Ceramic Industry Flashcards
Involves the production and processing of ceramic materials, which are non-metallic, inorganic solids typically made by heating raw materials like clay, silica, and feldspar at high temperatures. The industry includes a wide range of products used in construction, household items, industrial applications, and advanced technology.
Ceramic Industries
are defined as non-metallic, inorganic materials that are subjected to high temperatures during their formation.
Generally composed of elements such as silicon, oxygen, aluminum, and nitrogen, ceramics can be crystalline or partly crystalline in structure.
Ceramics
The word ceramics is traced back to the Greek term “_______”, meaning potter’s clay or pottery.
Keramos
What are the best-known ceramics?
- Pottery
- Glass
- Brick
- Porcelain
- Cement
Their findings indicate that humans were creating ceramics as early as ________ BCE, with early examples found in southern central Europe as sculpted figures.
- Ancient Origins
- 24,000
Around 10,000 BCE, functional ceramics like pots and bowls emerged, linked to the development of agriculture for food storage and cooking.
Neolithic Period
Civilizations like the Egyptians, Mesopotamians, and Chinese developed simple clay vessels and tiles for practical purposes, with the Egyptians mastering ________, an early form of glazed ceramics.
- Early Civilizations (4000 BCE)
- faience
The invention of the potter’s wheel led to smoother, more even pottery production using the _________ technique.
The Rise of Pottery (3500 BCE)
2. wheel-forming
Produced in Mesopotamia at the beginning of the Bronze Age, Egyptians started building factories to create glassware for ointments and oils around 1500 BCE.
Glazed Pottery
Flourished in various cultures, with examples like Greek terracotta figurines and Roman pottery showcasing both artistic and utilitarian aspects.
Ceramic Art (1000 BCE)
Brought advancements in kiln technology and ceramic formulations, leading to stronger and more reliable products.
Industrial Revolution (18th–19th century)
With the advent of electricity in
the late 19th and early 20th centuries, the insulating
properties of ceramics became crucial, paving the way
for advances in telecommunications and power
generation.
Technical Ceramics
Ceramics are used in a wide range of applications, from building materials and tableware to advanced technologies like electronics and aerospace.
Modern Ceramics
Mechanical Properties of Ceramics
- High Hardness
- Brittleness
- High Compressive Strength
- Low Ductility
- Low Toughness
- High Stiffness
Ceramics are extremely hard, making them resistant to scratching and wear.
High Hardness
They tend to fracture easily under stress, especially in tension, due to limited plastic deformation.
Brittleness
While they are weak in tension, ceramics can withstand very high compressive loads.
High Compressive Strength
Ceramics are not ductile and cannot stretch or deform before breaking.
Low Ductility
Ceramics have ________, meaning they are prone to cracking under sudden impact.
Low Toughness
They have a high Young’s modulus, meaning they are rigid and do not deform easily under stress.
High Stiffness
Thermal Properties of Ceramics
- High Melting Point
- Low Thermal Conductivity
- Thermal Expansion
- Thermal Shock Resistance
- Heat Capacity
- Refractoriness
Their materials are made from naturally occurring substances like clay and quartz sand, used for creating items like bricks, tiles, pottery, and tableware.
Traditional Ceramics
It is pottery clay that has not been vitrified (the process by which crystalline silicate components join to form non-crystalline glass compounds) which increases the porousness and coarseness of the pottery. Terracotta, unglazed clay-based pottery, as well as bricks, water pipes, and other materials, are typical forms of ________. Fired at low temperatures
(~____°C).
Earthenware
It is a vitreous or semi-vitreous product that is enameled to give it a glassy appearance and make it nonporous. It’s durable, chip-resistant, and long-lasting which makes it
ideal for cooking, baking, storage, and serving dishes in the kitchen. Fired at high temperatures (____°C - ____°C).
- Stoneware
- 1186 - 1285
Is a relatively heat-resistant and sturdy substance. This is due to the vitrification process and the creation of ________, a silicate mineral when heated. Bathroom and kitchen tiles, containers, ornamental sculptures, and other porcelain are common.
- Porcelain
- Mullite
commonly known as fine china, is translucent porcelain with a high strength and chip resistance. It was created by an English man -Josiah Spode circa 1800 and consists of a mixture of bone ash, feldspathic, and kaolin.
Bone China
also known as high-performance, high-tech, engineering, or technical ceramics, are engineered to have superior properties like strength, toughness, and resistance to high temperatures and harsh conditions, making them suitable for demanding applications.
Advanced Ceramics
Designed for applications requiring high strength, durability, and resistance to wear and heat. These ceramics are widely used in the aerospace and automotive industries.
Structural Ceramics
Specialized materials that can withstand extremely high temperatures and chemical exposure without degrading. These ceramics are critical in industries such as steel manufacturing, glass production, and power generation.
Refractory Ceramics
Possess unique electrical properties such as insulation, conductivity, and piezoelectricity. These ceramics are found in capacitors, telecommunications equipment, automotive sensors, and medical imaging devices.
Elecronics Ceramics
Biocompatible materials used in medical implants and prosthetics due to their stability, durability, and ability to integrate with human tissues. These advanced ceramics play a vital role in modern medicine.
Biomedical Ceramics
Possess unique properties such as magnetism, piezoelectricity, or thermal stability, making them suitable for advanced industrial applications. These ceramics are also found in highperformance machinery, heat exchangers, and industrial cutting tools.
