MODULE -2
Unit : 1 Materials Chemistry
Engineering Materials Carbon Nano Materials
Electronic memory devices
UNIT-5: MATERIALS CHEMISTRY Engineering Materials
Engineering Materials:
❖ Refractories-classification, refractoriness RUL, Chemical &
Thermal stability
❖ Lubricants - classification, viscosity, viscosity index, flash and fire
points, cloud and pour points
❖ Abrasives-types and properties; Ionic liquids as lubricants
Nano Materials:
❖ Carbon based Nanomaterials: Carbon nanotubes and graphene’s –
Synthesis, properties and applications. ;
Electronic memory devices; Introduction, organic semiconductors for
memory devices: p-type semiconductor-pentacene, n-type-
semiconductor perfluoropentacene; Introduction to organic memory
devices.
Electronic memory devices
Refractory
➢ In materials science, a refractory (or refractory material) is a
material that is resistant to decomposition by heat or chemical
attack and that retains its strength and rigidity at high temperatures.
➢ They are inorganic, non-metallic compounds that may be porous or
non-porous, and their crystallinity varies widely: they may be
crystalline, polycrystalline, amorphous, or composite.
➢ They are typically composed of oxides, carbides or nitrides of
the following elements: silicon, aluminium, magnesium,
calcium, boron, chromium and zirconium.
any refractories are ceramics
➢ Refractories are special heat-resistant materials (not metals) that can
work safely at very high temperatures — above 1000°F / 538°C —
without melting, breaking down, or reacting chemically.
➢ Refractory materials are used in furnaces, kilns, incinerators,
and reactors. Refractories are also used to make crucibles and
molds for casting glass and metals
“Why don’t furnace melt,
even though the metal
inside them is molten?”
Refractories are special materials that
don’t melt or break even at very high
temperatures.
They protect the furnace — just like
fire-resistant tiles protect a
fireplace.
REFRACTORIES
Materials that
– Withstand high temperatures and sudden
changes
– Resists chemical attack from slags (impurities),
gases, and molten metals.
– Withstand load at service conditions
– Withstand abrasive forces
– Conserve heat
– Have low coefficient of thermal expansion
– Will not contaminate the load
Refractories
Refractory lining of a furnace
arc
Refractory walls of a furnace
interior with burner blocks
(BEE India, 2005)
furnaces kilns
A kiln is a thermally insulated
Incinerator chamber, a type of oven
Incineration is conducted in an “incinerator,”
which is a type of furnace designed for
Chemical reactors
burning hazardous materials in a
Crucibles
Molds
Classification of refractory materials
Refractories are classified in multiple ways, based on:
❖ Chemical composition
❖ Fusion temperature
❖ Method of manufacture
❖ Size and shape
❖ Refractoriness
❖ Thermal conductivity
Chemical composition
Neutral refractories
❖ These are generally chemically stable to both acids and
bases. These are made from weakly acidic or basic
materials.
❖ The common example of these materials are alumina, and
chromium oxide (Cr2O3), zirconia, spinal, SiC etc.
❖ Silica refractories are highly resistant to thermal shock and
are commonly used in the iron and steel industry.
❖ Zirconia refractories, made of zirconium oxide, are ideal for
glass furnaces due to their low thermal conductivity and
resistance to
molten glass.
❖ These refractories are also useful for applications in high
temperature construction materials
Basic refractories
❖ Basic refractories consist of basic materials such as CaO and (MgO)
and these are used to on areas where slags and atmospheric are basic
❖ These are stable to alkaline materials but could react with acids.
Other examples includes dolomite and chrome-Magnesite.
❖ Magnesite refractories are made of ≥ 85% magnesium oxide (MgO)
and are highly resistant to lime and iron-rich slags. They are used in
metallurgical furnaces.
❖ Dolomite refractories are composed of calcium magnesium
carbonate and are used in converter and refining furnaces.
❖ Magnesia-chrome refractories contain magnesium oxide (MgO) and
chromium oxide (Cr2O3), offering high refractoriness and corrosion
resistance.
