Professional Documents
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Ceramic Os
Ceramic Os
59 G5593
02
Interceram_LOGO.indd 1 20.07.10 09:21
high-performance ceramics
2010
Trade Fairs &
Conventions
POWTECH 2010, Germany
CERA GLASS 2010, India
QUALICER 2010, Spain
IPB 2009, China
Ceramics Forum
The Glass Industry in the
EU Today a Survey
High-Performance
Ceramics
A. Kaiser*, R. Lutz*
Composition Modifications
on the Properties of Some Ceramic Bricks Filling
Bioactive Glasses and
Glass Ceramics Energy Saving
Titanium Nitride Coating
Building Materials
Effect of Bi2O3 on Cordie-
rite Formation in Cordieri-
of Larger Size
ness of Polished Porcelain
Stoneware Tiles Polished Porcelain
Effect of Diaspore Addition
on Microwave-Assisted Stoneware Tiles
Sintering of Floor Tile
12.04.10 13:54
The corresponding author, Dr. Alfred Kaiser, studied Chemistry This paper gives an overview about hydraulic pressing,
at the University of Wuerzburg, Germany, and received his PhD various shaping technologies and relat- shaping, advanced
in 1979. From 1979 to 1989 he was Project Manager, Depart- ed selection criteria for the production ceramics, high-perform-
ment Manager and Deputy Director at the Fraunhofer Institute of advanced ceramics. The uniaxial ance ceramics, vacuum
for Silicate Research in Wuerzburg, specializing in materials hydraulic pressing technology is ad- pressing, large speci-
development (sol-gel process) and environmental aspects of dressed in detail and recent develop- men
glass technology. From 1989 to 1995 he was Manager Technol- ments are discussed which enable new Interceram 60 (2011) [34]
ogy at the Test Center of Gustav Eirich, Hardheim, Germany, application possibilities of this technol-
where he focused on mixing and granulating technology. From 1995 to 2005 he ogy, especially for the manufacturing
worked as Manager Plant Engineering at Laeis GmbH in Trier, Germany. Since of parts having larger dimensions. Sev-
2005 he has been Manager Business Development at the same company, now eral examples of oxide ceramics, non-
located in Wecker, Luxembourg. Dr. Kaiser is a member of the German Ceramic oxide ceramics as well as carbon based
Society, the German Engineering Federation, and the American Ceramic Society. products clearly show the broad range
The author of numerous technical papers has served in various technical commit- of utilization possibilities.
tees. E-Mail: kaiser@laeis.eu
1 Introduction of the investigation is the statement, that technology), freeze gelation, so called rap-
Shaping of ceramics has a long tradition, this pressing technology is not recommend- id manufacturing technologies (printing
starting from free hand forming several able for the new product. In other cases etc.) and many more [1618].
thousand years ago up to the most sophisti- highly sophisticated shaping technologies Technically they can be classified by various
cated modern technologies [1]. The most are used which are still under development parameters, e.g.
important technologies for traditional ce- or generally suitable only for lab scale or body condition and moisture content
ramics can be classified into casting technol- prototype manufacturing. And again the (dry, semi-dry, plastic, slip, )
ogies, plastic forming technologies and result is the conclusion, that simple tech- shaping temperature (cold, warm, hot)
pressing technologies [2]. These well proven nologies like uniaxial hydraulic pressing pressure
and comparably economical technologies should not been considered. atmosphere (air, inert, reducing, vacu-
are also predominant in the manufacturing The aim of this paper is to show that mod- um, ...)
of advanced ceramics [3], at least when it ern uniaxial hydraulic pressing technology content of organic additives
comes to large scale production (in this pa- can be used very effectively to produce ad- This classification, however, does not give
per advanced or technical ceramics will vanced ceramics with high quality and with an indication of the most suitable selection
be referred to as ceramics produced mainly comparably low capital expenditure. for a specific task, and in some cases it can
from well defined raw materials, often syn- be misleading. Table 1 (taken from [3]) e.g.
