Ceramic Flashcards by Sherl Nicole M. TABANAO

ONE OF THE MAIN TYPE OF MATERIALS USED IN THE DIFFERENT FIELDS OF ENGINEERING ALONGSIDE METAL, POLYMER AND COMPOSITE MATERIALS.

CERAMICS

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A COMPOUND THAT PRIMARILY CONSIST OF METALLIC
AND NONMETALLIC ELEMENTS.

CERAMICS

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SOMETIMES ALSO CALLED THE CLAY PRODUCTS OR SILICATE INDUSTRIES.

CERAMIC INDUSTRY

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THE OLDEST KNOWN CERAMIC ARTIFACT

IT IS A STATUETTE OF A WOMAN, NAMED THE VENUS OF DOLNÍ VĚSTONICE

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THE 3 MAIN RAW MATERIALS FOR CERAMIC INDUSTRY:

CLAY
FELDSPAR (USUALLY KNOWN AS “SPAR” )
SAND (USUALLY KNOWN AS “FLINT”)

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MORE OR LESS IMPURE HYDRATED ALUMINUM SILICATES THAT HAVE RESULTED FROM THE WEATHERING OF IGNEOUS ROCKS SUCH AS FELDSPAR

CLAY

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THE DIFFERENT CLAY MINERALS / MINERAL SPECIES AND THEIR RESPECTIVE COMPOSITION:

KAOLINITE (AL2O3 2SIO2 2H2O)
BEIDELLITE (AL2O3 3SIO2 H2O)
MONTMORILLONITE (AL2O3 4SIO2 H2O)
HALLOYSITE (AL2O3 2SIO2 3H2O)

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A TERM USED TO IDENTIFY THAT AT A SPECIFIC TEMPERATURE, CLAY CAN BE FORMULATED TO PRODUCE NEW PRODUCTS.

MATURE

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T/F. THE HIGHER A CLAY BODY IS DESIGNED TO FIRE, THE MORE VITREOUS IT IS.

TRUE

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MORE RESISTANT TO WATER ABSORPTION, WHICH IN TURN CAN PREVENT DEFECTS AND CRACKING FROM HAPPENING.

VITREOUS CLAY

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IS A PROPERTY OF CLAY THAT ALLOWS IT TO CHANGE ITS SHAPE WITHOUT RUPTURING EVEN AFTER PUTTING A GREATER AMOUNT OF FORCE .

PLASTICITY

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THE MOST BASIC CLAY MINERAL USED IN THE CERAMIC INDUSTRY IS

KAOLINITE

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THE MOST ABUNDANT CLAY MINERAL OF ALL DIFFERENT TYPES (WIDELY USED IN POTTERY AS WELL).

KAOLINITE

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ARE BASED ON MONTMORILLONITE CLAYS, THEY ARE USED TO SOME EXTENT WHERE VERY HIGH PLASTICITY IS DESIRED.

BENTONITE CLAYS

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ONE WAY FOR US TO INCREASE THE CONTENT OF CLAY MINERALS IN
CLAYS IS BY

USING THE PROCESS OF BENEFICIATION WHILE DECREASING THE CONTENT OF QUARTZ.

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MAJORITY OF THE PROCESS OF BENEFICIATION OF CLAY CONSISTS OF UNIT OPERATIONS SUCH AS

SIZE SEPARATION BY SCREENING OR
SELECTIVE SETTLING, FILTRATION AND DRYING.

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ARE ADDED AS THE APPROPRIATE ADDITIONAL AGENTS USED TO CONTROL THE COLLOIDAL PROPERTIES OF CLAY.

SODIUM SILICATE AND ALUMINUM

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A GROUP OF ALUMINOSILICATE MINERALS THAT ALSO CONTAINS CALCIUM, SODIUM AND POTASSIUM.

FELDSPAR

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THE 3 COMMON TYPES OF FELDSPAR USED IN THE
CERAMIC INDUSTRY.

