Shaping of Ceramics

Dr. P Sudhakar Rao

psrao.iitr@gmail.com
9417090292
Shaping of Ceramics
 Ceramics

 What is Ceramics ?

A Ceramic material is an inorganic

compound consisting of a metal
and one or more nonmetals.
Examples are Silica, Alumina,
Zirconia.
Ceramics Applications

 Clay Construction Products, such as bricks,

clay pipe, tiles.
 Refractory Ceramics, like furnace walls,
crucibles.
 Cement used in construction.
 White-ware Products, including pottery,
stoneware, fine china, porcelain.
 Glass- Bottles, Window panes and light
bulbs.
Applications Continued.

 Glass fibers for insulating, FRP, Fiber

optics.
 Abrasives like alumina, silicon carbide.
 Cutting tools.
 Ceramic insulators in electric transmission,
spark plugs.
 Magnetic ceramics.
 Nuclear Fuels based on Uranium Oxide.
 Bio-Ceramics like artificial teeth & bones.
Examples of Ceramics
Applications
Characteristics
 High Strength at elevated temperatures.
 Low Electrical & Thermal Conductivities.

 Chemical Inertness.

 High Hardness.

 Extremely Brittle.

 Bio-compatibility.

 Physical Stability.
Classification of Ceramics
 Traditional Ceramics.
Examples : pottery, porcelain, white-
ware, bricks, tiles etc.
 New Ceramics (also known as engg.
or industrial )
Examples : cutting tools, artificial
bones, bio-ceramics, turbine,
automotive components etc.
 Glasses.
Steps in Making Ceramic
Products
Processing of Traditional
Ceramics
 Preparationof Raw Material.
 Shaping Process.

 Drying.

 Firing.
Preparation of Raw Materials
Shaping
Drying
Firing
Preparation of Raw Materials

 Crushing:
Refers to the reduction of large
lumps from the mines to smaller
sizes for subsequent reductions.

1.Jaw crushers
2.Roll crushers
3.Hammer mills
4.Gyratory crushers
Crushing

Jaw Crusher
Crushing

Roll Crusher
Crushing

Hammer Mill
Crushing

Gyratory Crusher
Grinding:
Refers to The Operation of
reducing the small pieces after
crushing to a fine powder.
1.Ball mill
2.Roller mill
3.Impact grinding
Grinding

Ball Mill
Grinding

Roller Mill
 Grinding

Impact Grinding
 Paste preparation:
Ingredients of ceramic paste are
1.Clay,which provides the consistency
and plasticity.
2. Non plastic raw material which do not
shrink in drying and firing.
3. Fluxes that melt during firing and
promotes sintering.
Shaping Processes

 Slip casting
 Plastic forming

 Wet pressing

 Dry pressing
 Shaping Processes

Four Categories of shaping processes compared to water content & pressure required
Slip Casting

Fig . Sequence of steps

In Drain casting-
(a) slip is poured into
mould cavity.
(b) Water is absorbed into
plaster mould to form a
firm layer.
(c) excess slip is poured
out.
(d) part is removed.
Slip Casting
Plastic Forming
 Manual method
Hand modeling
Potter’s wheel

 Mechanized methods
Jiggering
Plastic pressing
Extrusion
Jiggering
 Plastic Pressing
 It is a forming process in which a
plastic clay slug is pressed between
upper and lower moulds ,contained in
metal rings. Moulds are made of
porous material such as gypsum to
remove moisture from clay. The
mould section are then opened using
positive air pressure to prevent
sticking of the part.
Extrusion

It is used to
produce long
sections ,which
are then cut to
required piece
length.
Wet Pressing
Dry Pressing

 It is similar to wet pressing but the

moisture content is below 5 %.Binders
are usually added to the dry powder
mix to provide sufficient strength. The
dies must be made of hardened tool
steel or tungsten carbide to reduce
wear.
Drying

 Shrinkage is a problem during drying

as water contributes to the piece, and
when it is removed, the volume is
decreased. As water is initially added
to dry clay it replaces the air in the
pores. Increasing the water content
above a certain point causes the
grains to become separated , and the
volume to grow.
Drying

Volume of clay as a function of water content

Drying

Typical Drying rate curve & associated volume reduction.

Shrinkage
Firing

 It is a heat treatment process that

sinters the ceramic material.
Processing of New Ceramics

 Preparation of starting material

 Shaping

 Sintering

 Finishing
Preparation of Starting
Materials
 Freeze drying.
 Precipitation from solution.
Additives

 Plasticizers : improve plasticity and

workability.
 Binders.

 Wetting agents.

 Deflocculants: help to prevent

clumping and premature bonding.
 Lubricants.
Shaping Processes

 Hot pressing
 Iso-static pressing

 Doctor-blade process

 Powder injection molding

Hot Pressing

 It is similar to dry pressing except

that the process is carried out at
elevated temperatures
 Iso-static Pressing

Cold Iso-static Pressing Hot Iso-static Pressing

Doctor Blade Process
Ceramic Injection Molding

 Similar as MIM, except that the

powder is ceramic. Ceramic particles
are mixed with a thermoplastic
polymer; heated & injected into a mold
cavity. Upon cooling, mold is opened
& part ejected.
 Summary of Shaping Processes
TABLE 17.7
Process Advantages Limitations
Slip casting Large parts, complex shapes; low Low production rate; limited dimensional
equipment cost. accuracy.
Extrusion Hollow shapes and small diameters; Parts have constant cross section; limited
high production rate. thickness.
Dry pressing Close tolerances; high production rate Density variation in parts with high length-to-
with automation. diameter ratios; dies require high abrasive-wear
resistance; equipment can be costly.
Wet pressing Complex shapes; high production rate. Part size limited; limited dimensional accuracy;
tooling costs can be high.
Hot pressing Strong, high-density parts. Protective atmospheres required; die life can be
short.
Isostatic pressing Uniform density distribution. Equipment can be costly.
Jiggering High production rate with automation; Limited to axisymmetric parts; limited
low tooling cost. dimensional accuracy.
Injection molding Complex shapes; high production rate. Tooling can be costly.
Sintering

 To bond individual grains into a solid

mass.
 To increase density.

 To reduce or eliminate porosity.

 Finishing

 To increase dimensional
homogeneity.
 To improve surface finish.
 To make minor changes in
part geometry.
 Design Considerations

 Product should be designed for compression.

 Products should not be used in impact
loading or high stresses.
 Simple geometries for economy.

 Radii & chamfers should be provided.

 Shrinkage in drying, firing, sintering must be

considered.
 Screw threads should be avoided.