CHEMICAL PROCESSING INDUSTRIES

CERAMIC INDUSTRY
(ALA)
CHEMICAL 3rd semester-2016

SUBMITTED TO:
PROF. MAZHAR MULTANI

MADE BY:
AKSHAT KHANDELWAL(150420105001)
AKSHAY AMIPRA(150420105002)
JENISH BHANDERI(150420105003)

Index
Ceramic materials
History
Classification of ceramics
Properties of ceramics
Fabrication of ceramics
Summary
Reference

Ceramics materials:
Ceramics are classified as inorganic and nonmetallic materials
that are essential to our daily lifestyle.
keramikos - burnt stuff in Greek - desirable properties of
ceramics are normally achieved through a high temperature
heat treatment process (firing).

Usually a compound between metallic and non metallic

elements.

Always composed of more than one element (e.g., Al2O3,

NaCl, SiC, SiO2).

Bonds are partially or totally ionic, and can have combination

of ionic and covalent bonding

History of ceramics
Archeologists have uncovered human-made ceramics that date back to at
least 24,000 BC.
These ceramics were found in Czechoslovakia and were in the form of
animal and human figurines, slabs, and balls.

These ceramics were made of animal fat and bone mixed with bone ash
and a fine claylike material.

After forming, the ceramics were fired at temperatures between 500800C in domed and horseshoe shaped kilns partially dug into the ground
with loess walls.

While it is not clear what these ceramics were used for, it is not thought to
have been a utilitarian one.

The first use of functional pottery vessels is thought to be in 9,000 BC.

These vessels were most likely used to hold and store grain and other
foods.

Classification of ceramics
Based on their specific applications, ceramics are classified as:
Glasses
Clay products
Refractories
Abrasives
Cements
Advanced ceramics for special applications

Classification of ceramics
Based on their composition, ceramics are:
Oxides
Carbides
Nitrides
Sulphides
Flourides
Based on their engineering applications, ceramics are classified into
two groups as:
Traditional ceramics most made-up of clay, silica and feldspar.
Engineering ceramics these consist of highly purified aluminium
oxide (Al2O3 ), silicon carbide (SiC) and silicon nitiride (Si3N4 ).

Properties: hard,
wear-resistant,
brittle,
refractory,
thermal insulators,
electrical insulators,
nonmagnetic,
oxidation resistant,
prone to thermal shock, and
chemically stable.

Ceramic Fabrication Methods (i)

PARTICULATE
FORMING

GLASS
FORMING

Blowing of Glass Bottles:

Pressing
operation

Gob
Parison
mold

CEMENTATION
Pressing:

plates, cheap glasses

-- glass formed by application of

pressure
-- mold is steel with graphite
lining

Fiber drawing:
Compressed
air

Suspended
parison
Finishing
mold

wind up

Sheet Glass Forming

Sheet forming continuous casting
sheets are formed by floating the molten glass on a pool of molten tin

Heat Treating Glass

10

Annealing:

removes internal stresses caused by uneven cooling.

Tempering:
puts surface of glass part into compression
suppresses growth of cracks from surface scratches.
sequence:
before cooling

hot

initial cooling

cooler
hot
cooler

Result: surface crack growth is suppressed.

at room temp.
compression
tension
compression

11

Ceramic Fabrication Methods

GLASS
FORMING

PARTICULATE
FORMING

CEMENTATION

Hydroplastic forming:
Mill (grind) and screen constituents: desired particle size
Extrude this mass (e.g., into a brick)
Ao
force

container

ram

billet

container

Dry and fire the formed piece

die holder
extrusion

die

Ad

12

Ceramic Fabrication Methods (iia)

GLASS
FORMING

PARTICULATE
FORMING

CEMENTATION

Slip casting:
Mill (grind) and screen constituents: desired particle size
Mix with water and other constituents to form slip
Slip casting operation
pour slip
into mold

absorb water
into mold

green
ceramic

solid component

Dry and fire the cast piece

pour slip
into mold

drain
mold

hollow component

green
ceramic

Drying and Firing

Drying: as water is removed - interparticle spacings decrease
shrinkage .

wet body
partially dry
completely dry
Drying too fast causes sample to warp or crack due to non-uniform shrinkage
Firing:
heat treatment between 900-1400C
vitrification: liquid glass forms
from clay and flux flows between
SiO2 particles. (Flux
lowers melting temperature).

micrograph of porcelain

13

Si02 particle
(quartz)
glass formed
around
the particle

70 mm

14

Ceramic Fabrication Methods

GLASS
FORMING

PARTICULATE
FORMING

CEMENTATION

Powder Pressing: used for both clay and non-clay compositions.

Powder (plus binder) compacted by pressure in a mold
Uniaxial compression - compacted in single direction
Isostatic (hydrostatic) compression - pressure applied by fluid
powder in rubber envelope
Hot pressing - pressure + heat

15

Sintering occurs during firing of a piece that has

been powder pressed

powder particles coalesce and reduction of pore size

Aluminum oxide powder:

sintered at 1700C for 6 minutes.

15 m

16

Tape Casting

Thin sheets of green ceramic cast as flexible tape

Used for integrated circuits and capacitors
Slip = suspended ceramic particles + organic liquid
(contains binders, plasticizers)

17

Ceramic Fabrication Methods

GLASS
FORMING

PARTICULATE
FORMING

CEMENTATION

Hardening of a paste paste formed by mixing cement

material with water
Formation of rigid structures having varied and complex
shapes
Hardening process hydration (complex chemical
reactions involving water and cement particles)
Portland cement production of:
mix clay and lime-bearing minerals
calcine (heat to 1400C)
grind into fine powder

Summary

18

Categories of ceramics
Ceramic Fabrication techniques:
glass forming (pressing, blowing, fiber drawing).
particulate forming (hydroplastic forming, slip casting,
powder pressing, tape casting)
Cementation
Heat treating procedures
glassesannealing, tempering
particulate formed piecesdrying, firing (sintering)

 2002 John Wiley & Sons, Inc. M P Groover,

Fundamentals of Modern Manufacturing 2/e.
http://www.acers.org/acers/aboutceramics.asp?id=outr
each#Definition
Callister & Rethwisch 8e. (Fig. 13.8 is adapted from
C.J. Phillips, Glass: The Miracle Maker, Pittman
Publishing Ltd., London.)
Callister & Rethwisch
W.D. Kingery, Introduction to Ceramics, John Wiley
and Sons, Inc., 1960.
W.D. Kingery, H.K. Bowen, and D.R. Uhlmann,
Introduction to Ceramics, 2nd ed., John Wiley and
Sons, Inc., 1976, p. 483.

Thank you