POTASH FELDSPAR (K2O AL2O3 6SIO2)
SODA FELDSPAR (NA2O AL2O3 6SIO2)
LIME FELDSPAR (ALSO TERMED AS
ANORTHITE (CAO AL2O3 6SIO2)

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THE MOST COMMON TYPE OF FELDSPAR IS THE

POTASH FELDSPAR

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T/F. THE PRESENCE OF FLUXES TENDS TO LOWER THE TEMPERATURE OF THE FORMATION OF MULLITE

TRUE

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FORMS WHEN CLAY MINERALS ARE IN CONTACT WITH EACH OTHER AND UNDERGOES METAMORPHISM

MULLITE

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A TYPE OF MINERAL THAT NATURALLY CONSIST OF SILICA/ QUARTZ OR SIO2.

SAND

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SHOULD BE CHOSEN FOR THE MANUFACTURING OF LIGHT-COLORED CERAMIC PRODUCTS.

A SAND WITH A LOW IRON CONTENT

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ALL CERAMIC PRODUCTS ARE MADE BY

COMBINING VARIOUS AMOUNTS OF THE FOREGOING RAW MATERIALS SHAPING, AND HEATING TO FIRING TEMPERATURES.

HEATING TO FIRING TEMPERATURES MAY BE AS LOW AS AND HIGH AS

AS LOW AS 700°C TO AS HIGH AS 1300 TO 1400°C

THE PRINCIPAL REFRACTORY OXIDES:

SIO2, AL2O3, CAO, MGO , ZRO2, TIO2, CR2O3, BEO

AS THE TEMPERATURE OF THE AMORPHOUS ALUMINA (KAOLIN) CHANGES TO 940 C, IT FORMS A CRYSTALLINE FORM CALLED

GAMMA ALUMINA

GENERIC TERM FOR CERAMIC PRODUCTS WHICH ARE USUALLY WHITE AND OF FINE TEXTURE.

WHITEWARES

SOMETIMES CALLED SEMI-VITREOUS DINNERWARE, WHICH ARE POROUS AND NON-TRANSLUCENT WITH A SOFT GLAZE.

EARTHWARES

VITRIFIED TRANSLUCENT WARE WITH A MEDIUM GLAZE THAT CAN RESIST ABRASION TO A DEGREE AND USED FOR NONTECHNICAL PURPOSES.

CHINAWARE

THIS INCLUDES CHEMICAL, INSULATING, AND DENTAL PORCELAIN, VITRIFIED TRANSLUCENT WARE WITH A HARD GLAZE, AND CAN RESIST ABRASION TO THE MAXIMUM DEGREE.

PORCELAIN

FORMERLY MADE FROM CLAY, USUALLY POROUS; HENCE, HAS VITREOUS COMPOSITION, PREFIRED AND SIZED VITREOUS GROG IS SOMETIMES INCLUDED WITH THE TRIAXIAL COMPOSITION.

SANITARY WARE

ONE OF THE OLDEST OF CERAMIC WARES, WAS IN USE LONG BEFORE PORCELAIN WAS DEVELOPED, REGARDED AS A CRUDE PORCELAIN MADE FROM A POORER GRADE OF NOT CAREFULLY FABRICATED RAW MATERIALS.

STONEWARE

CLASSIFIED AS FLOOR TILES, RESISTANT TO ABRASION, IMPERVIOUS TO STAIN PENETRATION, MAY BE GLAZED OR UNGLAZED, ALSO USED AS WALL TILES WHICH HAVE A HARD, PERMANENT SURFACE AND COME IN A VARIETY OF COLORS AND TEXTURES.

WHITEWARE TILES

USED FOR PRODUCTION OF FINE-GRAINED HIGHLY GLAZED INSULATORS FOR HIGH-VOLTAGE SERVICE.

WET PROCESS PORCELAIN

PROCESS EMPLOYED FOR RAPID PRODUCTION OF MORE OPEN-TEXTURED LOW-VOLTAGE PIECES.

DRY PROCESS PORCELAIN

NECESSARY FOR THE MAKING OF PIECES THAT ARE EITHER TOO LARGE OR TOO INTRICATE FOR THE OTHER TWO METHODS (DRY & WET PROCESS).

CAST PORCELAIN

PROCESS WHERE THE PLASTIC CLAY IS PRESSED INTO OR ON A SINGLE REVOLVING MOLD.

JIGGING

IS ALWAYS IMPORTANT IN THE PRODUCTION OF WHITEWARES.

