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PRACTICAL ENGLISH IN CERAMICS

PRACTICAL ENGLISH IN CERAMICS. Ceramika ---- Ceramics Ceramika specjalna – Special ceramics Ceramika ogniotrwała – Refractory materials Szkło - Glass Szkliwa i emalie - Glazes and enamels Szkło-ceramika - Glass - ceramics Materiały wiążące - Binding materials

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PRACTICAL ENGLISH IN CERAMICS

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  1. PRACTICAL ENGLISH IN CERAMICS • Ceramika ---- Ceramics • Ceramika specjalna – Special ceramics • Ceramika ogniotrwała – Refractory materials • Szkło - Glass • Szkliwa i emalie - Glazes and enamels • Szkło-ceramika - Glass - ceramics • Materiały wiążące - Binding materials • Cienkie warstwy - Coatings • Biomateriały - Biomaterials

  2. Programm:Non-metalic inorganic materials 1. Characteristic of ceramic materials • Sintered (classic ceramics) • Melted (glasses and glazes) • Binding (lime, gypsum, cement, mortars binding) 2. Sintered ceramics – classic and advanced 3. Glasses and glass-ceramics 4. Special glasses and method of their production (sol/gel method) 5. Bioactive glasses and glass-ceramics materials 6. Amorphous coatings on glassy base 7. Binding materials

  3. CREDIT CONDITIONS OF COURSE • Presence in lectures • Preparation of the seminar paper References to the subject: • Draft of lectures • „Applied Ceramic Technology” vol. I and II; SACMI

  4. My motto • Not the most important presence at lectures!!!! • Most important is - something to understand, learn, remember!!!

  5. What does „ceramics” mean????? Ceramics derives from Greek wordKeramos; this is the product formed by the action of fire (sintering) Now (unambiguous definition: Non-metalic, inorganic products obtained by the transformation of mineral or chemical raw materials during high-temperature process

  6. How can we divide ceramics? • SINTERED PRODUCTS (classic ceramics) • MELTED PRODUCTS (glasses) • BINDING MATERIALS (lime, gypsum, cement)

  7. SINTERED MATERIALS Examples: • Porcelain tableware • Building ceramics – brick, slate, various tiles: floor and wall • Sanitary ware • Advanced ceramics

  8. SINTERED MATERIALS Kind of tiles: Floor and wall Wall tiles: double and single fired; • Classification on the base of forming method • Technical features: porosity between 13-18% • Glazes are usually used Floor tiles: • Vitrified single fired tiles („gres”)-compact mass • Porcelain tiles, usually glazed

  9. MELTED MATERIALS (GLASSES) • Soda-lima-silica glasses (building, automotive, packaging, tableware) • Optical glasses • Technical glasses • Crystal glasses • Bio-glasses

  10. BINDING MATERIALS • Lime (CaO from CaCO3)) • Gypsum (CaSO4) • Cement (cement clinker + gypsum + mineral additions –ashes)

  11. Basic differences between particular groups of materials • These differences concern: - production process -structure, microstructure and material properties -application

  12. DIFFERENCES - PROCESS SINTERED MATERIALS Raw materials preparation Preparation of ceramic body Formation ceramic body Drying and sintering

  13. SINTERED CERAMICS Raw materials: • Plastic: clay minerals - kaolinite Al4[Si4O10](OH)8 , illite Al2(Si5O10)(OH)2 montmorillonite; • Non-plastic: silica SiO2 (to do smaller body contraction), feldspars X4(Al4Si4O16) X – K, Na (fluxing agents)

  14. Kaolinite structure • Basic element of kaolinite: • - silica-oxygen sheet („tetrahedral sheet”) • - alumina-oxygen-hydroxyl sheet („octahedral sheet”) ------------------------------------------------------------ • L.K. Si = 4___________________________ [SiO2O5 ]-2 • ___________________________ H2O • L.K. Al = 6___________________________ [AlO6]-9

  15. Kaolinite spatial structure

  16. DIFFERENCES - PROCESS MELTED PRODUCTS (GLASSES) Raw materias preparation Melting Forming from the melt Vitrification

  17. GLASSES Raw materials: • Glass-forming compounds (high viscosity at melting temperature): SiO2; B2O3, P2O5; • Fluxing agents: carbonates of alkaline element – Na2CO3; K2CO3; Li2CO3 • Modifieres – PbO, BaO, ZnO

  18. BINDING MATERIALS • Materials in the form of powders; • Lack of product formation; • They are able to bind after water addition

  19. BINDING MATERIALS Raw materials: Limestone, marl, clays  clinker Clinker compounds: silicates and aluminates

  20. DIFFERENCES: STRUCTURE AND PROPERTIES Ceramics: Poly-crystalline products; can contain amorphous phase; produced from mineral raw materials by firing; products are not-translucent or translucent (porcelain) Glasses: amorphous products; no long-range ordering of structure; products are transparent Binding materials: poly-crystalline products in the form of powders

