CH 203 CPI

Lec 5.1 Ceramics and Glass

manufacturing

M. Ansar Khan
NEDUET
 Introduction To “Ceramics”

 The word CERAMIC is derived from the Greek word

(Keramikos).

 The term means the non-metallic material which is

processed by the action of heat like pottery, bricks,
tiles along with cements and glass.

 Ceramics are wide-ranging group of materials whose

ingredients are clays, sand and feldspar.
 Sand (SiO2)
 Sand is a naturally occurring granular
material composed of finely divided
rock and mineral particles.

 The most common constituent of sand

is Silicon dioxide (SiO2), usually in
the form of quartz.
 FELDSPAR
(KAlSi3O8 – NaAlSi3O8 – CaAl2Si2O8)
► They are a group of rock-forming minerals which make up as much
as 60% of the Earth's crust.

► They are formed by Magma.

► Feldspars are also found in many types of sedimentary rock.

► Feldspars are of three types;

1. Potash feldspar - KAlSi3O8

2. Albite (Sodium feldspar) - NaAlSi3O8

3. Anorthite (Calcium feldspar) - CaAl2Si2O8

 Clays
Contain some of the
following ingredients:
 Silicon & Aluminium as
silicates
 Potassium compounds
 Magnesium compounds
 Calcium compounds

Sand contains Silica and

Feldspar or Aluminium
Potassium Silicate.
 Properties of RAW MATERIALS

Raw Plasticity Fusibility Shrinkage

Melting on burning
Materials point
Clay (usually Plastic Refractory 1785 ‘C Much
Kaolinite) shrinkage
Feldspar Non-plastic Easily fusible 1150 ‘C Fuses

Sand Non-plastic Refractory 1710 ‘C No

shrinkage
 General Procedure of
Processing
 Raw
Materials
 Mixing

 Calcination
 Characterization
 Milling
 Poling
 Sintering

 Binder
Burnout
1. raw materials
 Weighing the
raw materials
according to the
stoichiometric
formula of the
ceramic desired
.
2. Mixing
 Mixing the  Mechanical mixing is
usually done by either
powders either; ball milling or attrition
milling for a short
Mechanically time.
 Chemical mixing on
or the other hand is more
homogeneous as
chemically it is done by
precipitating the
precursors in the same
container.
 3.Calcination
The solid phase
reaction takes
place between
the constituents
giving the
molten phase
during the
calcination step.
4. Milling
 The lumps
are ground
by Milling
after
Calcining.
 5. binder burnout
 After shaping,
the green bodies
are heated very
slowly to
between 500-
600°C in order to
remove any
binder present.
 6.Sintering
 After the binder
burnout is over,
the samples are
taken to a higher
temperature for
sintering to take
place.

7.Poling
it does not show any
piezoelectricity when the
ceramic is cooled after
sintering . Piezoelectric
behavior can be induced
in a ferroelectric ceramic
by a process called
"poling" .
 In this process a direct
current (dc) electric field
with a strength larger than
the coercive field strength
is applied to the ceramic
at a high temperature, but
below the Curie point.
 8.Characterization
 On the application
of the external dc
field the
spontaneous
polarization within
each grain gets
orientated towards
the direction of the
applied field. This
leads to a net
polarization in the
poling direction
 TYPES OF CERAMICS

AMORPHOUS CRYSTALLINE

WHITE-WARES GLASSES ABRASIVES CEMENTS

REFRACTORIES
AMORPHOUS CERAMICS

 White-wares

 Refractories

 Glasses
 White-wares
 Crockery
 Floor and wall tiles
 Sanitary-ware
 Electrical porcelain
 Decorative ceramics
 Refractories
 Firebricks for furnaces
and ovens. Have high
Silicon or Aluminium oxide
content.
Brick products are used in
the manufacturing plant
for iron and steel, non-
ferrous metals, glass,
cements, ceramics,
energy conversion,
petroleum, and chemical
industries.
Glasses
 Main ingredient is Silica (SiO2)
 If cooled very slowly will form
crystalline structure.
 If cooled more quickly will form
amorphous structure consisting
of disordered and linked chains
of Silicon and Oxygen atoms.
 This accounts for its
transparency as it is the crystal
boundaries that scatter the
light, causing reflection.
 Glass can be tempered to
increase its toughness and
resistance to cracking.
Glass Types
Three common types of glass:
 Soda-lime glass - 95% of all
glass, windows containers
etc.
 Lead glass - contains lead
oxide to improve refractive
index
 Borosilicate - contains Boron
oxide, known as Pyrex.
Glass Containers
Crystalline Ceramics

 Abrasives.

 Cements.
 Abrasives
 Natural Abrasives:
(garnet, diamond,
etc.)

 Synthetic
abrasives: (silicon
carbide, diamond,
fused alumina, etc.)
are used for grinding,
cutting, polishing,
lapping, or pressure
blasting of materials
 Cements
 Used to produce concrete roads, bridges,
buildings, dams.
 Advanced Ceramics

 Advanced ceramic materials have been developed over the past half
century

 Applied as thermal barrier coatings to protect metal structures,

wearing surfaces, or as integral components by themselves.
 Engine applications are very common for this class of material which
includes silicon nitride (Si3N4), silicon carbide (SiC), Zirconia (ZrO2)
and Alumina (Al2O3)
 Heat resistance and other desirable properties have lead to the
development of methods to toughen the material by reinforcement with
fibers and whiskers opening up more applications for ceramics
Advanced Ceramics

 Structural: Wear parts,

bioceramics, cutting tools,
engine components, armour.
 Electrical: Capacitors,
insulators, integrated circuit
packages, piezoelectrics,
magnets and superconductors
 Coatings: Engine
components, cutting tools, and
industrial wear parts
 Chemical and environmental:
Filters, membranes, catalysts,
and catalyst supports
 National
perspective Of
Ceramics
 Ceramics manufacturing
sector plays a significant
role in the economy
of Pakistan.
 The sector employs over
36,000 people and
contributes 0.1% to total
GDP of the country.
 Its contribution to
the exports of the country
is about $ 12.30 Million
per annum.
 Ceramic Industries In Pakistan
COMPANY PRODUCTS

EMCO Industries Wall, Floor-tiles & Insulators

Sanitary-wares, Tiles &
Frontier Ceramics
Wall-tiles
Karam Ceramics Wall-tiles & Sanitary-wares
Master Tiles Wall-Tiles & Sanitary Fittings
Shabbir Tiles Wall-Tiles
National Tiles Floor & Face Tiles
Swat Ceramics Wall-Tiles & Sanitary-wares
Marshal Tiles Wall-Facing & Flooring-Tiles
 CONCLUSION:-

Ceramics plays a vital role in daily life. Almost

all the buildings, architectures, house-wares,
automobiles parts etc. are the derivatives of
ceramics. But due to economic crisis, Pakistan
is suffering a lot in this major field. It is the
duty of the economists, engineers and other
authorities to enrich the productivity of the
ceramics, so that national growth of various
departments should be withstand.