GLAZING

A THIN COATING OF GLASS THAT IS MELTED AND IS APPLIED THE SURFACE OF THE POROUS CERAMIC WARE.

GLAZE

THE PURPOSE OF GLAZING

TO IMPART THE PHYSICAL AND CHEMICAL CHARACTERISTICS OF GLASS INTO THE CERAMIC MOLD FOR THE IMPROVEMENT OF PRODUCT ROBUSTNESS.

GLAZING NATURALLY CONTAINS TWO INGREDIENTS:

1. THE REFRACTORY MATERIALS (FELDSPAR, SILICA, AND CHINA CLAY) 2. THE FLUXES (SODA, POTASH, FLUORSPAR AND BORAX)

IS THE TECHNICAL TERM FOR THE FIRING OF THE GLAZE INSIDE THE KILN.

GLOST FIRING

LOW-COST BUT VERY DURABLE PRODUCTS.

HEAVY CLAY PRODUCTS

ARE FREQUENTLY MANUFACTURED FROM THE CHEAPEST OF COMMON CLAYS WITH OR WITHOUT ANY GLAZING.

COMMON BRICK, FACE BRICK, TERRA COTTA, SEWER PIPE, AND DRAIN TILE

THE PROCESS OF GLAZING IN SEWER PIPE AND DRAIN TILE BY THROWING SALT UPON THE KILN FIRE FOR IT TO REACT AND FORM THE FUSIBLE COATING OR THE GLAZE.

SALT GLAZE

ONE OF THE MOST IMPORTANT OF CLAY PRODUCTS IS

BUILDING BRICK

BUILDING BRICK IS COMPRISED OF

COMMON AND FACE BRICK

ARE THE STANDARD BRICK TYPE AND THE MOST ABUNDANTLY USED BUILDING MATERIAL IN MODERN CONSTRUCTION.

COMMON BRICKS

TENDS TO HAVE A MORE AESTHETICALLY PLEASING APPEARANCE IN COMPARISON WITH A COMMON BRICK, AS THEY ARE MORE UNIFORM IN COLOR AND SMOOTHER IN TEXTURE THAN THE COMMON BRICK.

FACE BRICK

THE RAW MATERIALS FOR BUILDING BRICKS (WHICH ARE CLAYS) COMES FROM THESE 3 GROUPS:

1. RED BURNING CLAY (MOST USED CLAY FOR BOTH COMMON AND FACE BRICK) 2. WHITE BURNING CLAY 3. BUDD BURNING CLAY, WHICH IS USUALLY A REFRACTORY.

BRICKS ARE MANUFACTURED BY ONE OF THREE PROCESSES:

1. SOFT-MUD PROCEDURE 2. STIFF-MUD PROCEDURE 3. DRY-PROCESS PROCEDURE

CONSIST OF MOLDING THE CLAY MIXTURE CONTAINING 20 TO 30 PERCENT WATER IN MOLDS COATED WITH A THIN LAYER OF EITHER SAND OR WATER TO PREVENT STICKING.

SOFT-MUD PROCEDURE

USUALLY MUCH EMPLOYED FOR FIREBRICK AND IS THE ANCIENT METHOD FOR MAKING BUILDING BRICKS.

SOFT-MUD PROCEDURE

UTILIZES THE SAME CONCEPT WITH THE SOFT MUD PROCEDURE BUT DIFFERS IN THE CONCENTRATION OF WATER WHEN MIXING WITH THE CLAY

STIFF-MUD PROCEDURE

THE WATER CONTENT IS FROM 4 TO 7 PERCENT (USUALLY THE "AS-IS" CONDITION) WHICH MAKES THE CLAY RELATIVELY NONPLASTIC.

DRY-PROCESS PROCEDURE

EMPLOYED FOR THE MANUFACTURE OF PRACTICALLY EVERY CLAY PRODUCT, INCLUDING ALL TYPES OF BRICK, SEWER PIPE, DRAIN TILE, HOLLOW TILE, FIREPROOFING, AND TERRA COTTA.

STIFF-MUD PROCESS

THE PROCESS OF REMOVING AIR FROM THE PUG MILL.

DE-AIRING

IT ALSO INCREASES THE WORKABILITY, PLASTICITY, AND' STRENGTH OF THE UNDRIED BRICK BY REDUCING VOIDS, FOR ALL BUT A FEW CLAYS.

