EFFECT OF SINTERING METHOD ON PHYSICAL PROPERTIES OF CERAMICS

AIM:
To study the influence of sintering technique on the physical properties of
ceramics.
MATERIALS REQUIRED:
 Ball clay
 Silica sand
 Water

APPARATUS REQUIRED:
 Extruder
 Tray
 Knife or thread
 Weighing balance
 Tile
 Electric Muffle Furnace
 Microwave Furnace

THEORY:

Sintering of ceramics: Sintering (Firing) of ceramic materials is the method involving

consolidation of ceramic powder particles by heating the “green” compact part to a high
temperature below the melting point, when the material of the separate particles diffuse
to the neighboring powder particles.

TYPES OF SINTERING:

Solid state sintering-Only solid phases are present at the sintering temperature.

Liquid phase sintering-Small amounts of liquid phase are present during sintering.

Reactive sintering-Particles react with each other to form New product phases.
 STAGES OF SOLID STATE SINTERING:

Initial Sintering:
Contact area increases by neck growth. Three to five percent linear shrinkage
occurs. The relative density increases to 65 %.
Intermediate Sintering:
Pores almost reached equilibrium shape and continuous, usually idealized in
terms of spaghetti like array.,(i.e) pore sitting along the grain edges. Densification
achieved by pore shrinkage. Pores become unstable leaving isolated pores. Density –
1.9 of the theoretical value.
Final sintering:
Grain growth takes place, the pores breakup and form closed spherical bubbles.
Pore pinch of and become isolated at the corners. Pores assumed to shrink
continuously .Some pores may disappear. Grain growth takes place
SINTERING TECHNIQUES:
1. Pressureless sintering / Conventional sintering
2. Microwave sintering
3. Pressure assisted sintering
4. Activated sintering
PROCEDURE:
 Prepare two batches with following
compositions: BATCH 1: 90% ball clay,
10% silica sand BATCH 2: 80 % ball clay,
20% silica sand
 Weigh the raw materials appropriately and mix with water in a tray to get plastic
mass.
  Lubricate the extruder barrel and die, and load the barrel with plastic mass.
 Ensure that the mass is homogeneous by forcing the plastic mass through the
die and refill it in the barrel again.
 Measure the diameter of the die and cut the extruded sample with the length
twice that of the diameter to minimize warpage.
 Air dry the sample overnight and then dry it in oven at 110˚C for 2hrs.
 Sinter the samples under following conditions:
CONVENTIONAL SINTERING: 1200˚C,3hrs soaking
MICROWAVE SINTERING : 1000˚C,5 mins soaking
 Cool the samples and then tested it for Density, Porosity and Water absorption.

FORMULAE:
1. GBD (g/cc) = mass / volume
2. BD (g/cc) = (Dry weight) / (Saturated weight - Suspended weight)
3. AP (%) = { (Saturated wt - Dry wt) / (Saturated wt - Suspended wt)} x 100
4. WA (%) = { (Saturated wt - Dry wt) / (Dry wt)} x 100

TABULATION:

Property Conventional Microwave

Sintering Sintering
GBD (g/cc)
BD (g/cc)
AP (%)
WA(%)

RESULT:
1. The samples sintered using conventional sintering has
a Bulk density = g/cc
Apparent porosity = %
Water absorption = %
 2. The samples sintered using microwave
sintering has a Bulk density =
g/cc
Apparent porosity = %
Water absorption = %

INFERENCE:

QUESTIONS:

1. Write 4 differences between microwave sintering and conventional sintering.

2. Sketch and briefly explain the heating schedule in conventional sintering.
3. Among all the electromagnetic waves why is microwaves chosen for
sintering ceramic samples.
4. List some of the furnace heating elements used in conventional sintering
with use temperature and atmosphere.
5. Write short notes on interaction of microwaves with various materials.