Chen,I-W.(eds.) Aldinger,F.,Weberruss,V.A. CeramicsScienceand AdvancedCeramicsand Technology FutureMaterials AnIntroductiontoStructures,Properties, 4VolumeSet 2014 Technologies,Methods ISBN:978-3-527-31149-1,alsoavailablein 2010 digitalformats ISBN:978-3-527-32157-5 Riedel,R./Chen,I-W.(eds.) Krenkel,W.(ed.) CeramicsScienceand Verbundwerkstoffe Technology 17.SymposiumVerbundwerkstoffeund Werkstoffverbunde Volume1:Structures 2009 2008 ISBN:978-3-527-32615-0, ISBN:978-3-527-31155-2,alsoavailablein alsoavailableindigitalformats digitalformats Barsoum,M. Riedel,R./Chen,I-W.(eds.) MAXPhases CeramicsScienceand PropertiesofMachinableTernary Technology CarbidesandNitrides Volume2:MaterialsandProperties 2013 2010 ISBN:978-3-527-33011-9, ISBN:978-3-527-31156-9,alsoavailablein alsoavailableindigitalformats digitalformats Riedel,R./Chen,I-W.(eds.) CeramicsScienceand Technology Volume3:SynthesisandProcessing 2011 ISBN:978-3-527-31157-6,alsoavailablein digitalformats Krenkel,W.(ed.) CeramicMatrixComposites FiberReinforcedCeramicsandtheir Applications 2008 ISBN:978-3-527-31361-7, alsoavailableindigitalformats Edited by Ralf Riedel and I-Wei Chen Ceramics Science and Technology Volume 4: Applications Editors AllbookspublishedbyWiley-VCHarecarefully produced.Nevertheless,authors,editors,and publisherdonotwarranttheinformationcontained Prof.Dr.RalfRiedel inthesebooks,includingthisbook,tobefreeof TUDarmstadt errors.Readersareadvisedtokeepinmindthat InstituteforMaterialsScience statements,data,illustrations,proceduraldetailsor Petersenstr.23 otheritemsmayinadvertentlybeinaccurate. 64287Darmstadt LibraryofCongressCardNo.:appliedfor Germany BritishLibraryCataloguing-in-PublicationData Prof.Dr.I-WeiChen Acataloguerecordforthisbookisavailablefromthe UniverstityofPennsylvania BritishLibrary. SchoolofEngineering BibliographicinformationpublishedbytheDeutsche 3231WalnutStreet Nationalbibliothek Philadelphia,PA19104-6272 TheDeutscheNationalbibliothekliststhis USA publicationintheDeutscheNationalbibliografie; detailed bibliographicdataareavailableonthe Internet at < http:// dnb.d-nb.d e> . #2013Wiley-VCHVerlagGmbH&Co.KGaA, Boschstr.12,69469Weinheim,Germany Allrightsreserved(includingthoseoftranslationinto otherlanguages).Nopartofthisbookmaybe reproducedinanyform–byphotoprinting, microfilm,oranyothermeans–nortransmittedor translatedintoamachinelanguagewithoutwritten permissionfromthepublishers.Registerednames, trademarks,etc.usedinthisbook,evenwhennot specificallymarkedassuch,arenottobeconsidered unprotectedbylaw. PrintISBN: 978-3-527-31158-3 ePDFISBN: 978-3-527-63198-8 oBookISBN: 978-3-527-63197-1 SetISBN: 978-3-527-31149-1 CoverDesign Grafik-DesignSchulz,Fußgönheim Typesetting ThomsonDigital,Noida PrintingandBinding betz-druckGmbH,Darmstadt PrintedintheFederalRepublicofGermany Printedonacid-freepaper j V Contents Preface XV ListofContributors XVII PartOne StructuralApplications 1 1 OxidationandCorrosionofCeramics 3 ElizabethJ.OpilaandNathanS.Jacobson 1.1 Introduction 3 1.2 Silica-FormingCeramics 4 1.2.1 