CERAMIC SLIP CASTING

LABORATORY REPORT

Presented to
the Department of Materials and Resources Engineering and Technology Bachelor of Science
in Ceramic Engineering
MSU – Iligan Institute of Technology Iligan City

In Partial Fulfillment
of the Requirements for the Degree
BACHELOR OF SCIENCE IN CERAMIC ENGINEERING

GROUP MICRON:
MA. LOURDES ACTUB
FAHAD DATU-IMAM

January 2024
 ABSTRACT

Ceramic slip casting is a technique for producing complex and detailed ceramic shapes

from a liquid clay mixture, called slip. The slip is poured into a porous mold, usually made of

plaster, which absorbs the water from the slip and forms a solid layer of clay on the mold

surface. The excess slip is then drained or poured out, leaving a hollow clay body that

conforms to the shape of the mold.

The clay body is then removed from the mold and dried and fired to obtain the final

ceramic product. Ceramic slip casting is widely used in the ceramics industry for making

tableware, sanitary ware, art objects, and technical ceramics. It has the advantages of high

dimensional accuracy, uniform wall thickness, and low cost. However, it also has some

limitations, such as the need for high-quality slip, mold maintenance, and drying control.

Ceramic slip casting is a versatile and efficient method for creating ceramic parts with

various shapes, sizes, and properties.

 TABLE OF CONTENTS

TITLE PAGE………………………………………………………………………………....i

ABSTRACT………………………………………………………………………………….ii

LIST OF TABLES…………………………………………………………………………..iii

LIST OF FIGURES…………………………………………………………………………iv

CHAPTER 1: INTRODUCTION 1

1.1 Background of the Study…………………………………………………………..1

1.2 Objective of the Study …………………………………………………………….1

1.3 Significance of the Study……………………………………………………….....2

1.4 Scope and Limitations……………………………………………………………..2

CHAPTER 2: REVIEW OF RELATED LITERATURE 3

CHAPTER 3: METHODOLOGY 4

3.1 Pre-experimental Procedure……………………………………………………….4

3.2 Main Experiment………………………………………………………………….4

CHAPTER 4: RESULTS AND DISCUSSION 12

4.1 Specific Gravity………………………………………….……………………….12

4.2 Rheological Evaluation…………………………………………………………..12

4.3 Actual Torque………………………………………………….…………………13

4.1 Shear Stress………………………………………………………………………14

4.2 Casting Rate………………………………………………….…………………..16

4.3 Drying, Firing, Thickness Shrinkage …………………………...………….……16

CHAPTER 5: CONCLUSIONS AND RECOMMENDATION 17

5.1 Conclusion………………………………………………………………………..17

5.2 Recommendation…………………………………………………………………18

REFERENCES 18
 CHAPTER I

INTRODUCTION

1.1 Background of the Study

Ceramic slip casting is a technique for producing complex and detailed ceramic shapes

from a liquid clay mixture, called slip. The slip is poured into a porous mold, usually made of

plaster, which absorbs the water from the slip and forms a solid layer of clay on the mold

surface. The excess slip is then drained or poured out, leaving a hollow clay body that

conforms to the shape of the mold. The clay body is then removed from the mold and dried

and fired to obtain the final ceramic product.

Ceramic slip casting has a long history that can be traced back to ancient civilizations

such as the Egyptians, Greeks, Romans, and Chinese, who used the technique to create

pottery, figurines, and porcelain pieces with intricate designs. Ceramic slip casting is widely

used in the ceramics industry for making tableware, sanitary ware, art objects, and technical

ceramics. It has the advantages of high dimensional accuracy, uniform wall thickness, and

low cost. However, it also has some limitations, such as the need for high-quality slip, mold

maintenance, and drying control.

1.2 Objectives of the Study

The objectives of ceramic slip casting are to produce complex and detailed ceramic shapes

from a liquid clay mixture, called slip, by using porous molds that absorb the water from the

slip and form a solid layer of clay on the mold surface. The clay layer is then removed from

the mold and dried and fired to obtain the final ceramic product. Ceramic slip casting is a
versatile and efficient method for creating ceramic parts with various shapes, sizes, and

properties123. Some examples of ceramic products made by slip casting are tableware,

sanitary ware, art objects, and technical ceramics.

