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The development of cracks and other porosity has a significant effect on the durability of a ceramic. Cracking can significantly reduce the strength and toughness of a ceramic, and a crack that extends through the body may permanently reduce its strength.[30] Cracks that occur in a ceramic can develop to such an extent that the body will fracture. When this happens, a ceramic is no longer useful for the intended purpose and may have to be destroyed. When ceramic parts are broken or cracked, the components, the whole or part of the parts, or the context in which they are used may be destroyed.
After the green or unfired body has been sintered, any cracks that did not close before the green body was sintered will appear as microscopic defects, and are called porosity. If cracks close during the sintering process, the density of the piece will be higher than if the cracks did not close.[29]
In general, the most common cause of crack formation in sintered ceramics is the mechanical action of the compacting tool on the compact. Tools that exert pressure directly to the body are more likely to produce cracking than are tools that exert pressure indirectly, such as a roller or press. The cracks that form are usually perpendicular to the direction of the applied force. A typical ceramic can withstand forces of about 1,200 to 1,800 psi (8.9 MPa to 11.4 MPa), and cracking is often extensive and pervasive.[28]
Cracking can also occur in the kiln as a result of stresses generated by temperature gradients within the kiln. The density of the pieces is constantly changing throughout the sintering process, and parts that shrink at different rates will develop internal stresses, which can result in the creation of cracks. It is estimated that temperature gradients within the kiln can generate internal stresses of several hundred psi.[27]
The same effect can occur if the green body is partially sintered before the compacting operation. This will cause the cracks to close and densification to continue, producing a denser piece.[29]
Even in the case of non-cracking porosity, internal pores can develop to such an extent that part of the body will fracture. The strength of the body may not be reduced to the extent that the body will fracture, but it will be reduced.
If the drying shrinkage is not uniform or too great, the shrinkage can be followed by internal cracking along the drying shrinkage gradients present in the green compact. Compacts with complex shrinkage gradients are associated with more severe internal cracking, and thus limit the densification end-point.[23]
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