DE-AIRING

REFER TO MATERIALS WHICH ARE USED TO WITHSTAND THE THERMAL, CHEMICAL, AND PHYSICAL EFFECTS THAT ARE PRESENT IN FURNACE PROCEDURES.

REFRACTORIES

THE USUAL CLASSIFICATION OF COMMERCIAL REFRACTORIES DIVIDES THEM INTO

ACID, BASIC, AND NEUTRAL GROUPS

T/F. IT IS USUALLY UNADVISABLE TO EMPLOY AN ACID BRICK IN CONTACT WITH AN ALKALINE PRODUCT OR VICE VERSA

TRUE

THE QUALITY OR DEGREE OF HAVING MINUTE SPACES OR HOLES THROUGH WHICH LIQUID OR AIR MAY PASS.

POROSITY

THE POINT WHERE THE MOLECULES HOLDING THEIR BONDS TOGETHER BREAK APART AND FORM A LIQUID.

FUSION POINTS

FUSION POINTS CAN BE DETERMINED BY THE USE OF

PYROMETRIC CONES

IT MEASURES HEAT-WORK, THE EFFECT OF TIME, AND TEMPERATURE.

PYROMETRIC CONES

A FRACTURING OF A REFRACTORY BRICK OR BLOCK DUE TO UNEVEN HEAT STRESSES OR COMPRESSION CAUSED BY HEAT.

SPALLING

ARE MOST SUSCEPTIBLE TO SPALLING WHEN SUBJECTED TO RAPID COOLING AND HEATING

THOSE THAT UNDERGO THE GREATEST EXPANSION AT THE LEAST UNIFORM RATE

RESISTANCE TO ABRASION OR EROSION IS ALSO IMPORTANT FOR FURNACE CONSTRUCTIONS.

STRENGTH

THE COMPRESSIVE OR FLEXURAL STRENGTH DETERMINED PRIOR TO FIRING.

COLD STRENGTH

USUALLY ONLY HAS A SLIGHT BEARING ON STRENGTH AT HIGH TEMPERATURES.

COLD STRENGTH

ARE THE MOST RESISTANT TO RAPID THERMAL CHANGES AND DEVELOP LESS STRAIN.

BRICKS WITH THE LOWEST THERMAL EXPANSION AND COARSEST TEXTURE

FURNACE HEAT CAPACITY DEPENDS UPON THE FOLLOWING PROPERTIES OF THE REFRACTORY:

A) THE THERMAL CONDUCTIVITY, B) THE SPECIFIC HEAT, C) THE SPECIFIC GRAVITY

THE MOST IMPORTANT SINGLE PROPERTY TO PRODUCE IN MANUFACTURE IS

HIGH BULK DENSITY

AFFECTS MANY OF THE OTHER IMPORTANT PROPERTIES, SUCH AS STRENGTH, VOLUME STABILITY, SLAG AND SPALLING RESISTANCE, AS WELL AS HEAT CAPACITY.

HIGH BULK DENSITY

ONE OF THE MOST IMPORTANT FACTORS IS THE SIZE OF THE PARTICLES IN THE BATCH

GRINDING

IT IS KNOWN THAT A MIXTURE IN WHICH THE PROPORTION OF COARSE AND FINE PARTICLES IS ABOUT

55 : 45

THE REAL FUNCTION OF _______ IS THE DISTRIBUTION OF THE PLASTIC MATERIAL SO AS TO THOROUGHLY COAT THE NONPLASTIC CONSTITUENTS.

MIXING

IS PARTICULARLY SUITED FOR BATCHES THAT CONSISTS PRIMARILY OF NONPLASTIC MATERIALS.

DRY-PRESS METHOD

USED TO REMOVE THE MOISTURE ADDED BEFORE MOLDING TO DEVELOP PLASTICITY.

DRYING

MAY BE CARRIED OUT IN TYPICAL ROUND, DOWNDRAFT KILNS OR CONTINUOUS TUNNEL KILNS.

BURNING

ARE THE MOST WIDELY USED OF ALL AVAILABLE REFRACTORY MATERIALS, SINCE THEY ARE WELL SUITED FOR A VARIETY OF APPLICATIONS.