IdealOxidationBehaviorofSilica-FormingCeramics 4 1.2.1.1 StructureofSilicaandTransportofOxygeninSilica 4 1.2.1.2 OxidationofSiliconinDryOxygen 5 1.2.1.3 OxidationofSiliconCarbideinDryOxygen 7 1.2.1.4 OxidationofSiliconNitrideinDryOxygen 9 1.2.2 SiCOxidation:DeviationsfromNortonPermeation 11 1.2.2.1 CrystallizationoftheSilicaScale:EffectonSiCOxidation 11 1.2.2.2 IonicExchangewiththeSilicaNetwork:EffectonSiCOxidation 12 1.2.2.3 EffectsofLow-LevelImpuritiesonSiCOxidation 12 1.2.3 OxidationofSilica-FormersinthePresenceofLow-Level Impurities 13 1.2.3.1 EffectofAlkali-MetalImpuritiesontheOxidationofSilica-Formers 13 1.2.3.2 EffectofAluminumImpuritiesonSilica-Formers 14 1.2.4 AdditiveEffectsontheOxidationofSilica-Formers 14 1.2.4.1 AlandBAdditionstoSiC:EffectonOxidationRates 15 1.2.4.2 EffectofSinteringAdditivesontheOxidationofSiliconNitride 15 1.2.5 Deposit-InducedCorrosionofSilicon-BasedCeramics 16 1.2.6 TemperatureCycling 24 1.2.7 OxidationofSilica-FormersinOtherOxidants 25 1.2.7.1 OxidationofSilica-FormersinOtherOxidants:H O 26 2 1.2.7.2 OxidationofSilicaFormersinOtherOxidants:Carbon Dioxide(CO2) 36 1.2.7.3 OxidationofSilicaFormersinOtherOxidants:DissociatedOxygen 37 1.2.8 ActiveOxidationofSilicaFormers 38 j VI Contents 1.2.9 UpperTemperatureLimitforSilica-FormingMaterials 45 1.2.10 OxidationofPolymer-DerivedSi-BasedCeramics 46 1.2.11 OxidationofSiC-BasedComposites 48 1.2.11.1 OxidationofCarbon 48 1.2.11.2 OxidationofBoronNitride 49 1.2.11.3 OxidationofSiC/C/SiCandC/C/SiCComposites 49 1.2.11.4 OxidationofSiC/BN/SiCComposites 51 1.2.11.5 ImprovedOxidation-ResistantSiCComposites 53 1.2.11.6 Oxidation-ResistantCoatingsandAdditivesforSiC-Based Composites 55 1.2.12 EnvironmentalBarrierCoatingsforSilicon-BasedCeramics andComposites 55 1.3 Alumina-FormingCeramics 57 1.3.1 OxidationofAlN 58 1.3.1.1 OnsetofAlNOxidation 58 1.3.1.2 EarlyStagesofAlNOxidation 58 1.3.1.3 OxidationKineticsofAlN 59 1.3.1.4 OxidationofAlNinWaterVapor 61 1.3.1.5 EffectofOxygenandNitrogenPartialPressureon OxidationofAlN 62 1.3.1.6 EffectofSinteringAdditivesontheOxidationofAlN 62 1.3.2 OxidationofAl4C3 63 1.4 Ultrahigh-TemperatureCeramics 64 1.4.1 OxidationofZirconiumandHafnium 65 1.4.2 OxidationofZrB2andHfB2 65 1.4.2.1 EffectofAdditivesonZrB andHfB Oxidation 2 2 Rates 67 1.4.3 OxidationofZrCandHfC 74 1.4.4 OxidationofZrNandHfN 77 1.4.5 OxidationofTaCandTa2C 78 1.4.6 OxidationofUHTCCompositeMaterials 79 1.5 OxideCeramicDegradationMechanisms 80 1.5.1 OxideCeramicDegradationinWaterVapor 80 1.5.2 OxideCorrosion 81 1.6 ConcludingRemarks 83 References 83 2 ThermalBarrierCoatings 95 RobertVaßen 2.1 Introduction 95 2.2 ManufacturingRoutes 97 2.2.1 ElectronBeam-PhysicalVaporDeposition(EB-PVD) 97 2.2.2 AtmosphericPlasmaSpraying(APS) 98 2.2.2.1 GeneralRemarks 98 j Contents VII 2.2.2.2 ThermallySprayedMCrAlYs(M(cid:2)(cid:2)(cid:2)(cid:2)Ni,Co)Bond Coatings 99 2.2.3 AtmosphericPlasma-Sprayed(APS)Yttria-StabilizedZirconia(YSZ) Topcoats 101 2.2.4 NewThermalSprayProcesses 103 2.2.4.1 LiquidFeedstock/SuspensionPlasmaSpraying 103 2.3 YSZ-BasedTBCS 105 2.3.1 