Alumina Femoral Head Component - Relative Bulk Density - Engineering Assignment Help

Assignment Task:

1) An alumina femoral head component (shown in the figure on the right) is to be fabricated from a commercially-available alumina powder by a processing route involving ceramic dry forming.  The component is to have the following specifications:  Outside diameter = 25.4 ± 0.01 mm  Relative bulk density >99.95%  Phase Composition = single-phase (α-Al2O3) alumina  Grain size (<1.2 µm) 
 
a) Specify three characteristics that the starting powder should have in order to achieve the above specifications.  For each characteristic, explain its significance/importance in the fabrication process.

b) Using the as-supplied powder described above as the starting point, propose a feasible processing route to fabricate the component and specify the main equipment used.

c) Define the term relative bulk density.  Explain how the forming process will influence and determine the relative bulk density and dimensional tolerances attained in the final component. 
 
 
2) A structural clay product is to be made from a naturally occurring clay by a process involving the mining, crushing, grinding of the clay followed by extrusion (using an auger extruder), drying and firing.  The product has a complicated cross-sectional shape and so the clay needs to have high plasticity for forming.

a) Define the term plasticity and explain how plasticity is achieved in a clay material. 

b) Specify and explain three aspects of the clay material which could be controlled so as to increase plasticity.

c) Briefly explain the principle of operation of the auger extruder. 

d) As a consequence of the two aspects described in part b) it is found that the product tends to suffer an increased incidence of cracking during drying.  Explain the reason for this and prescribe a possible solution to the problem.
 
 
3) An alumina component is manufactured by a process involving slip casting and drying in an intermittant (batch) dryer.

a) With reference to the electrical characteristics of ceramic particles in water (DLVO theory), explain how pH and/or deflocculant addition should be manipulated in order to control the viscosity and casting rate of the casting slip and the bulk density of the cast layer after drying. 

b) Draw a schematic diagram showing the layout and main features of an intermittent (batch) dryer.  Explain briefly the principle of operation of the dryer. c) Define the term relative humidity.  Draw a schematic graph showing the relative magnitudes of temperature and relative humidity as a function of the drying cycle. 

d) It is found that the product tends to crack early in the drying cycle.  Explain a likely cause of this cracking and, with reference to your answers in parts a) and b), propose a potential solution to the problem.
 

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