thetic powders, rather than traditional or 2 Shaping technologies for shows a compilation of various organic ad-
classical ceramics mainly made from nat- dvanced ceramics
a ditives used for the individual shaping
ural raw materials). In the course of new Most of the well proven shaping technolo- processes. This table seems to indicate a low
product developments in laboratories or in gies for traditional ceramics are used also organic content for injection moulding and
R&D centers, however, the focus usually is for the production of advanced ceramics. a high organic content for uniaxial pressing
on material optimization and not on the These are mainly uniaxial and isostatic due to the number of different organic ad-
shaping technology. Therefore, very often pressing, slip casting and pressure casting as ditives. If one looks at the quantity of or-
one of the available lab scale technologies is well as extrusion, often modified to meet ganics, however, it can be seen that the
used without systematic investigation into the higher demands of technical ceramics organic content of bodies for injection
better alternatives and especially without [410]. Other also well established technol- moulding typically is 12 orders of magni-
regard of a future industrial scale produc- ogies are not widely used in traditional ce- tude higher than for uniaxial pressing
tion. Sometimes, the available technologies ramics production, but more dedicated to (Table 2). Various papers compare data ob-
are just small scale presses which do not advanced ceramics, like hot isostatic press- tained with different shaping technologies
provide all of the features of an up-to-date ing, tape casting, injection moulding, thick [1921], but generally the results require a
modern production size press and the result film and thin film technologies [1115], very careful interpretation and must not be
and further technologies are just being es- simply generalized.
tablished or are under development, in- Table 2 gives also a synopsis of other charac-
* LAEIS GmbH, Am Scheerleck 7, L-6868 Wecker,
cluding the spark plasma sintering (SPS), teristic features of selected shaping technol-
Luxembourg also called FAST (field assisted sintering ogies. Such a survey can help to restrict the
0210 APRIL VOL. 59 G5593
02
Interceram_LOGO.indd 1 20.07.10 09:21
high-performance ceramics
2010
Trade Fairs &
Conventions
POWTECH 2010, Germany
CERA GLASS 2010, India
QUALICER 2010, Spain
IPB 2009, China
Ceramics Forum
number of suitable technologies, e.g. when material properties (reactivity against wa- may show a result similar to that shown in
The Glass Industry in the
EU Today a Survey
High-Performance
Ceramics
high moisture contents are not acceptable or ter, sintering behavior, ) Table 3 (comparison of hydraulic pressing,
Composition Modifications
on the Properties of Some Ceramic Bricks Filling
Bioactive Glasses and
Glass Ceramics Energy Saving
Titanium Nitride Coating
of Cobalt Chromium
when high production capacities (i.e. short downstream production steps (possibility pressure slip casting and tape casting of alu-
Coronary Stents:
a SEM-EDS Analysis
Ceramic Based
Bio-Medical Implants
Preparation of Ca-_/`-
Sialon Powders by Micro-
cycle times) are required. For practical pur- and costs of machining of the green and/ mina in various thicknesses).
