Ceramics
Transcript of Ceramics
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CERAMICSCERAMICS
Carasco, Allan Gabriel
Doliente, Lorenzo Miguel
Jacinto, Stephanie
Villanueva, Von Kirby
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Ceramics
• One of the largest groups of materials with the properties of nonmetals and all are made by firing or burning, often including silicates and metal oxides.
• Greek term Keramos, meaning "a potter" or "pottery”.
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Ceramic materials are attractive for several reasons :Cheap in terms of its starting materials.Compared to metals, lightweight and
retain their strength up to 1000˚C where metals tends to fail.
They have electrical, optical, and magnetic properties of value in the computer and electronic industries.
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HistoryThe art of making pottery by forming and
burning clay has been practiced from the earliest civilizations.
Burnt clayware has been found dating from about 15,000 B.C. and as well developed as an industrial product in Egypt by about 5000 B.C.
Formed glass dates from the period 7000-5000 B.C. and was a stable industry in Egypt by about 1500 B.C.
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Ceramics Industry
An important characteristic of the ceramics industry is that it is basic to the successful operation of many other industries.
In the Philippines, smuggled ceramics has cause severe effect on the ceramic industry locally. But exporting of ceramic materials is significantly increasing.
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Uses of CeramicsThe ceramics industry is divided in the
manufacture of the ff. products: Structural Clay Products Whitewares Refractories Glasses Abrasives Cements Advance Ceramics
-Structural-Electrical-Coating
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Classifications of the Ceramics
Traditional CeramicsNew Ceramics
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Raw Material
WeighingBall Milling
Vibrating Screen and HomoTank
Spray Dryer
Powder Storage (SILO)
Dry Pressing Horizontal
Dryer Glazing
Silk Screen PrintingRoller Heart Kiln
Ceramic Tile Processes
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Raw Materials
The traditional ceramics industry is largely based on various combinations of clay minerals, feldspar and silica.
The mineral raw materials used in the ceramic industry are mainly inorganic, nonmetallic, crystalline solids formed by complex geologic processes.
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Raw Materials
Oxygen, silicon, and aluminum together account for 90% of the elements in the earth’s crust , These, together with other minerals compounds of oxygen, constitute the greatest bulk of naturally occurring ceramic raw materials.
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Raw Materials
Clay MineralsTalc and Related
MineralsSilica and Silicate
MineralsFeldspars and related
minerals. Refractory Raw
Materials
TalcSilica
Clay
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Common Types of ClayKaolin or China Clay Ball ClaysFire ClaysFlint ClaysPottery ClayShaleVitrifying ClaysBrick ClaysSlip Clays
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Important Characteristics of Claysin Ceramic Bodies
Clays have the ability to form clay-water composition and to maintain their shape and strength during drying and firing
They fuse over a temperature range depending on their composition in such a way as to become dense and strong without losing their shape
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Talc and Related Minerals
Talc is a hydrous magnesium silicate which has a layer structure similar to that of the clay minerals.
It is an important ceramic raw material for the manufacture of electrical and electronic components
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Talc and Related Minerals
Pyrophyllite Block talc Asbestos
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Silica and Silicate Minerals
Silica is a major ingredient in glass, glazes, enamels, refractories, abrasives, and whiteware compositions.
It is widely used because it is inexpensive, hard, chemically stable
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Silica and Silicate Minerals
The major source of silica for the ceramic industry is sandstone, consisting of lightly bonded quartz grains.
The sand is frequently mined by loosening the quarts grains with a stream of high-pressure water.
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Feldspars and Related Minerals
Feldspar are anhydrous aluminosilicates containing K+, Na+, and Ca2.; they are present in virtually all igneous rocks.
Most production comes from pegmatites which are coarsely crystalline rock formed in the later stages of crystallization of a magma
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Feldspars and Related Minerals
Nepheline syeniteWollastoniteSillimanite
Sillimanite
WollastoniteNepheline syenite
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Refractory Raw Materials
AluminaMagnesiaDolomiteChrome Ore
Alumina
Dolomite Chrome Ore
Magnesia
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Other Raw Materials
Soda ashBorate mineralsFluorsparPhosphate minerals Abrasive raw
materials
Soda Ash
Borate Minerals
Flourspar
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Ball MillingSpheres mixed with
the stock to be comminuted are rotated inside a large cylindrical container.
These operations are often carried out with water
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Ball Milling
Stock
Balls
Drive rolls
Container
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Spray Dryer
Characterized by atominization of a solution or suspension into droplets, followed by drying.
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Spray Dryer
Schematic Diagram of Spray Dryer
Particle Trajectory
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Dry Pressing
Forming of the “greenware” tile body.
Non-clumping granulates are compressed in steel dies designed appropriately for the part to be manufactured.
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Glazing
The application of glassy coatings on ceramic wares to give them decorative finishes and to make them impervious to moisture
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Roller Hearth KilnA roller tunnel kiln for firing a drying
refractory material advanced along the refractory rotatable rollers includes an upper section comprising a prefiring zone, a firing zone, a first forced cooling zone, a natural cooling zone and a second forced cooling zone.
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Roller Hearth Kiln
Firing zone
Gear system
Entrance
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Traditional Ceramic Processes
A. Preparation of Raw Materials• Crushing
Types of Equipments Useda) Jaw Crushers
b) Gyratory Crushers
c) Roll Crushers
d) Hammer Mills
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Crushing
Jaw CrusherGyratory Crusher
Roll CrusherHammer Mill
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Traditional Ceramic Processes
• Grinding
Types of Equipments Useda) Ball mill
b) Roller mill
c) Impact grinding
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Grinding
Ball Mill Roller Mill Impact Grinding
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Traditional Ceramic Processes
B. Shaping Processesa) Slip Casting
1. Drain Casting
2. Solid Casting
b) Plastic Forming
1. Manual Forming Hand modeling Hand molding Hand throwing
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Drain Casting
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Traditional Ceramic Processes
2. Mechanized Jiggering Plastic pressing Extrusion
c) Semi-dry Pressing
d) Dry Pressing
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Semidry Pressing
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Traditional Ceramic Processes
C. Drying
D. Firing
E. Glazing
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New Ceramic Processes
A. Preparation of Raw Materials1. Freeze Drying
2. Precipitation from solution
B. Shaping1. Hot pressing
2. Isostatic pressing
3. Doctor-blade process
4. Injection molding
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New Ceramic Processes
C. Sintering1. To bond individual grains into a solid mass
2. To increase density
3. To reduce or eliminate porosity
D. Finishing1. To increase dimensional accuracy
2. To improve surface finish
3. To make minor changes in part geometry
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New Ceramic Processes
Doctor blade Process
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Factors Affecting Ceramic Process
OxidationDecomposition ReactionsPhase TransformationsTrapped GasesNon uniform MixingOver firingHot Pressing
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Common Errors in Ceramic Process
Firing ShrinkageWarping