SomeBasicPropertiesofYSZ(BulkMaterial) 105 2.3.2 PropertiesofAPSYSZThermalBarrierCoatings 106 2.3.3 PropertyChangesDuringHeatTreatment 107 2.3.4 FailureofYSZ-BasedTBCSystems 109 2.4 NewTBCSystems 110 2.5 Summary 112 Acknowledgments 112 References 112 3 CeramicFiltersandMembranes 117 IngolfVoigt,J€orgAdler,MarcusWeyd,andRalfKriegel 3.1 CeramicsinHotGasFiltration 117 3.1.1 Introduction 117 3.1.2 HotGasCleaninginAdvancedCoal-FiredElectricalPower Systems 118 3.1.2.1 AdvancedCoal-FiredElectricalPowerSystems 118 3.1.2.2 AshFiltrationFromHotGases 119 3.1.2.3 FilterMaterials 119 3.1.2.4 RigidCandleFilter 121 3.1.2.5 CandleFilterFailingsandFailsafeDevices 123 3.1.2.6 ExperiencewithCandleFiltersinPFBCApplications 124 3.1.2.7 ExperiencewithCandleFiltersinIGCCApplications 124 3.1.2.8 CombinationofFiltrationandCatalyticTreatment 124 3.1.2.9 SummaryofHotGasCleaninginAdvancedCoal-FiredElectrical PowerSystems 125 3.1.3 ParticulateFiltrationofDieselExhaustGases 125 3.1.3.1 PollutantsinDieselExhaust 126 3.1.3.2 LimitsofPollutantsbyLegislation 126 3.1.3.3 PrinciplesandFunctionoftheDieselParticulateFilter 126 3.1.3.4 ArchitectureofaDPFanditsManufacture 127 3.1.3.5 CeramicMaterialsforDPF 130 3.1.3.6 DPFSummaryandOutlook 132 3.2 CeramicMembranesforLiquidFiltration 132 3.2.1 Introduction 132 3.2.2 MicrofiltrationMembranes 135 3.2.2.1 PreparationofCeramicMicrofiltrationMembranes 135 3.2.2.2 ApplicationofCeramicMicrofiltrationMembranes 136 3.2.3 UltrafiltrationMembranes 137 j VIII Contents 3.2.3.1 PreparationofCeramicUltrafiltrationMembranes 137 3.2.3.2 ApplicationofCeramicUltrafiltrationMembranes 138 3.2.4 NanofiltrationMembranes 139 3.2.4.1 PreparationofCeramicNanofiltrationMembranes 139 3.2.4.2 ApplicationofCeramicNanofiltrationMembranes 139 3.3 CeramicMembranesforPervaporation/VaporPermeation 142 3.3.1 Introduction 142 3.3.2 MembranesforPervaporation/VaporPermeation 144 3.3.3 DehydrationofIsopropanol 148 3.3.4 DehydrationofEthanol 149 3.4 CeramicMembranesforGasSeparation 151 3.4.1 Introduction 151 3.4.2 MixedIonicElectronicConductingMembranes 152 3.4.3 OxygenSeparationfromAir 155 References 162 4 High-TemperatureEngineeringCeramics 169 RonaldJ.KeransandAllanP.Katz 4.1 Introduction 169 4.2 EngineeringCeramicSystems 170 4.3 TurbineEngineApplications 172 4.4 ApplicationsforRocketPropulsionandHypersonicVehicles 179 4.5 FrictionMaterials 184 4.6 ConcludingRemarks:BarrierstoApplication 186 References 188 5 AdvancedCeramicGlowPlugs 191 TakeshiMitsuoka 5.1 Introduction 191 5.2 GlowPlugs 191 5.3 Metal-TypeGlowPlugs 193 5.4 CeramicGlowPlugs 194 5.5 FabricationProcedureofHeaterElementsforCeramicGlowPlugs 197 5.6 MaterialDesignoftheCeramicHeaterElement 200 5.7 SiliconNitrideCeramics 201 5.8 Conclusions 206 References 206 6 NanosizedandNanostructuredHardandSuperhard MaterialsandCoatings 207 StanVepr9ek,MaritzaG.J.Vepr9ek-Heijman,andPavelHolub(cid:2)ar9 6.1 Introduction:SmallisStrong 207 6.2 DifferentMechanismsofHardnessEnhancementinCoatings 213 6.3 MechanismsofDecompositionofSolidSolutionandFormationof Nanostructure 220