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    Processing of Ceramics-20190913025210

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    This document provides an overview of ceramic manufacturing processes. It begins by distinguishing traditional ceramics from advanced/new ceramics and glasses. For traditional ceramics, the key processing steps are described as preparation of raw materials, forming/shaping, drying, firing, and post-firing. Specific forming methods like slip casting and techniques for drying and firing are also outlined. The document then briefly discusses the properties of ceramics and reasons for differences in processing advanced ceramics compared to traditional ones before summarizing some common techniques.

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    Processing of Ceramics-20190913025210

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    Sajjad
    44 views44 pages
    This document provides an overview of ceramic manufacturing processes. It begins by distinguishing traditional ceramics from advanced/new ceramics and glasses. For traditional ceramics, the key processing steps are described as preparation of raw materials, forming/shaping, drying, firing, and post-firing. Specific forming methods like slip casting and techniques for drying and firing are also outlined. The document then briefly discusses the properties of ceramics and reasons for differences in processing advanced ceramics compared to traditional ones before summarizing some common techniques.

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    This document provides an overview of ceramic manufacturing processes. It begins by distinguishing traditional ceramics from advanced/new ceramics and glasses. For traditional ceramics, the key processing steps are described as preparation of raw materials, forming/shaping, drying, firing, and post-firing. Specific forming methods like slip casting and techniques for drying and firing are also outlined. The document then briefly discusses the properties of ceramics and reasons for differences in processing advanced ceramics compared to traditional ones before summarizing some common techniques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    44 views44 pages

    Processing of Ceramics-20190913025210

    Uploaded by

    Sajjad
    This document provides an overview of ceramic manufacturing processes. It begins by distinguishing traditional ceramics from advanced/new ceramics and glasses. For traditional ceramics, the key processing steps are described as preparation of raw materials, forming/shaping, drying, firing, and post-firing. Specific forming methods like slip casting and techniques for drying and firing are also outlined. The document then briefly discusses the properties of ceramics and reasons for differences in processing advanced ceramics compared to traditional ones before summarizing some common techniques.

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    of 44

    KKKM2833 MANUFACTURING PROCESSES

    (EXECUTIVE PROGRAMME)
    SEM 1 SESSION 2019/2020

    PROCESSING OF CERAMICS
    Professor Dr Andanastuti Muchtar
    Centre for Materials Engineering and Smart Manufacturing
    (Pusat Kejuruteraan Bahan dan Pembuatan Pintar)
    Universiti Kebangsaan Malaysia
    AT THE END OF THE LECTURE,YOU WILL...

    • Appreciate the relationship between the properties of ceramics


    and the choice of manufacture of ceramic components
    • Understand several techniques for manufacturing products, both
    traditional and advanced ceramics

    KKKM2833 Sem 1 2019/2020


    INTRODUCTION

    1. Traditional ceramics - clay products such as pottery


    and bricks, common abrasives, and cement

    KKKM2833 Sem 1 2019/2020


    Introduction (cont.)

    2. New ceramics (Advanced Ceramics,


    Fine Ceramics) - more recently
    developed ceramics based on oxides,
    carbides, etc., and generally
    possessing mechanical or physical
    properties superior or unique
    compared to traditional ceramics
    3. Glasses - based primarily on silica
    and distinguished by their
    noncrystalline structure
    PROPERTIES OF CERAMICS

    • High hardness, electrical and thermal insulating,


    chemical stability, and high melting temperatures
    • Brittle, virtually no ductility - can cause problems in
    both processing and performance of ceramic
    products
    • Some ceramics are translucent, window glass (based
    on silica) being the clearest example

    KKKM2833 Sem 1 2019/2020


    PROCESSING OF CERAMICS

    • In contrast to polymers and metals, ceramics are not melted


    for shaping.
    • Why?
    • There are methods that are used for both traditional and
    advanced ceramics manufacture – however, in the case of
    advanced ceramic components, the composition and other
    processing parameters are strictly controlled compared to
    the manufacture of traditional ceramics.
    • Why?

