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Ceramic Industry3
Ceramic Industry3
INTRODUCTION
Introduction
• The traditional ceramic industries, have
as their finished materials a variety of
products that are essentially silicates.
• In recent years, new products have been
developed as a result of the materials
that withstand higher temperatures,
resist greater pressures, etc.
What are Ceramics?
• pots and other articles made from
clay hardened by heat.
• A ceramic is an inorganic non-metallic
solid made up of either metal or non-
metal compounds that have been
shaped and then hardened by
heating to high temperatures. In
general, they are hard, corrosion-
resistant and brittle.
What are Ceramics?
• Ceramic comes from the Greek word
meaning ‘pottery’. The clay-based
domestic wares, art objects and building
products are familiar to us all, but pottery
is just one part of the ceramic world.
• Nowadays the term ‘ceramic’ has a more
expansive meaning and includes materials
like glass, advanced ceramics and some
cement systems as well.
How about Pottery?
• pots, dishes, and other articles made
of earthenware or baked clay. Pottery
can be broadly divided into
earthenware, porcelain, and
stoneware.
• Pottery is generally considered to be
containers made from clay. "Pot" is a
term used for any number of container
forms.
Introduction
• In this particular discussion, we will
tackle about:
– Whitewares
– Structural Clay Products
– Refractories
– Specialized Ceramic Products
– Enamels and Enameled metal
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HISTORY
History
• Burnt clayware has been found
dating from about 15,000 BC
• Well developed in Egypt in 5, 000 BC
• Various ancient races were found to
have created clay products
independently of each other
History
• The advent of cross-fertilization of
silicate chemistry, metallurgy, solid-
state physics, computer-controlled
processes, and advanced automation
modernized methods of fabrication.
• It is now possible to produce
ceramics with superior qualities.
History
• Recently, new process have been
developed for brickmaking from
inorganic wastes (fly ash, foundry
sand, mine tailings, furnace slag,
etc.)
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HUMAN UTILIZATION
Human Utilization
• Building brick
• Sewer pipe
• Drain tile
• Filler in paper
• Filler in rubber
• Filler in plastics
• Filler in paint
• Filler in fertilizers
Human Utilization
• Fridge magnets
• Metals production
• Aerospace
• Electronics
• Automotive
• Personal protection
Human Utilization
• In modern medicine, advanced ceramics –
often referred to as bioceramics – play an
increasingly important role. Bioceramics
such as alumina and zirconia are hard,
chemically inert materials that can be
polished to a high finish. They are used as
dental implants and as bone substitutes in
orthopaedic operations such as hip and knee
replacement.
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CLASSIFICATION OF CERAMIC
PRODUCTS BASED ON
DEGREE OF VITRIFICATION
Classification of ceramic products
• Whitewares
• Heavy-clay products
• Refractories
• Enamels
• Glass
Whitewares
• Varying amounts of fluxes
• Heat at moderately high
temperatures
• Varying vitrification
Heavy-clay products
• Abundant fluxes
• Heat at low temperatures
• Little vitrification
Refractories
• Few fluxes
• Heat at high temperatures
• Little vitrification
Enamels
• Very abundant fluxes
• Heat at moderate temperatures
• Complete vitrification
Glass
• Moderate fluxes
• Heat at high temperatures
• Complete vitrification
Classification of ceramic products
WHITEWARES
Whitewares
• Whiteware is a generic term for
ceramic products which are usually
white and of fine texture
• Because of the different amounts and
kinds of fluxes, there is a
corresponding variation in the degree
of vitrification among whitewares.
Whitewares
• Earthenware – “semivitreous”
dinnerware. Porous and
nontranslucent with a soft glaze
• Chinaware – vitrified translucent
ware with a medium glaze which
resists abrasion to a degree. Used for
nontechnical purposes
Whitewares
• Porcelain – vitrified translucent ware with
a hard glaze which resists abrasion to the
maximum degree. Includes chemical,
insulating, and dental porcelain
• Sanitary ware – formerly made from clay,
usually porous. Prefired and sized
vitreous grog is sometimes included in
the triaxial composition
Whitewares
• Stoneware – one of the oldest
ceramic wares. Crude porcelain not so
carefully fabricated from raw material
of a poorer grade
• Whiteware tiles – generally classifid
as floor tiles. Resistant to abrasion
and impervious to stain penetration.
May be glazed or unglazed
Whitewares
• Stoneware – one of the oldest
ceramic wares. Crude porcelain not so
carefully fabricated from raw material
of a poorer grade
• Whiteware tiles – generally classifid
as floor tiles. Resistant to abrasion
and impervious to stain penetration.
May be glazed or unglazed
Glazing
• Important in whitewares and in
tableware
• A glaze is a thin coating of glass
melted onto the surface of more-
or-less porous ceramic ware
Glazing
• A glaze contains ingredients of
two distinct types in different
proportions:
– Refractory materials (feldspar,
silica, china clay)
– Fluxes (soda, potash, flourspar, and
borax)
Glazing
• “glost firing” – technical term for
the firing of the glaze
• Earthenware should be glazed
between 1050 – 1100 °C
• Stoneware – 1250 to 1300°C