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Ceramic Processing
Kwame Nkrumah University of
Science & Technology, Kumasi, Ghana

• The constituent oxide for ceramics have high melting

points.

MSE 351 • Oxide particles are bonded through a process known as

Engineering Ceramics I sintering or powder metallurgy.

Ing. Anthony Andrews (PhD) • Example: to produce mullite (Al2O3 + SiO2): mix 3
Department of Materials Engineering molecular weights of Al2O3 + 2 molecular weight SiO2.
Faculty of Mechanical and Chemical Engineering
College of Engineering
Website: www.anthonydrews.wordpress.com www.knust.edu.gh

Ceramic Processing Ceramic Processing

Overview Ceramic Materials
1. Introduction – The process (microstructure, homogeneity)
2. Characteristics of powders
Traditional Ceramics Advanced Ceramics
3. Interaction between powder particles
4. Preparation of powders and coatings
Natural materials Chemical processes
5. Treatment of powders Large amounts Specific properties
6. Compaction processes Low costs Not always visible
7. Thermal processes
8. Sintering Bricks Electronics, Medical,
Tiles Membranes/Filters,
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Sanitary Engine parts www.knust.edu.gh

Different kinds of technical Different kinds of technical

ceramics ceramics

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Two possibilities improving the strength: Ceramic Processing

1. Reduction of the defect size
– Improvement of the technology

2. Increased fracture toughness

– Microstructural design

• Strength is determined by the largest defect in the

sample under stress
• Mostly defects from the raw powder or from the
processing
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Principles of Ceramic Processing Traditional Ceramic Processing

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Traditional Ceramic Processing Comminution

• Reducing particle size in ceramics processing by using
Preparation of raw materials
mechanical energy.
• Most shaping processes require the starting material to
be a plastic paste
• Most effective on brittle materials such as cement and
metallic ores
• Raw ceramic material => rocky lumps
• Two types of comminution operations:
1. Crushing
2. Grinding

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Crushing Jaw Crusher

• Large jaw toggles back and forth to crush lumps against a hard,
• Reduction of large lumps from the mine to smaller sizes rigid surface
for subsequent further reduction

• Several stages may be required

• Crushing of minerals is accomplished by

– Compression against rigid surfaces or
– Impact against surfaces

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Roll Crusher Grinding

• Ceramic lumps are squeezed between rotating rolls • Grinding refers to the reduction of small pieces after
crushing to fine powder

• Accomplished by abrasion, impact, and/or compaction

by hard media such as balls or rolls

• Examples of grinding include:

– Ball mill
– Roller mill
– Impact grinding
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Ball Mill Roller Mill

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Main Ingredients of Ceramic Additional Ingredients of

Paste Ceramic Paste
1. Clay 3. Non-plastic raw materials
– Chemistry = hydrous aluminum silicates
4. Other ingredients
2. Water – Fluxes
– Creates clay-water mixture with good plasticity for – Wetting agents
shaping

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Shaping Processes Effect of Water Content in

• Slip casting Shaping Processes
– The clay-water mixture is a slurry

• Plastic forming methods

– The clay is plastic

• Semi-dry pressing
– The clay is moist but has low plasticity

• Dry pressing
– The clay is basically dry (less than 5% water) and has no
plasticity
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Slip Casting Drain Casting

• Slip, is poured into porous plaster of paris mold

• Water from the mix is absorbed into the plaster to form a

firm layer of clay at the mold surface

• Slip composition is 25% to 40% water

• Two principal variations:

– Drain casting
– Solid casting
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Plastic Forming Methods Plastic Forming Methods

• Starting mixture must have a plastic consistency • Hand molding (manual method)
– Composition 15% to 25% water
• Jiggering (mechanized method)
• Variety of manual and mechanized methods
– Manual methods => use clay with more water • Plastic pressing (mechanized method)
– Mechanized methods => use clay with less water
• Extrusion (mechanized method)

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Hand Molding Jiggering

• Fabrication of ceramic product by manipulating plastic

clay into desired geometry

• Hand molding - a mold is used to define portions of the

part geometry

• Hand throwing on a potter's wheel

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Plastic Pressing Extrusion

• Plastic clay slug is pressed between upper and lower • Equipment utilizes a screw-type action to assist in mixing
molds the clay and pushing it through die opening

• Molds are made of porous material • Products: hollow bricks, shaped tiles, drain pipes, tubes,
and insulators

• Mold sections are then opened, using positive air pressure • Also used to make starting slugs for jiggering and plastic
to prevent sticking of part in the mold pressing

• Advantages??

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Semi-dry Pressing Dry Pressing

• Process sequence similar to semi-dry pressing

• Dies made of hardened tool steel or cemented carbide

• No drying shrinkage occurs

• Products: bathroom tile, electrical insulators, refractory

brick, and other simple geometries

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Clay Volume vs. Water Content Clay Volume vs. Water Content

• Water plays an important role in traditional ceramics

shaping processes

• Shrinkage is a problem during drying

• Volume of clay as a function of water content

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Drying Firing of Traditional Ceramics

• Performed in a furnace called a kiln

• Bonds are developed between ceramic grains

• In firing of traditional ceramics, a glassy phase forms

among the crystals that acts as a binder

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Firing Temperature Profile Stages in Vitrification

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Densification During Firing Glazing

• Application of a ceramic surface coating to make the piece more
impervious to water and enhance its appearance

• Usual processing sequence with glazed ware:

1. Fire the piece once before glazing to harden the body of the
piece
2. Apply glaze
3. Fire the piece a second time to harden glaze

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