    KKKM2833 Sem 1 2019/2020


    PROCESSING OF TRADITIONAL
    CERAMICS

    • Examples of raw materials: white clay, ball


    clay dan white clay powder

    KKKM2833 Sem 1 2019/2020


    PROCESSING SEQUENCE OF
    TRADITIONAL CERAMICS

    • Processing Sequence
    1. Preparation of Raw
    Materials
    2. Forming/Shaping
    3. Drying
    4. Firing
    5. Post Firing

    Raw Materials

    KKKM2833 Sem 1 2019/2020


    PREPARATION OF RAW MATERIALS

    • Comminution
    • Crushing
    • Grinding
    • Crushing – reduction of large lumps from the
    mine to smaller sizes
    • Grinding/Milling – reducing the small pieces
    after crushing to a fine powder

    KKKM2833 Sem 1 2019/2020


    CRUSHING
    Swing jaw

    Fixed jaw

    Jaw Crusher

    Roll Crusher

    KKKM2833 Sem 1 2019/2020


    Roll Crusher
    JAW CRUSHER

    KKKM2833 Sem 1 2019/2020


    MILLING

    Balls

    Roller Milling

    Stock
    + +

    Ball Mill
    Air

    Impact Grinding
    KKKM2833 Sem 1 2019/2020
    BALL MILLING IN INDUSTRY

    KKKM2833 Sem 1 2019/2020


    TRANSPORTATION OF RAW MATERIALS

    Hop car (left) and slur car (right)

    KKKM2833 Sem 1 2019/2020


    FORMING/SHAPING

    • Dependent on consistency of mixture, as well as


    pressure required for forming
    • Slip casting - >25% water content
    • Plastic forming, hand modeling - 15 to 25%
    • Semidry pressing - 10 to 15%
    • Dry pressing - <5%

    KKKM2833 Sem 1 2019/2020


    Slip Casting
    Common method to produce ceramic components

    In slip casting, a suspension of ceramic powders in water, called a


    slip, is poured into a porous plaster of paris mould so that
    water from the mix is gradually absorbed into the plaster to
    form a firm layer of clay at the mould surfaces.

    KKKM2833 Sem 1 2019/2020


    SLIP CASTING (CONT.)

    Slip must be sufficiently fluid to flow into the crevices of the


    mould cavity, yet lower water content is desirable for faster
    production rates

    Two principle variations: drain casting & solid casting

    What is the difference between drain casting and solid casting?

    KKKM2833 Sem 1 2019/2020


    Slip Casting (cont.)
    Plaster of Paris
    Mould

    Green Body

    KKKM2833 Sem 1 2019/2020


    Slip Casting (cont.)

    • Slip casting in the industry (left)


    • Solid Casting – right pic

    KKKM2833 Sem 1 2019/2020


    Hand Modelling

    Hand Modeling – creation of the ceramic product by manipulating


    the mass of plastic clay into the desired geometry

    KKKM2833 Sem 1 2019/2020


    Post Processing
    • After the shaping of the green body, several other
    processes may still be necessary prior to
    achieving the end product. For e.g. :

    • Drying
    • Firing / Sintering
    • Film printing and coating
    • Surface finishing
    • Machining

    KKKM2833 Sem 1 2019/2020


    Drying

     First stage – rapid drying with shrinkage


     Second stage – Slow drying without
    shrinkage
     Shrinkage of 15-20% occur during drying
    when the liquid between the particles is
    removed and the interparticle separation
    is reduced.

    KKKM2833 Sem 1 2019/2020


    Drying (cont.)

    • Drying is a critical stage due to the tendency of the part to


    warp or crack, from variations in the moisture content and
    the thickness within the part.

    • Warping effects generally may be reduced by ensuring


    uniform drying and decreasing the average drying
    shrinkage.

