Ceramic Industry Flashcards

1
Q

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.

A

Ceramic Industries

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2
Q

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.

A

Ceramics

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3
Q

The word ceramics is traced back to the Greek term “_______”, meaning potter’s clay or pottery.

A

Keramos

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4
Q

What are the best-known ceramics?

A
  1. Pottery
  2. Glass
  3. Brick
  4. Porcelain
  5. Cement
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5
Q

Their findings indicate that humans were creating ceramics as early as ________ BCE, with early examples found in southern central Europe as sculpted figures.

A
  1. Ancient Origins
  2. 24,000
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6
Q

Around 10,000 BCE, functional ceramics like pots and bowls emerged, linked to the development of agriculture for food storage and cooking.

A

Neolithic Period

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7
Q

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.

A
  1. Early Civilizations (4000 BCE)
  2. faience
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8
Q

The invention of the potter’s wheel led to smoother, more even pottery production using the _________ technique.

A

The Rise of Pottery (3500 BCE)
2. wheel-forming

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9
Q

Produced in Mesopotamia at the beginning of the Bronze Age, Egyptians started building factories to create glassware for ointments and oils around 1500 BCE.

A

Glazed Pottery

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10
Q

Flourished in various cultures, with examples like Greek terracotta figurines and Roman pottery showcasing both artistic and utilitarian aspects.

A

Ceramic Art (1000 BCE)

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11
Q

Brought advancements in kiln technology and ceramic formulations, leading to stronger and more reliable products.

A

Industrial Revolution (18th–19th century)

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12
Q

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.

A

Technical Ceramics

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13
Q

Ceramics are used in a wide range of applications, from building materials and tableware to advanced technologies like electronics and aerospace.

A

Modern Ceramics

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14
Q

Mechanical Properties of Ceramics

A
  1. High Hardness
  2. Brittleness
  3. High Compressive Strength
  4. Low Ductility
  5. Low Toughness
  6. High Stiffness
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15
Q

Ceramics are extremely hard, making them resistant to scratching and wear.

A

High Hardness

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16
Q

They tend to fracture easily under stress, especially in tension, due to limited plastic deformation.

A

Brittleness

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17
Q

While they are weak in tension, ceramics can withstand very high compressive loads.

A

High Compressive Strength

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18
Q

Ceramics are not ductile and cannot stretch or deform before breaking.

A

Low Ductility

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19
Q

Ceramics have ________, meaning they are prone to cracking under sudden impact.

A

Low Toughness

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20
Q

They have a high Young’s modulus, meaning they are rigid and do not deform easily under stress.

A

High Stiffness

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21
Q

Thermal Properties of Ceramics

A
  1. High Melting Point
  2. Low Thermal Conductivity
  3. Thermal Expansion
  4. Thermal Shock Resistance
  5. Heat Capacity
  6. Refractoriness
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22
Q

Their materials are made from naturally occurring substances like clay and quartz sand, used for creating items like bricks, tiles, pottery, and tableware.

A

Traditional Ceramics

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23
Q

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).

A

Earthenware

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24
Q

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).

A
  1. Stoneware
  2. 1186 - 1285
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25
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.
1. Porcelain 2. Mullite
26
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
27
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
28
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
29
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
30
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
31
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
32
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
33
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
34
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)
35
Role: Helps in glazing and improves durability by providing a stable base for glaze adhesion. Applications: Used in glazing processes for ceramics.
Limestone (CaCO₃)
36
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
37
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)
38
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)
39
Properties: High thermal conductivity, extreme hardness, and chemical resistance Applications: Abrasives, cutting tools, semiconductor devices, and thermal processing components
Silicon Carbide (SiC)
40
Properties: Exceptional strength at high temperatures and resistance to thermal shock Applications: Used in engine parts, bearings, and high-temperature sensors
Sialons
41
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)
42
Can produce a range of colors, including blues, greens, reds, and browns, depending on the firing atmosphere.
Copper Oxide (CuO)
43
Adds a range of colors, from reds and browns to yellows and blacks.
Iron Oxide (Fe2O3)
44
Creates beautiful blues in glazes.
Cobalt Oxide (CoO)
45
Produces green colors.
Chromium Oxide (Cr2O3
46
Used to create purples, browns, and blacks.
Manganese Oxide (MnO2)
47
The raw materials are purified, ground, and sometimes chemically processed to achieve the required composition.
Raw Material Preparation
48
The prepared raw materials are mixed with binders, plasticizers, and additives to enhance workability.
Mixing and Batching
49
The ceramic material is shaped into the desired form using different techniques:
Forming/Shaping
50
Used for simple shapes
Dry pressing
51
Suitable for complex geometries
Injection Molding
52
Used for producing tubes, pipes, and rods
Extrusion
53
Liquid ceramic slurry is poured into a mold, allowing water absorption to form a solid structure.
Slip Casting
54
Used for thin ceramic sheets in electronic applications
Tape Casting
55
Before firing, the shaped ceramic undergoes a drying process to remove moisture and prevent defects like cracks or warping.
Drying
56
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
57
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
58
After sintering, ceramics may require additional processing such as grinding, polishing, or laser cutting to achieve precise dimensions and surface finish.
Machining and Finishing
59
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
60
Plates, bowls, mugs, & decorative ceramic items
Pottery and Tableware
61
toilets, sinks, & bathtubs
Sanitaryware
62
Construction for walls, floors, and roofing
Bricks and Tiles
63
Firebricks & furnace linings
Refractory Materials
64
kitchenware, & decorative items with protective finishes
Glazed and Unglazed Ceramics Products
65
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
66
Zirconia cutting tools & silicon carbide armor plates
Structural Ceramics
67
Refractory bricks & ceramic nozzles
Refractory Ceramics
68
Piezoelectric sensors, ceramic capacitors, & glass-ceramic substrates
Electronics & Electrical Ceramics
69
Zirconia dental implants & alumina hip replacement
Biomedical Ceramics
70
Silicon carbide grinding wheels, boron carbide cutting tools, ceramic heat exchangers, & ceramic membranes
Industrial & Functional Ceramics
71
Caused by rapid temperature changes leading to fractures.
Thermal Cracks
72
Small surface imperfections due to trapped gases.
Pitting and Pinholes
73
Uneven shrinkage during firing leading to misshaped products.
Warping and Distortion
74
Raised areas on the surface due to trapped air or gases.
Blistering
75
Fine cracks in the glaze due to differences in thermal expansion.
Crazing
76
Flaking or peeling of the surface due to thermal or mechanical stress.
Spalling
77
Swelling of the ceramic body due to trapped gases during firing.
Bloating
78
White deposits on the surface caused by soluble salts.
Efflorescence
79
eparation of ceramic layers due to poor bonding or stress.
Delamination