Glass & Ceramics

Forming
Under Supervision of Dr/Soher Samy
 01 02
Introduction
Glass
techniques
• Defentions • Blowing
• Pressing
TABLE OF •
•
Float Glass
Drawing
CONTENTS 03 04
Ceramics Add Itional
techniques Processes
• Casting • Heat Treatment
• Pressing • Hardening Processes
• Extrusion
• Tape Casting
 01
Introduction
Glass:
• A hard, amorphous (non crystalline) solid
material made by melting sand, lime, and varying
amounts of calcium oxide and silicon dioxide, at
very high temperatures.

• Typically, brittle and optically transparent.

• It has no sharp melting point and definite

structural formula.
Ceramics:
 Ceramics are generally made by
taking mixtures of clay, earthen
elements, powders, and water and
shaping them into desired forms.

 Once the ceramic has been shaped, it

is fired in a high temperature oven to
make them hardened and heat
resistant.
 02
Glass techniques
 Blowing
• Glassblowing is a glass forming technique that involves inflating molten
glass into a bubble with the aid of a blow tube
• A person who blows glass is called a glassblower or glassmith.
• A lampworker (often also called a glassblower or glassworker) manipulates
glass with the use of a torch on a smaller scale, such as in producing
precision laboratory glassware out of borosilicate glass.
 Glass Blowing Process
Steps:
1. From a raw lump of glass, a parison (temporary shape) is formed by mechanical
pressing in a mold.
2. This piece is inserted into a finishing or blow mold and forced to conform to the mold
contours by the pressure created from a blast of air.
Video
 Glass Pressing:
 Pressing process is the most common process that is applied to molten glasses
to obtain products such as glass ware, drinking glasses and automobile
headlights.
 Pressing glass makes it possible to mass-produce intricate glass products with
detailing on the inside, as well as the outside, of the shapes. It is best suitable for
items with thick edges
 Glass Pressing Process
1- The glass drop is deposited in a mold which shapes the outer form of the product.
2- A central plunger stamps out its inner volume.
3- The item is then cooled in air.
4- The item is removed from the mold.
5- The item is burnt to get rid of small defects and make the glass smooth and shiny.
 Float Glass Process
The float glass process involves floating a glass ribbon on a bath of molten tin and creates
a smooth surface naturally.

Floating is possible because the density of a typical soda-lime-silica glass (~2.3 g/cm3) is
much less than that of tin (~6.5 g/cm3) at the process temperature.

After cooling and annealing, glass sheets with uniform thicknesses in the ~1–25 mm range
and flat surfaces are produced.

The float glass process is used to produce virtually all window glass as well as mirrors and
other items that originate from flat glass.
 Float Glass Process
Steps:
1. The first stage is the loading of raw material
2. Melting: in melting furnace at a temperature of 1500°C or higher where it flows as
molten glass.
3. Tin Bath: The molten glass at 1050°C flows gently over a refractory and is spread
evenly over the surface of this bath, floating on the molten tin.
4. Molten glass leaves the float bath as a solid ribbon at 600°C.
5. Annealing: annealing process in produced and the glass leaves with 25°C.
6. The glass is ready to be cut and shipped.
Video
 Glass Drawing
• Glass drawing process involved drawing the molten glass upwards or
downwards of a bath and allowing it to cool as it is lifted into the air.

• This would ensure a transparent but distorted sheet of glass.

  Flat drawing Process:
• This was done using a straight metal bait which would be lowered into a bath of
molten glass, which would then draw a continuous sheet of glass.
• To create large sheets of glass a tower was built to allow the metal bait to continue
rising uninterrupted.
• The glass was gradually cooled and hardened as it rose through the tower.
Video
  Down drawing Process:

• The down-draw process was developed as an

advanced technique for producing thin and ultra-thin
glasses with exceptionally tight tolerances.

• This state-of-the-art method involves a ribbon of

molten glass being fed through a nozzle, then pulled
down through rollers and an annealing furnace, before
moving across several drums and through a cooling
track.