Acidic refractories
❖These are not attacked or affected by acidic
materials but are easily affected by basic materials.
These include substances such as silica (SiO2) and
fire clay refractories.
❖Ceramic materials, such as hydrated aluminum
silicates like kaolinite, are commonly used to line high-
temperature industrial structures like furnaces and
kilns due to their resistance to extreme heat, thermal
shock, and corrosion.
On the basic of Fusion temperature
Refractory materials are classified into three types-based
temperature (melting point).
Normal refractories: Fusion temperature of 1580–1780 °C (e.g. fire clay)
High Refractories: Fusion temperature of 1780–2000 °C (e.g. chromite)
Super Refractories: Fusion temperature of > 2000 °C (e.g. zirconia)
Classification Based on manufacture
Some important ways refractories are produced include:
Dry-press process
Fused-cast process
Hand-molded process
Approx.
Material
Refractoriness
Examples Fireclay brick 1500–1700°C
Silica brick 1650–1750°C
High alumina brick 1750–1850°C
Magnesite brick > 2000°C
Refractoriness is measured by a Pyrometric Cone Equivalent (PCE) test
Refractoriness
The Pyrometric Cone Equivalent (PCE) test measures the heat-resistance of refractory
materials by determining the temperature at which they soften and deform.
Refractories are classified as:
❖ Super duty: PCE value of 33–38
❖ High duty: PCE value of 30–33
❖ Intermediate duty: PCE value of 28–30
❖ Low duty: PCE value of 19–28
Thermal conductivity
❖ Refractories may be classified by thermal conductivity as either conducting,
nonconducting, or insulating
❖ Examples of conducting refractories are silicon carbide (SiC) and zirconium
carbide (ZrC)
❖ Whereas examples of nonconducting refractories are silica and alumina
❖ Insulating refractories include calcium silicate materials, kaolin, and zirconia.
➢ Refractoriness is the property of a refractory's multiphase to reach a specific
softening degree at high temperature without load, and is measured with a
pyrometric cone equivalent (PCE) test
➢ Refractoriness under load (RuL) RuL is the deformation behavior of a refractory
subjected to the combined effects of load, time and temperature.
➢ Typically, the test entails applying a compressive load at elevated temperature to
determine the resistance of the refractories to deformation (ISO 1893-89).
Refractory materials are useful for the following functions
❖ Serving as a thermal barrier between a hot medium and the wall of a containing
vessel
❖ Withstanding physical stresses and preventing erosion of vessel walls due to the hot
medium
❖ Protecting against corrosion
❖ Providing thermal insulation
Refractories have multiple useful applications
❖ In the metallurgy industry, refractories are used for lining furnaces, kilns, reactors,
and other vessels which hold and transport hot media such as metal and slag.
❖ Refractories have other high temperature applications such as fired heaters,
hydrogen reformers, ammonia primary and secondary reformers, cracking furnaces,
utility boilers, catalytic cracking units, air heaters, and sulfur furnaces.
❖ They are used for surfacing flame deflectors in rocket launch structures.
Refractory Applications
furnaces Refractory bricks
REFRACTORINESS “THE RUL TELLS US HOW
UNDER LOAD (RUL) STRONG THE
IS DEFINED AS: TEMPERATURE REFRACTORY
AT WHICH A REMAINS AT HIGH
REFRACTORY TEMPERATURES
UNDER WORKING
MATERIAL LOAD — SIMILAR TO
BEGINS TO HOW IT PERFORMS
DEFORM OR INSIDE A REAL
FURNACE.
COLLAPSE
UNDER A
SPECIFIED
MECHANICAL
LOAD WHILE
BEING
HEATED.”
❖ Super duty: PCE value of 33–38
❖ High duty: PCE value of 30–33
❖ Intermediate duty: PCE value of 28–30
❖ Low duty: PCE value of 19–28
Refractories characteristics
Functions of Lubricants
Classification of Lubricants
Semi Solid Lubricants
Solid Lubricants
Mechanism