1.3 Significance of the Study

Ceramic slip casting is important because it is a technique that allows for the production of

complex and detailed ceramic shapes from a liquid clay mixture, called slip. It has many

advantages, such as high dimensional accuracy, uniform wall thickness, low cost, and

versatility. Ceramic slip casting can be used to make various ceramic products, such as

tableware, sanitary ware, art objects, and technical ceramics, that have different shapes, sizes,

and properties. This is also a historical and artistic method that has been used by many

ancient civilizations and modern artists to create pottery, figurines, and porcelain pieces with

intricate designs. Slip casting is a valuable and efficient method for creating ceramic parts

with high quality and functionality.

1.4 Limitations of the Study

Some of the limitations of ceramic slip casting are:

● Complexity of mold making: Slip casting requires the creation of intricate and precise

molds, which can be costly and time-consuming. The molds also need to be

maintained and replaced regularly, as they wear out or crack over time12

● Dependence on slip properties: Slip casting relies on the proper formulation and

preparation of the slip, which is the liquid clay suspension. The slip needs to have the

right viscosity, thixotropy, specific gravity, and deflocculation to achieve a uniform

and smooth cast. The slip properties can be affected by various factors, such as the

raw materials, water quality, ambient conditions, and mixing energy.

 ● Shrinkage and cracking: Slip casting involves the removal of water from the slip

through the porous mold, which causes the cast to shrink and detach from the mold.

However, excessive or uneven shrinkage can lead to cracking, warping, or

deformation of the cast. The shrinkage also continues during the drying and firing

stages, which can affect the dimensional accuracy and stability of the final product24

● Low mechanical strength: Slip casting produces ceramic products with low

mechanical strength, as the cast layer is relatively thin and porous. The cast products

are also fragile and prone to damage during handling and processing. Therefore, slip

casting is not suitable for producing high-performance or structural ceramics.

CHAPTER II

REVIEW OF RELATED LITERATURE

There are many studies on the literature of ceramic slip casting, covering different aspects

such as the rheology of the suspension, the mold design and fabrication, the drying and

sintering behavior, and the properties of the final product. Some of the recent reviews on

ceramic slip casting are:

Magnetic slip casting for dense and textured ceramics: a review of current achievements and

issues by Hortense Le Ferrand. This review focuses on the use of external magnetic fields to

align the ceramic grains along preferential crystallographic directions, creating controlled

texture and enhanced properties in the ceramic parts.

Designing advanced ceramics: A review on tape casting of preceramic polymers by J.

Gurauskis et al. This review discusses the wet processing of preceramic polymers, which are
polymers that can be converted into ceramics by pyrolysis. Tape casting is a technique to

produce thin and flexible sheets of preceramic polymers, which can be further shaped and

processed into complex ceramic structures.

Slip casting of silicon carbide by S. Blackburn et al. This review summarizes the research on

slip casting of silicon carbide, a ceramic material with high hardness, thermal conductivity,

and chemical resistance. The review covers the aspects of slip preparation, mold materials,

drying and sintering conditions, and the properties of the slip cast silicon carbide parts.

CHAPTER III

METHODOLOGY

3.1 The Pre-experimental Procedure (Discuss how the starting materials are procured and

prepared)

3.2 Main Experiment ((Discuss the experiment proper, and draw the experimental set-up if

possible.)

I. Clay Slip Preparation

● Prepare at least 1 tub plastic container (60 litres) and 30 kgs of ground clay.
 ● Soaked the ground clay with 40% water for 24 hrs.

● After soaking, using electric mixer, blunge the clay until a good flowing suspension is

achieve.

● If a low viscosity slip is obtained, add 0.0020% of sodium silicate as your

deflocculant based on the solid loading and mixed it together with the loaded water.

● Then slaked the clay slip using a 80 mesh screen (177 microns) or 100 mesh screen

(149 microns).

II. Formulated Slip Preparation

● Prepare the raw materials to be used and screen passing through 200 mesh sieve

screen for Silica and Feldspar and 100 mesh for clay.