  21. CERAMIC PRODUCT CLASIFICATION • Criteria: • Physical features (colour, porous structure, optical properties) • Production technology ( method of formation; double or single firing; use or not glazes) • Application

  22. CERAMIC PRODUCT CLASIFICATIONPhysical features Porosity: Compact or porous structure (porosity 3-12%) – dependent on formation method and firing temperature) Color: White or red after firing (dependent on the content of iron in raw materials)

  23. Porous products Coloured (red) after firing • brick • refractory • pottery White after firing • faience • Some products of advanced ceramics

  24. NON-POROUS PRODUCTS Low-translucent products (yellow) Steatite products Advanced products for the electronic Not-translucent: • Stoneware; • Semi-vitreous Translucent, white • Porceain

  25. CERAMIC PRODUCT CLASIFICATIONProduction technology Formation: • castings, • plastic extrusion • pressing

  26. PRODUCTION PROCESS SINTERED MATERIALS Raw materials preparation Preparation of ceramic body Formation from ceramic body Drying and sintering

  27. SINTERED CERAMICS Raw materials: • Plastic: clay minerals - kaolinite Al4[Si4O10](OH)8 , illite Al2(Si5O10)(OH)2 montmorillonite; • Non-plastic: silica SiO2 (to do smaller body contraction -shrinkage), feldspars X4(Al4Si4O16) X – K, Na (fluxing agents) • Helpful raw materials

  28. Plastic raw materials • Clays (illite-chlorite, illite-kaolinitic types) • Kaolins • Bentonites • Shale rocks • Mineralogical characterisation: sedimentary rocks composed of various types of silicate minerals, mostly hydrarted aluminum silicates (Al2O3mSiO2nH2O).

  29. Plastic raw materials • Basic feature of clays: PLASTICITY– ability, after introducing of water, formation of mass, which can be shaped by various methods, and obtained shape is preserved during and after drying and firing

  30. COMPLEMENTARY RAW MATERIAL Role in production process - to reduce shrinkageduring drying and firing of plastic raw materials • Silica raw materials(SiO2): Quartz, qartzites, quartz sands • Raw materials of high content of alumina Al2O3 • Aluminum raw materials: alumina, aluminum hydroxides; • aluminum, synthetic materials (corundum); • Aluminum-silicate raw materials: : sillimanite, mullite

  31. COMPLEMENTARY RAW MATERIAL Role in production process Fluxes; decreasing sintering and melting temperatures! • Feldspars: • Potasium feldspar (ortoklaz) K2O Al2O3 SiO2; • Sodium feldspar (albit) Na2O Al2O3 SiO2; • Calcium feldspar (anortyt) CaO Al2O3 SiO2 • Carbonates of calcium and magnezium (Ca, Mg): • Calcium carbonateCaCO3; • Magnesium carbonate MgCO3; • Double calcium/magnesium carbonate CaCO3 MgCO3;

  32. Clays classification as the raw materials for ceramics production: • Content of impurities in the form of iron compounds (it affects on the product color after firing • Content of impurities in the form of calcium, magnesium, potasium, sodium compounds playing the role of fluxing agents (this determines the fire resistance)

  33. Examples: • Kaolin and clays (ball clays, china clays) – firing in white or cream(low content of iron compounds) they are used to porcelain and faience production • Clays for brick production (marl-carbonate clay, vitrifiable clay); after firing they take on beige-orange color due to present of ferrous minerals; • Refractory clays (Kaolin-type china-clays), low content of fluxing agents (less than 6%), give a product with a high fire resistance

  34. Sintered products • Raw materials preparation • Preparation of ceramic body • Shaping of ceramic body (ambient conditions) • Drying and sintering (firing) – high-temperature process

  35. Raw materials and ceramic body preparation Raw materials preparation: • Enrichment(removal of not-profitable components) • Pre-processing - (crushing) Compilation of ceramic body; Examples: faience: clays: medium-plastic 30% very plastic 32% marble or chalk(CaCO3) 12% quartz sands 26% porcelain Clays – kaolin type 50% (Ball-clays, china clays) Feldspar 25% Quartz 25%

  36. Body compilation- wall tiles

  37. Ceramic body preparation Removal of water and air from mass using special filter or vacuum press Vacuum press

  38. Ceramic body fate What is the fate of body ? content of H2O in % • Casting 25-35 • Plastic extrusion 15-25 • Plastic pressing 10-14 • Dry pressing 3-9

  39. Shaping of body • Casting in gypsum form • Formation from plastic mass –hand made, extrusion, formation on press • Pressing • Dry and semi-dry mass • Plastic mass • Thermo-plastic formation

  40. Casting in gypsum form Preparation of slip body - water suspension of ground raw ceramic – low viscosity, low sedimentation rate, low shrinkage (addition of fluidization agents : sodium silicates – „water” glass)

  41. Casting Casting of slip body in gypsum form Body is left in gypsum form up to body densification (water is removed from body by gypsum form absorption)

  42. Plastic body formation Hand made: • Various type of clay body modeling Turning of ceramics: The oldest way of formation: – potter's wheel

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