On-Line NDE for Control and Modeling of Ceramic Processing

Abstract

The high-temperature structural properties of ceramics make them unique candidates for application in such systems as advanced gas turbines and other heat engines. Of concern, however, is the variability in fast fracture strength of structural ceramics which is due, in part, to the sensitivity of ceramics to very small (e.g., 20–50 μm) critical flaws and the difficulty in detecting and characterizing this type of flaw by nondestructive examination (NDE) techniques.The flaw sensitivity of ceramics and the typically wide variation in flaw sizes result in the situation illustrated in Figure 1, which is a frequency distribution of fast fracture strengths for a hypothetical structural ceramic with characteristic strength of 350 MPa and Weibull modulus of 5. The strength requirement, 250 MPa, for a particular application is shown. In this illustration, a significant fraction of the population of ceramic parts, 17%, has a strength below the 250 MPa requirement.The situation illustrated in Figure 1 is typical of structural ceramics today: although in many cases the average properties of a specific ceramic may be suitable for the intended use, a significant fraction of the parts made of that material will be unsuitable. The unacceptable parts are, of course, very difficult to distinguish from the rest of the population.