● Then prepare the ternary ceramic composition based on the formulation assign to each

group.

● Using brogniarts equation (see the example below) :

 Mass (g) Volume (mL) SG
Clay x x/1.75 2.6
Water 1000-x 1000/1.75 - x/2.6 0.333
Clay Slip 1000 1000/1.75 1.75

Solution:

● Compute the water content of the slip and adjust such that the suspension will

compose of 60% solids and 40% water.

● Compute the amount of silica and feldspar needed for the body formulation of a total

batch weight of about 3 kgs.

● Add 0.0020% of sodium silicate as your deflocculant based on the solid loading and

mixed it together with the loaded water.

● Using a blunger premixed initially the liquid solution and then gradually add the

preweighed ternary powder to the suspension.

● Continuously stir the ternary ceramic suspension until all the solids are completely

suspended and dispersed well with the liquid solution and then observe right after the

fluidity of the slurry.

III. Measurement of Casting Slip Properties

Specific Gravity

● After mixing the ternary ceramic suspension, determine the specific gravity of the

slurry using a small cylindrical container. Make sure that, the container is dry, clean

and free from adhering foreign objects.

● First, determine the weight of the cylindrical container.

● Then fill the container with water, then weigh and record it. This will be your weight

water + weight container.

● Remove the water from the container and dry if after.

● Then pour sample slip into the cylindrical container until it reaches the brim and get

the weight of the filled container and record it.

● Calculate the specific gravity of the slurry by using the following formula:

Rheological Evaluation of the Ceramic Slip

● After determining the specific gravity, gather sample slip in a 600 ml beaker and

determine its viscosity of the slurry using the Brookfield Viscometer.

● Measure the viscosity using spindle no. 4 at varying spindle speeds of 10, 20, 30, 50,

60 & 100 RPM.

● Initially, determine the thickness and radius of the spindle disc and record it.

● Then set-up the sample slip in the viscometer with spindle. Take note that the level of

the slip to be examined should be higher than the level line as marked on the spindle

and the level bubble of the viscometer should also be at the center.

● Begin measuring the viscosity at the lowest spindle speed and record the % Torque

and Viscosity {cP (centipoise) = 1 mPa-s} as shown on the digital screen of the
 viscometer after 3 mins (10 rpm), followed by 2 mins each at 20, 30, 50, 60 & 100

rpm.

● Then calculate the actual torque of the slip given only the % torque of the data

gathered and using the actual torque, the shear stress with the measured dimensions of

the spindle used can be calculated using the equations shown below.

Where L : thickness of the spindle

R : radius of the spindle

● Then compute the shear rate of the casting slip in 1/ sec unit.

● Plot your data in shear rate vs. apparent viscosity.

Ageing of Ceramic Slip

● Investigate the ageing property of the slurry with respect to its viscosity at certain

period of time.

● Time of ageing is measured after 1st, 3rd and 5th day age slip.

Casting rate

● Prepare the 3 piece plaster mold with cylindrical model.

● Make sure that the mold is fully dried and securely attached the pieces together by

using two rubber bands to prevent leakage of slip.

● Agitate first, the casting slip for about 1 minute using the blunger in order to break the

agglomerates formed during standby.

 ● Pour a prescribed weight of freshly stirred slip on the mold and properly cover the

mold to make sure that there will be no direct evaporation from the slip surface.

● After a few minutes, turned upside down the mold and drain back the excess slurry

into the bucket and stay for at least 5 minutes to allow the slip to flow into the bucket

for re-use.

● Vary the casting time of 30 minutes, 1 hour and 1.5 hours.

● Then place back the mold in its normal position and let the cast layer stand for a few

minutes.

● Safely remove the cast layer as soon as the loss of sheen is observed and it is strong

enough for it to be removed from the mold without any damage.

● Cut the cast layer in half and measure the thickness of its center at each time

increment using a Vernier caliper.

● Plot your data in each time increment vs. thickness of the cast layer.

Physical Characterization

● Air dry the cast layer cut in half for 3-5 days and then oven dry at 110°C for four

hours.