    KKKM2833 Sem 1 2019/2020


    Firing

    • Firing – green body fired in a kiln


    • Also known as sintering; similar to powder metallurgy
    • Accompanied by shrinkage
    • Firing/sintering of ceramics is important to improve mechanical
    properties
    • Traditional ceramics: 1000-1300°C
    • Improvement in properties results from:
    • Development of a strong bond between the complex
    particles in the ceramic
    • Reduced porosity

    KKKM2833 Sem 1 2019/2020


    Firing (cont.)

    • Post firing processes – applying ‘decals’ or glazing


    (Most ceramics products are coated with slip that
    will form glassy coating after firing).
    • Decalcomania is an indirect printing method
    whereby the pattern is first printed on a special
    paper before being transferred to the ceramic
    product.

    KKKM2833 Sem 1 2019/2020


    FINISHING

    • Printing decals (top), Sticking ‘decals’ (left) and hand painting


    (right)

    KKKM2833 Sem 1 2019/2020


    GALLERY : MANUFACTURE OF LABU
    SAYONG

    KRAF SAZILAH LABU SAYONG WORKSHOP

    KKKM2833 Sem 1 2019/2020


    RAW MATERIALS MIXING

    KKKM2833 Sem 1 2019/2020


    MIXING IN THE
    ADDITIVES THE SLIP

    KKKM2833 Sem 1 2019/2020


    SLIP CASTING PLASTER OF PARIS
    MOULDS

    KKKM2833 Sem 1 2019/2020


    GREEN BODY
    FINISHING POTTER’S WHEEL

    KKKM2833 Sem 1 2019/2020


    See
    GREEN BODIES video!

    KKKM2833 Sem 1 2019/2020


    SELF MADE KILN COMMERCIAL KILN

    KKKM2833 Sem 1 2019/2020


    ENGRAVED GREEN BODY

    END PRODUCT

    KKKM2833 Sem 1 2019/2020


    PROCESSING OF ADVANCED CERAMICS

    • Superior strength and hardness


    • Improved brittleness
    • Strict control to avoid contamination
    • Use of additives, e.g.
    • Plasticisers, binders, wetting agents. Deflocculants and
    lubricants

    Radomes for missiles


    PROCESSING STEPS

    • Powder preparation
    • Examples of powder synthesis
    methods:
    • Co-precipitation for Y-TZP, Ce-
    TZP, etc. nanopowders and
    YBa2Cu3Ox superconductors
    • Sol-gel processing for YBa2Cu3Ox
    superconductors, mullite, silica,
    etc.
    Particle size – nanometer or
    • Freeze drying for submicron
    superconductors Ultra purity fine-grained
    • Spray drying for zirconia powders = 99.99% -
    powders and YBa2Cu3Ox 99.9999%
    superconductors

    KKKM2833 Sem 1 2019/2020


    PROCESSING STEPS (CONT.)

    • Forming Methods (some examples)


    • Slip Casting, Extrusion and Dry Pressing
    • Hot & Isostatic Pressing
    • Doctor-blade Process
    • Ceramics Injection Moulding
    • Sintering at 70-90% of melting temp (1200-1800°C)
    • Finishing
    • Surface finishing, minor geometrical modifications

    KKKM2833 Sem 1 2019/2020


    DOCTOR BLADE PROCESS

    • To make thin sheets of green ceramic cast as flexible tape


    • Used as substrates for integrated circuits and capacitors.

    KKKM2833 Sem 1 2019/2020


    DOCTOR BLADE PROCESS (CONT.)

    • Tape caster

    KKKM2833 Sem 1 2019/2020


    Doctor Blade Process (cont.)

    • Picture on right shows green tape

    KKKM2833 Sem 1 2019/2020


    CERAMICS INJECTION MOULDING

    KKKM2833 Sem 1 2019/2020


    Ceramic Injection Moulding
    Products

     very good wear and corrosion resistance for chemical engineering,


    biomedical, dental and electrical applications.
    (http://www.wundermold.com/pages/ceram_prod.html)

    KKKM2833 Sem 1 2019/2020


    SINTERING

    Ceramic components being


    loaded into a furnace

    • Box furnace

    KKKM2833 Sem 1 2019/2020

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