Functional Industrial Ceramics
Types: Kaolinite, ball clay, and fire clay
Role: Provides plasticity, allowing the material to be shaped easily and is essential for forming the ceramic body.
Applications: Used in products like bricks, tiles, and tableware.
Clay Materials
Forms: Quartz sand, sandstone, or flint pebbles.
Role: Acts as an additive to improve the strength of the unfired body, maintain shape during firing, and enhance hardness and durability in the final product.
Applications: Found in whitewares, refractories, and industrial abrasives
Silica (SiO₂)
Role: Helps in glazing and improves durability by providing a stable base for glaze adhesion.
Applications: Used in glazing processes for ceramics.
Limestone (CaCO₃)
Composition: Aluminosilicates containing sodium (Na), potassium (K), or calcium (Ca). Role: Acts as a fluxing agent, reducing the melting temperature of aluminosilicate phases during firing.
Applications: Common in porcelain and other high-temperature ceramics
Feldspar
Alumina Properties: High hardness, excellent wear resistance, good electrical insulation, and thermal stability.
Applications: Used in substrates for electronics, medical implants, ballistic protection, cutting tools, and heat-resistant components
Aluminium Oxide (Al₂O₃)
Zirconia Properties: High crack resistance, low thermal conductivity, and excellent thermal insulation.
Applications: Dental crowns and bridges, oxygen sensors, insulating rings, and decorative parts like watch cases.
Zirconium Oxide (ZrO₂)
Properties: High thermal conductivity, extreme hardness, and chemical resistance
Applications: Abrasives, cutting tools, semiconductor devices, and thermal processing components
Silicon Carbide (SiC)
Properties: Exceptional strength at high temperatures and resistance to thermal shock
Applications: Used in engine parts, bearings, and high-temperature sensors
Sialons
Properties: High thermal shock resistance, low thermal expansion, excellent mechanical strength, and good chemical durability
Applications: Used in cookware, telescope mirrors, heat-resistant windows, & aerospace components
Lithium-Aluminum-Silicate (LAS)
Can produce a range of colors, including blues, greens, reds, and browns, depending on the firing atmosphere.
Copper Oxide (CuO)
Adds a range of colors, from reds and browns to yellows and blacks.
Iron Oxide (Fe2O3)
Creates beautiful blues in glazes.
Cobalt Oxide (CoO)
Produces green colors.
Chromium Oxide (Cr2O3
Used to create purples,
browns, and blacks.
Manganese Oxide (MnO2)
The raw materials are purified, ground, and sometimes chemically processed to achieve the required composition.
Raw Material Preparation
The prepared raw materials are mixed with binders, plasticizers, and additives to enhance workability.
Mixing and Batching
The ceramic material is shaped into the desired form using different techniques:
Forming/Shaping
Used for simple shapes
Dry pressing
Suitable for complex geometries
Injection Molding
Used for producing tubes, pipes, and rods
Extrusion
Liquid ceramic slurry is poured into a mold, allowing water absorption to form a solid structure.
Slip Casting
Used for thin ceramic sheets in electronic applications
Tape Casting
Before firing, the shaped ceramic undergoes a drying process to remove moisture and prevent defects like cracks or warping.
Drying
The dried ceramic is subjected to high temperatures in a kiln or furnace to achieve densification. _____ bonds the ceramic particles together, improving mechanical strength and other properties.
Firing/Sintering
For certain products, where a glass-like coating is applied to improve aesthetics, water resistance, or durability. The glaze is fused to the ceramic during a secondary firing.
Glazing
After sintering, ceramics may require additional processing such as grinding, polishing, or laser cutting to achieve precise dimensions and surface finish.
Machining and Finishing
Finished ceramic products are tested for density, strength, thermal stability, and electrical properties to ensure they meet industry standards before being packaged and shipped.
Quality Control and Packaging
Plates, bowls, mugs, & decorative ceramic items
Pottery and Tableware
toilets, sinks, & bathtubs
Sanitaryware
Construction for walls, floors, and roofing
Bricks and Tiles
Firebricks & furnace linings
Refractory Materials
kitchenware, & decorative items with protective finishes
Glazed and Unglazed Ceramics Products
refers to engineering ceramics. They exhibit superior mechanical properties, corrosion/oxidation resistance, or electrical, optical, and/or magnetic properties. Alumina, Titanium carbide and tungsten carbide are some examples of these.
Advanced Ceramics Materials
Zirconia cutting tools & silicon carbide armor plates
Structural Ceramics
Refractory bricks & ceramic nozzles
Refractory Ceramics
Piezoelectric sensors, ceramic capacitors, & glass-ceramic substrates
Electronics & Electrical Ceramics
Zirconia dental implants & alumina hip replacement
Biomedical Ceramics
Silicon carbide grinding wheels, boron carbide cutting tools,
ceramic heat exchangers, & ceramic membranes
Industrial & Functional Ceramics
Caused by rapid temperature changes leading to fractures.
Thermal Cracks
Small surface imperfections due to trapped gases.
Pitting and Pinholes
Uneven shrinkage during firing leading to misshaped products.
Warping and Distortion
Raised areas on the surface due to trapped air or gases.
Blistering
Fine cracks in the glaze due to differences in thermal expansion.
Crazing
Flaking or peeling of the surface due to thermal or mechanical stress.
Spalling
Swelling of the ceramic body due to trapped gases during firing.
Bloating
White deposits on the surface caused by soluble salts.
Efflorescence
eparation of ceramic layers due to poor bonding or stress.
Delamination