wave Reaction Nitridation
Building Materials
Effect of Bi2O3 on Cordie-
rite Formation in Cordieri-
te Based Bodies
poses, however, the most important selec- or fired parts, necessity of near net shap- TILE & BRICK
The Use of Residues in
the Manufacture of
Ceramic Tile Bodies
3 Hydraulic pressing
Hot-Pressed Gres
Polished Porcelain
process for advanced ceramics are Further important aspects are the availabil Uniaxial pressing is one of the most used
Stoneware Tiles
Effect of Diaspore Addition
on Microwave-Assisted Stoneware Tiles
Sintering of Floor Tile
product geometry (maximum length and ity of a technology which has been proven shaping technologies in practically all fields
U1_U4_IC_2_10.indd 2 12.04.10 13:54
width, product height and aspect ratio, already for comparable tasks, the necessary of ceramic production. The main advantag-
complexity capital expenditure and the operating costs es (especially with respect to advanced ce-
of product) (CAPEX / OPEX) for technologies in ques- ramics production) are:
throughput capacity tion and last but not least sustainability and possibility of dry pressing: moisture
special product requirements (density, environmental impact. contents of press bodies are typically be-
microstructure, contamination restric- If these criteria are carefully evaluated, a low 3mass-% and very often even no
tions, ) comparative study as a basis for a decision moisture at all is applied; therefore no
separate drying step before firing is neces-
sary
Table 1 Qualitative compilation of organic additives used for various shaping tech- high green density, depending on the ma-
nologies (from [3]) terial properties and the applied pressure,
similar to what can be reached with iso-
Thermoplastic binder
static pressing
Temporary binder
Antifoam agent
allowing for an easy and safe handling
Filtration aid
Pressing aid
Typical temperature
Typical pressure
02
Interceram_LOGO.indd 1 20.07.10 09:21
high-performance ceramics
2010
Trade Fairs &
Conventions
POWTECH 2010, Germany
CERA GLASS 2010, India
QUALICER 2010, Spain
IPB 2009, China
Ceramics Forum
High-Performance
Ceramics
control; controller
Composition Modifications
on the Properties of Some Ceramic Bricks Filling
Bioactive Glasses and
Glass Ceramics Energy Saving
Titanium Nitride Coating
of Cobalt Chromium
Coronary Stents:
a SEM-EDS Analysis
Ceramic Based
Bio-Medical Implants
design:
Preparation of Ca-_/`-
1) nominal v alue,
Sialon Powders by Micro-
wave Reaction Nitridation
Building Materials
Effect of Bi2O3 on Cordie-
2) motion controller,
rite Formation in Cordieri-
te Based Bodies
3) proportional valve,
Ceramic Tile Bodies
Hot-Pressed Gres
Porcellanato Body
Effect of Calcite on the
Brick Body Closing
Tile surface
4) cylinder,
Glossiness and Slipperi-
ness of Polished Porcelain
Stoneware Tiles Polished Porcelain
Effect of Diaspore Addition
on Microwave-Assisted Stoneware Tiles
Fig. 2 High alumina plates, pressed with vacuum
5) pressure transducer,
Sintering of Floor Tile
6) measuring
rod/actual value
invest costs medium high low fixed (Fig. 5). As the upper die descends, the
mould frame moves down simultaneously
production capacity medium high medium
at a defined speed which can be selected via
0210 APRIL VOL. 59 G5593
02
Interceram_LOGO.indd 1 20.07.10 09:21
high-performance ceramics
2010
Trade Fairs &
Conventions
POWTECH 2010, Germany
CERA GLASS 2010, India
QUALICER 2010, Spain
IPB 2009, China
Ceramics Forum
3 4 5
The Glass Industry in the
EU Today a Survey
High-Performance
Ceramics
Composition Modifications
on the Properties of Some Ceramic Bricks Filling
Bioactive Glasses and
Glass Ceramics Energy Saving
Titanium Nitride Coating
of Cobalt Chromium
Coronary Stents:
a SEM-EDS Analysis
Ceramic Based
Bio-Medical Implants
Preparation of Ca-_/`-
Sialon Powders by Micro-
wave Reaction Nitridation
Building Materials
Effect of Bi2O3 on Cordie-
rite Formation in Cordieri-
te Based Bodies
the press control panel relative to the plung- and/or better performance. Flat plates or Another very interesting application is the
er speed (so called active mould). The tiles are pressed and sintered in the tradi- manufacturing of carbon-based filters for
speed of the mould can be changed several tional way. For the multi-curved body pro- molten metal purification. Fig. 8 demon-
times at pre-defined plunger positions or af- tection plates different technologies have strates the very delicate design of such fil-
ter reaching pre-selected pressures, thus been established: they are either flat pressed ters, which have been pressed directly into
providing a precisely controlled densifica- and sintered on curved supports for bend- the shape as shown in the picture, including
tion regime. ing, or they are directly pressed into the the fine pore structure. Up to now, this proc-
Additional filling and fill compensation curved shape. In the latter case, extraordi- ess has been realized only in pilot scale.