FIRE CLAYS

ARE THE LARGEST CONSUMERS OF REFRACTORIES FOR THE LININGS OF BLAST FURNACES, STOVES, OPEN HEARTHS, AND OTHER FURNACES.

STEEL INDUSTRIES

CONTAINS APPROXIMATELY 95 TO 96% SIO2 AND ABOUT 2% LIME ADDED DURING GRINDING TO FURNISH THE BOND.

SILICA BRICK

HAVE HIGHER REFRACTORINESS AND LOWER PERMEABILITY TO GASSES THAN CONVENTIONAL SILICA BRICKS

SUPERDUTY SILICA BRICKS

THE IMPORTANT BASIC BRICKS ARE MADE FROM

MAGNESIA. CHROMITE. AND FORSTERITE.

TO ACHIEVE THE REQUIRED STRENGTH AND OTHER PHYSICAL PROPERTIES, BASIC BRICKS ARE

USUALLY POWER-PRESSED AND ARE EITHER CHEMICALLY BONDED OR HARD-BURNED.

ARE MADE FROM DOMESTIC MAGNESITES OR MAGNESIA EXTRACTED FROM BRINES

MAGNESIA REFRACTORIES

EMPLOYED BOTH AS A BOND AND AS A BASE FOR HIGH-TEMPERATURE REFRACTORIES.

FORSTERITE (2MGO · SI02)

USUALLY ADDED TO CONVERT SOME ACCESSORY MINERALS TO FORSTERITE, WHICH IS THE MOST STABLE SILICATE AT HIGH TEMPERATURES.

DEAD-BURNED MAGNESITE

THE MOST IMPORTANT USE OF FORSTERITE IS IN

GLASS-TANK SUPERSTRUCTURES AND CHECKERS

THERE ARE TWO TYPES OF INSULATING BRICKS

FOR BACKING REFRACTORY BRICKS AND FOR USE IN PLACE OF REGULAR REFRACTORY BRICKS.

ARE MADE FROM NATURALLY POROUS DIATOMACEOUS EARTH

BRICKS USED FOR BACKING

USUALLY CALLED LIGHTWEIGHT REFRACTORIES, ARE SIMILAR IN COMPOSITION TO HEAVY BRICKS AND OWE THEIR INSULATING VALUE TO THE METHOD OF MANUFACTURE.

BRICKS USE IN PLACE OF REGULAR REFRACTORY BRICKS

THEIR ABILITY TO ABSORB AND RELEASE HEAT RAPIDLY AND THEIR RESISTANCE TO SPALLING UNDER REPEATED TEMPERATURE CHANGES MAKE THEM DESIRABLE FOR RECUPERATORS.

SILICON CARBIDE

SILICON CARBIDE ARE REPLACING ____________________ IN IRON-MAKING BLAST FURNACES BECAUSE OF THEIR STABILITY UNDER REDUCING CONDITIONS AND GOOD ALKALI RESISTANCE.

CARBON AND ALUMINOSILICATE PRODUCTS

-LIGHT WEIGHT (REDUCE FURNACE LOAD AND EXTEND FURNACE LIFE); -LOW HEAT CAPACITY (LESS HEAT ABSORPTION AND RAPID TEMPERATURE RISE); -LOW THERMAL CONDUCTIVITY (LESS HEAT LOSS); -SIMPLE CONSTRUCTION (NO NEED TO LEAVE EXPANSION JOINTS); -WIDE RANGE OF USE; -THERMAL SHOCK RESISTANCE; -RESISTANCE TO MECHANICAL VIBRATION (WITH FLEXIBILITY AND ELASTICITY); -GOOD SOUND INSULATION PERFORMANCE (REDUCE NOISE POLLUTION);

ALUMINUM SILICATE AND ALUMINA PRODUCTS.

ALSO KNOWN AS "PORCELAIN ENAMEL" IS A SMOOTH, GLASSY, AND DURABLE SURFACE THAT IS FUSED AT TEMPERATURES HIGHER THAN 800 C.

VITREOUS ENAMEL

THE VITREOUS ENAMEL PROCESS STARTS WITH SMALL PIECES OF GLASS CALLED

“FRIT”