• The thickness of the glass can be controlled by the

speed of the process.
Video
 03
Ceramics techniques
 Slip casting
• A method of forming ceramics where a
deflocculated (low water content) slurry is
poured into absorbent plaster molds,
forming a layer against mold walls, then
poured out.
• A suspension of ceramic powders in water,
called a slip, is poured into a porous plaster
of plaster mold, so that water from the mix
is absorbed into the plaster to form a firm
layer of clay at the mold surface .
• The slip composition is 25% to 40% water.
 Slip casting process
Steps:
1. slip is poured into mold cavity.
2. water is absorbed into plaster mold to form a firm layer.
3. excess slip is poured out.
4. part is removed from mold and trimmed.
 CASTING types
 SOLID CASTING:
Like drain casting but Instead of draining the slip the slip is retained in the mold until a
solid casting is achieved.

 VACUUM CASTING: Vacuum casting can be conducted with drain or solid

casting.
• A vacuum is pulled around the outside of the mold. The mold can consist of a
rigid permeable form or of a thin permeable membrane.
 Hydro -plastic Forming (Extrusion)
• Hydro-plastic forming - Processes where a moist ceramic clay body is
formed into a useful shape by extrusion.
 Hydro -plastic Forming process
Steps:

1. high-quality raw materials are blended to create a homogenous mixture.

2. Extrusion process: liquid is added to the raw material mixture and poured into a
conical hopper.

3. The mixture is then transformed into a paste-like substance.

4. The substance is then fed into a screw extruder and through a honeycomb die,
which creates thousands of tiny parallel channels.

5. Materials, sizes, and shapes will vary according to engine and vehicle
manufacturer specifications. However, each finished piece is cut to a specific
length, meeting all manufacturer requirements
 Powder Pressing
1- Uniaxial compression
compacted in single direction.

2- Isostatic (hydrostatic) compression

pressure applied by fluid - powder in rubber envelope.

3- Hot pressing

pressure and heat is applied.

 Pressing processes
Dry Pressing:

- Simultaneous uniaxial compaction and shaping of power along with binder.

- Wide variety of shapes can be formed rapidly and accurately.
 Pressing processes
Isolatic (isostatic) pressing:

- Ceramic powder is loaded into a flexible chamber and pressure is applied outside the
chamber with hydraulic fluid.
- Examples: Spark plug insulators, carbide tools
Hot pressing:
Pressing processes
• Ceramics parts of high density and improved mechanical properties are produced by
combining the pressing and firing operations.
• Both uniaxial and isostatic methods are used
 Tape Casting
• Tape casting is used to fabricate thin sheets of ceramics in large quantities and at low cost.

• Thin sheets of green ceramic cast as flexible tape

• Used for integrated circuits and capacitors

• Like slip casting, but on a film instead of a mold

 04
Additional
Processes
 Heat Treatments
Drying:
• Parts are dried before firing to remove
water from ceramic body.
• Usually carried out at or below 100°C.

Sintering (Firing):
• turns raw clay into ceramic through high-
temperature heating.

• Small particles are bonded together by

solid state diffusion producing dense
coherent product.

• Carried out at extremely high temperature

but below Molten temp usually 800°C.
 Glass Hardening processes
Tempering:

 Glass is heated into near softening point and rapidly cooled.

• Surface cools first and contracts.
• Interior cools next and contracts causing tensile stresses in the interior and compressive
stress on the surface.
 This type of glass is six times as hard to break as ordinary glass
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Chemical Hardening:

 - Cations with large ionic radius are diffused into the surface
 - This strains the "lattice" inducing compressive strains and stresses.
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Laminating

 adhering two or more layers of glass together with a flexible PVB interlayer.
 This takes place through a heat and pressure process in which the chemical bond
formed between the glass and PVB interlayer does not merely join them but 'conjoins'
them to create an entirely new material.
Video
 THANKS!

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By:
Ahmed Mohamed Allam
Mohamed Mohamed Salah
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