● Measure the initial and final wall thickness of the dried samples, this will determine

linear shrinkage of the cast samples. Use the equation below :

where :

%S - the percent thickness shrinkage of the dry sample

T1 - the initial thickness of the green body

T2 - the final thickness of the fired samples.

 ● Conduct water absorption test on each of the cast layer samples.

● Determine the apparent porosity of the samples by using the Archimedes

displacement method according to the equation.

Where: I – the weight of the immersed sample after boiling

F – the weight of the fired sample before immersion

S – suspended weight of the sample while it was submerged in water.

IV. Ceramic Drain Casting

● Using a drilled mixer or blunger agitate first the casting slip for about 1

minute.

● Then pour ceramic slip into your desired mold slowly and evenly. Fill mold

slightly above the pouring hole to form a sprue.

● Let the ceramic slip sit until desired thickness is reached (about 3-5 mm). If

your doing several castings, monitor the thickness as a function of time.

● Pour the excess slip out of the mold back into the pouring container. Leave the

mold inverted to drain.

● Turn the mold over, and let it sit for at least 1 hour or until firm.
● Carefully remove the casting from the mold by removing the rubber bands and

lifting it out. Try not to twist or deform the casting as this may cause it to warp

as it dries. (Make note of any pieces that get deformed, so you can observe if

they dry or fire differently.)

● Put the mold away where it can dry out and stay clean. [Do not dry or store

plaster molds to temperatures above 57°C.]

● Using an X-acto knife or a cutter, remove the sprue. Be careful not to damage

the ware.

● Let the cast body set for a few hours before continuing.

● After the cast body is hard and dry to the touch it is still very fragile, but can

be handled.
 ● Using an X-acto knife or a cutter and a damp (NOT WET) sponge, fettle the

cast body. Fettling is trimming off any excess clay and removing the “seam”

marks made by the mold. Pay special attention to the rim and bottom. Rub any

chips down with the sponge. Generally, “patching” does not work, so be

careful. (Put your initials and date on the bottom of the cast body).

● Allow the cast body to dry at room temperature for 3-5 days.

CHAPTER IV

RESULTS AND DISCUSSION

4.1 Specific Gravity

By applying the formula, an SG of 1.75 was attained, falling within the range of values that

suggest a satisfactory slip for a ceramic suspension.

4.2 Rheological Evaluation

Table 4.2 Measured Viscosity of the Ceramic Suspension in Different Aging Time measured

in cP (centipoise) by viscometer.
 VISCOSITY (cP = 1mPa-s)

RPM 1st day 3rd day 5th day

10 24595 12450 13390

20 9679 6840 7520

30 5986 2789 3990

50 5572 2684 4332

60 4811 1457 2591

100 3678 1372 1420

As we can see in Table 4.2 RPM 10 shows the highest viscosity which is 24595 cP during the

first day of aging. The viscosity during the 5th day of RPM 100 has the lowest value which is

1420 cP. Therefore, the pattern of declining viscosity following each RPM results from the

agitation causing some thickening to form and because it depends on time, the second and

subsequent readings will produce a reading of viscosity that is lower than the first one.

4.3 Actual Torque

Table 4.3 Measured Actual Torque of the Ceramic Suspension in each day measured in

dyne-cm.

ACTUAL TORQUE (dyne-cm)

RPM 1st day 3rd day 5th day

10 945.7 785.79 899.4

20 998.3 873.98 943.3

30 1197.2 1064.7 1100.5

50 1114.4 1005.6 1104.4

60 3935.2 2565.8 2920.1

100 1548.64 1084.4 1344.6

The measured real torque of the ceramic suspension at various age times is shown in the

table. Torque has been observed to decrease with time and to increase with spindle speed

(RPM).

4.4 Shear Stress

Table 4.4 Shear Stress, τ, of the Ceramic Suspension in Different Aging Time measured in

dyne/cm2.