measures can be applied for complex shapes nary care and attention has to be paid to a Also carbon fibre reinforced carbon materi-
and vacuum systems are available for all proper filling of the mould cavity. Fig. 6 als have been pressed under elevated tem-
types of presses. If necessary, also further shows a multi-curved SiC body protection perature (approx. 150C) in order to pro-
measures can be taken to avoid contamina- plate as pressed, with a good green strength duce pre-forms for ceramic brake discs.
tion, e.g. selection of special materials for all for handling before firing. Fig.9 shows the very homogeneous struc-
components coming in contact with the Ceramic armour can be pressed in uniaxial ture of a disc with a diameter of 300 mm
press body and even by enclosure of the hydraulic presses for subsequent pressure- and a thickness of approx. 30 mm.
whole press and running the process under less sintering. Sometimes, however, uniaxial
inert atmosphere. pressing is used also as a pre-densification 4.3 Sputtering targets
step for a hot pressing process to follow, in Sputtering targets are used in PVD coating
4 Applications order to make better use of the capacity of (PVD = physical vapor deposition) as a
The presses mentioned above are currently the hot press. source for the coating material, which
being used for the production of very differ- through the bombardment with high energy
ent types of technical ceramics. Some of 4.2 Carbon based products particles transfers into the gas phase and is
them are described here in order to high- Manufacturing of various carbon based then deposited in extremely thin layers on
light the possibilities which are offered now- products can also be a challenging task. Sev- different surfaces. By this method, coatings
adays by state-of-the-art uniaxial hydraulic eral presses of various types have been used with special optical, electrical or other char-
presses. to produce such different items like bipolar acteristics are being achieved for example
plates for low temperature (PEM) fuel cells on large plasma screens, displays of laptops,
4.1 Ceramic armour (Fig. 7) or large sized carbon blocks made mobile phones or architectural glass.
Ballistic protection plates for body protec- from carbon black and graphite as interme- For this application a wide range of different
tion as well as for vehicle protection is one diate products for carbon brushes etc. In presses have been supplied to various cus-
of the present top themes and steadily in- this case it is very important to guarantee a tomers (see Table 4). Materials to be used
creasing production capacities are planned very even density distribution throughout are indium tin oxide (ITO), alumina doped
and realized. Whilst vehicle protection the whole volume of the block, since the zinc oxide (AZO) and others. Again, the
plates and tiles of different formats and small final products must have identical uniaxial pressing is used either as the only
thicknesses are still mainly made of high properties regardless whether they are cut shaping method for a subsequent pressure-
alumina, the majority of the body protec- from the center or from the outer area of less sintering or as pre-densification for a
tion armour plates tends to be made of sili- such a block. HPF type presses are used for second compaction step in an isostatic press.
con carbide (SiC), due to the lower weight the production of these carbon blocks. The advantage there is reduction of scrap to
0210 APRI L VOL. 59 G5593
02
Interceram_LOGO.indd 1 20.07.10 09:21
high-performance ceramics
2010
Trade Fairs &
Conventions
POWTECH 2010, Germany
CERA GLASS 2010, India
QUALICER 2010, Spain
IPB 2009, China
Ceramics Forum
6 7 8
The Glass Industry in the
EU Today a Survey
High-Performance
Ceramics
Composition Modifications
on the Properties of Some Ceramic Bricks Filling
Bioactive Glasses and
Glass Ceramics Energy Saving
Titanium Nitride Coating
of Cobalt Chromium
Coronary Stents:
a SEM-EDS Analysis
Ceramic Based
Bio-Medical Implants
Preparation of Ca-_/`-
Sialon Powders by Micro-
wave Reaction Nitridation
Building Materials
Effect of Bi2O3 on Cordie-
rite Formation in Cordieri-
te Based Bodies
12.04.10 13:54
a minimum (especially ITO is a very expen- Fig. 7 PEM bipolar plate (as pressed) Fig. 8 Carbon filter (size approx. 100 x 100 mm)
sive material) and to increase the through-
put capacity of the isostatic press. 9 10