Ceramic materials are central to many innovative applications in modern engineering. From construction to cutting-edge medical innovations, they’re the driving force behind countless technological advancements.
They’re made from clay, earthen elements and powders that are combined and molded into their desired shape before being heated or “fired” to finish the fabrication. Ceramics are extremely diverse and have a wide range of properties including high strength, hardness, chemical resistance, and thermal insulation.
Strength
Ceramics have a high resistance to wear, chemical corrosion and are very tough. The hardness of a ceramic is dictated by the type and arrangement of its atoms. Those characteristics make them ideal for use in applications requiring durability. Ceramic materials such as alumina, zirconia and carbides can withstand abrasions, impact forces and temperature fluctuations. They also possess a compressive strength that is often ten times higher than their tensile strength.
These properties are utilized in everyday applications of ceramics such as spark plugs, electrical insulators, dishes and dinnerware. Ceramics can resist acids, salts and detergents and are impervious to changes in temperature. They are also capable of storing electric charges and are employed in electronic devices like capacitors and circuits.
Another benefit of ceramics is their light weight, a factor that contributes to improved performance in machinery and vehicles. Technical ceramics are typically half the weight of metal parts and can reduce centrifugal forces in automotive engines and machine tools.
Ceramics can be difficult to work with due to their hardness and high melting points. Their complexity can require complex machining techniques that can add to the cost of production. Additionally, ceramics tend to be inconsistent in their properties due to the way they are made. CoorsTek, however, has vertical integration in its manufacturing processes and assures consistent quality through a control process that includes raw material preparation, processing and polishing.
Durability
Most ceramics are hard, brittle materials. We use them to make pottery, bricks, tiles, glass, and cement. Ceramic products are also used in gas turbine engines and bio-ceramics like dental implants and synthetic bones. Ceramics can be crystalline, glassy, or a mixture of both. They are chemically inert and can withstand high temperatures. They are also strong because of the strong atomic bonds that hold their structure together.
Some advanced ceramics have improved fracture toughness, a measure of how much stress they can take before fracturing. This makes them suitable for wear applications. They can replace hardened metals in oil and gas equipment like pump bushings, fracking buttons, and valve faces, reducing wear and increasing production.
Ceramics are being used in more areas than ever before. For example, 3D printing is being used to create aerospace parts made from ceramics. Ceramics are also important in renewable energy, because they can be used to insulate solar panels and fuel cells. They also show up in medical devices because of their biocompatibility and strength. They are also important to energy applications because of their thermal stability and ability to dissipate heat. Some ceramics even have anti-corrosion and scratch resistance properties. They can be glazed or unglazed, and have a wide variety of surface colors.
Thermal Insulation
Ceramics have good thermal insulation properties that are characterized by their ability to dissipate heat. This helps them retain temperature within a space, and it also makes them ideal for use in building construction, especially in areas of the home like kitchens and bathrooms.
To make ceramics, the clays and minerals are dug up from the ground and refined to improve their purity before being crushed into small particles. These are then mixed with a gluelike substance, which is used to help the material bind together into one solid piece that can be shaped. Various methods are then used to shape the ceramics, such as laser cutting and electric discharge machining (EDM). Advanced manufacturing techniques can make this process more cost-effective by turning the defining hardness and high melting points of ceramic materials into an advantage, producing parts with fine details that would be impossible to create using softer materials.
Ceramics are used in a range of industries for their strength, durability, and versatility. The aerospace industry relies on them for components such as heat shields and nose cones, while technical ceramics such as refractories are essential in high-temperature industrial processes including steel, aluminium, cement, glass, the chemical industry and energy production. Ceramics are even used in medical implants such as hip replacements and dental implants due to their biocompatibility.
Environmentally Friendly
With a high emphasis on sustainability, the ceramic industry has made an admirable step towards being environmentally friendly. Ceramic materials are known to emit minimal polluting gases throughout their life cycle, reducing the need for a significant amount of energy. This is especially true when compared to other construction materials, such as concrete and gypsum.
The use of ceramic materials also reduces the need for additional chemical components, further lowering environmental pollution. Additionally, ceramic products do not break down easily, which means that they will have an extended lifespan compared to other construction materials.
During production, ceramics use much less energy than other building materials, and their kilns are more efficient. They also use renewable energy sources, which minimizes their reliance on fossil fuels and reduces the emission of greenhouse gases. In addition, many ceramic manufacturers have started to integrate solar power into their operations, such as the Baldocer company, which uses solar panels to generate 50% of its electricity.
As for recycling, ceramics are not biodegradable, but they can be recycled using unique applications that will transform them into new products without losing their unique properties. For example, old ceramic tiles can be used for mosaics or other art projects. Alternatively, broken pieces can be recycled for use as plant pots or even bird feeders. Lastly, they can be crushed and reused as aggregate in construction materials.