Shear Stress (dyne/cm^2)

RPM 1st day 3rd day 5th day
10 42.89434632 35.64126932 40.79430589
20 45.28013739 39.64132473 42.78548893
30 54.30169336 48.29185844 49.9156478
50 50.5461135 45.61124528 50.09254105
60 178.4898294 116.3776185 132.4476903
100 70.24204344 49.18539616 60.98735123

Spindle speed (RPM) increases shear stress. and gets smaller over time. When shear is

applied to the slurry, the viscosity decreases. Table 4.4 illustrates this tendency, showing that

applied shear causes the viscosity to drop.

By measuring the viscosity and shear stress on the 1st day of aging we have observed that

when viscosity decreases as its RPM value increases, the shear stress increases.
By measuring the viscosity and shear stress on the 3rd day of aging we have observed that

when viscosity decreases as its RPM value increases, the shear stress increases.

By measuring the viscosity and shear stress on the 5th day of aging we have observed that

when viscosity decreases as its RPM value increases, the shear stress increases. As what the

behavior of the viscosity and shear stress have shown we have interpreted that based on this

formulation and certain conditions the viscosity and shear stress rate is inversely

proportional.
4.5 Casting Rate

The graph illustrates the time in relation to the cast layer's thickness, suggesting that as

casting time grows, so does the cast layer's thickness. When casting time increases the

contact between the slip and the support surface, capillary action causes a thick cake layer to

form on the support surface. Thus, it is observed that body thickness depends on time.

4.6 Drying, Firing, Thickness Shrinkage and Apparent Porosity

Table 4.6 Data Gathered for the determination of % Drying and % Firing Shrinkage.

% Shrinkage
Mold Length %Drying %Firing
Cast Body (cm) Dry Length (cm) Fired Length (cm) Shrinkage Shrinkage
1 19.55 19.05 17.5 2.557544757 8.13648294
2 19.05 18.79 18.02 1.364829396 4.097924428

Avg 1.961187077 6.117203684

As we can see in the results each cast body has different drying and Firing shrinkages as they

have different lengths. The average drying shrinkage percentage is 1.96% and average firing

shrinkage is 6.12% based on the table. It is observed that the rate of firing shrinkage is higher

than drying shrinkage.

Thickness Shrinkage
T1 (mm) T2 (mm) %S
5.3 4.3 18.86792453
5.1 4.1 19.60784314
Avg 12.82525589

We have calculated the Thickness Shrinkage from the data that we have gathered after our

measurements during processes. The average thickness of Thickness is 12. 83% as shown in

the graph.

CHAPTER V

CONCLUSION AND RECOMMENDATION

This study used the ceramic slip casting technique and looked into the different slip casting

characteristics and properties. After the processes and results we have concluded that:

● The rheological properties of ceramics are significantly impacted by their age.

● Time-dependent thixotropy is significantly impacted by mechanical alterations.

● Viscosity diminishes with time and agitation.

● Casting time affects slip thickness; the longer the casting time, the cast body will be

thicker.

● Between 1.7 and 1.8 specific gravities yield a decent slip.

● Developing the slip's particular gravity requires trial and error.

Recommendations

● Use the same type of clay for your slip and make sure it is compatible with your firing

temperature.

● Measure the specific gravity of your slip to ensure it has the right clay to water ratio.

A good value is around 1.7-1.8.

REFERENCES

Garrofé, A., Picca, M., & Kaplan, A. (2022, April 29).

https://actaodontologicalat.com/wp-content/uploads/2022/05/aol_2022_35-1-03.pdf. Acta

Odontológica Latinoamericana, 35(1), 10–15. https://doi.org/10.54589/aol.35/1/10

Bento, B. (2023, November 9). The famous method of Slip Casting. Sporvil | Lighting | Vases

| Manufacturer | Wholesaler. https://www.sporvil.com/blog/slip-casting-of-ceramics/

D’Souza, S. (2019, October 17). How to Slip Cast Ceramics. The Spruce Crafts.

https://www.thesprucecrafts.com/how-to-slipcast-ceramics-4154220

https://inass.org/wp-content/uploads/2022/05/2022083131-2.pdf. (2022, August 31).

International Journal of Intelligent Engineering and Systems, 15(4).

https://doi.org/10.22266/ijies2022.0831.31