Code No. 7763
Ceramics Manufacturing
T - P - C
3 - 6 - 5
AIMS
To provide the student with an opportunity to develop the knowledge and skill to.

Understand basic concept of ceramic manufacturing process.

Understand the production methods of ceramics wares.

Understand the basic concept of ceramic raw materials.

Understand the basic concept of tile.

Understand the basic concept of ceramic glaze.

Understand the basic concept of Firing.
SHORT DESCRIPTION OF THE CONTENTS
Introduction of ceramic; Manufacturing process of ceramic ware; Glaze; Ceramic, body
processing; Porcelain body; Stone ware body; Bone-china body; Sanitary ware; Tile; Ceramic
fabrication; Jiggering; Casting; Firing system; Coloring glaze; Frit.
DETAILED DESCRIPTION THEORY:
1
2
Understand the introduction of ceramics and ceramic raw materials.
1.1
Define ceramic.
1.2
Explain the classification of ceramic.
1.3
Mention the early stages of ceramics.
1.4
Describe the modern stages of ceramics.
1.5
List the Ceramic raw materials.
1.6
Describe the classification of ceramic raw materials.
Understand the basic concept of ceramic wares.
2.1
Define ceramic wares.
2.2
Classify the ceramic wares on structure basis.
2.3
Classify the ceramic wares on ASTM basis.
2.4
Explain vitreous and semi vitreous body.
2.5
Distinguish between vitreous and semi virtuous body.
2.6
Mention the causes of virtuousness and semi virtuousness.
3
4
5
6
7
2.7
List the name of 5 vitreous and 5 semi vitreous bodies.
2.8
Classify the vitreous and semi vitreous products.
Understand the manufacturing process of ceramic ware;.
3.1
Explain the ceramic manufacturing process.
3.2
Describe the different types of manufacturing process.
3.3
Describe the Soft mud process.
3.4
Describe the stiff mud process.
3.5
Describe the Dry press process.
3.6
Describe the Slip casting process.
3.7
Describe the Extrusion process.
Understand the concept of body calculation process.
4.1
Define ceramic body.
4.2
Describe the calculation process of ceramic body.
4.3
Explain the necessity of calculation for ceramic body.
4.4
Describe body preparation by dry and wet process.
4.5
Explain the dry measurement and wet measurement.
4.6
Describe the effect of specific gravity in body calculation.
4.7
Solve the problem on body calculation.
Understand the ceramic body processing.
5.1
Explain processing system of ceramic body.
5.2
Describe water separation process.
5.3
Describe the slip residue determination process.
5.4
Explain blunging and aging of body slip.
Understand the stoneware body.
6.1
Define the stoneware body.
6.2
Describe the characteristics of stone ware body.
6.3
Describe the classification of stone ware body.
6.4
Describe the firing system of stone ware body
Understand the porcelain.
8
7.1
Define porcelain.
7.2
Classify the porcelain.
7.3
Describe the development of porcelain.
7.4
Describe the characteristic of hard porcelain.
7.5
Distinguish between earthenware and porcelain.
7.6
Distinguish between stoneware and porcelain.
Understand drying shrinkage and firing shrinkage.
8.1
Define shrinkage, drying shrinkage and firing shrinkage.
8.2
Determine the drying shrinkage and firing shrinkage of ceramic body and clay
materials by drying method.
8.3
Explain liner and volume shrinkage.
8.4
Describe the relation between linear and volume shrinkage.
8.5
Determine the volume shrinkage by suspended method.
8.6
Explain the necessity of measuring drying and firing shrinkage of ceramic body.
8.7
Describe the relation between moisture content (dry basis) and volume
shrinkage.
8.8
9
10
11
Solve the problems on drying and firing shrinkage.
Understand the water of plasticity.
9.1
Define water of plasticity.
9.2
Determine the water of plasticity of plastic cake.
9.3
Describe the necessity of water of plasticity.
9.4
Explain shrinkage water and pore water.
9.5
Solve the problem on water of plasticity, shrinkage water and pore water.
Understand ceramic Fabrication.
10.1
Define ceramic fabrication.
10.2
Describe the different method of ceramic fabrication.
10.3
Describe the modern stage of ceramic fabrication.
Understand jiggering.
11.1
Explain jiggering process.
11.2
Describe the formation and activities of roller head jiggering machine.
11.3
12
13
14
15
Explain the condition of clay for jiggering.
Understand Casting.
12.1
Explain casting process.
12.2
Describe the classification of casting.
12.3
Describe the properties of casting slip.
12.4
Describe the mixing procedure of casting slip.
Understand the semi dry press process and dry press process.
13.1
Describe the semi dry press process of forming ceramic ware.
13.2
Mention the advantages of semi dry press process.
13.3
Draw the flow sheet of semi dry press process.
13.4
Explain the dry press process of making ceramic ware.
13.5
Describe the hydraulic automatic dry press process of forming ceramic ware.
13.6
Explain the advantages of dry pressing process.
Understand the sanitary wares.
1.1
Define sanitary ware.
1.2
List 10 (ten) sanitary ware products.
1.3
Describe the raw materials and their quality for sanitary wares.
1.4
Mention the composition of sanitary ware.
1.5
Discuss the production method of sanitary ware.
1.6
Describe the drying, glazing and firing of sanitary wares.
1.7
Describe the characteristics of sanitary ware.
1.8
Describe the properties of sanitary ware.
Understand the tiles.
15.1
Define tiles.
15.2
Classify tiles on the basis of uses and water absorption.
15.3
Describe the uses of tile.
15.4
Describe the raw materials of tiles and their quality.
15.5
Mention the composition of tiles.
15.6
Describe the tile forming Method of tile.
15.7
Describe the properties of tiles.
16
17
18
19
20
Understand the bone China.
16.1
Define bone China.
16.2
Describe the main materials of bone China and its quality.
16.3
Describe the characteristics of bone China.
16.4
Mention the composition of bone China body.
16.5
Calculate the batch composition on bone China body from empirical formula.
Understand the manufacturing process of bone China.
17.1
List the name of forming process of bone China ware.
17.2
Describe the difficulties of bone China in firing process.
17.3
Describe the different forming process on bone china products.
17.4
Describe drying and firing procedure of bone china products.
17.5
Describe biscuit firing, glazing and glost firing of bone China products.
Understand the frit.
18.1
Define frit.
18.2
Describe the raw materials of frit.
18.3
Describe the manufacturing process of frit.
18.4
Describe the application of frit.
Understand the glazes.
19.1
Define glaze.
19.2
Describe the antiquity of glaze.
19.3
Describe the purpose of glaze.
19.4
Describe the colour glaze.
19.5
Describe the advantage and disadvantage of glaze.
Understand the glaze calculation.
20.1
Define molecular formula or seger formula.
20.2
Describe the calculating process of molecular formula from batch
composition.
20.3
Describe the calculating process of batch composition from molecular
formula.
20.4
21
22
23
24
25
Discuss and solve the problems of chemical composition of glaze.
Understand the different types of glaze.
21.1
Describe the classification of glaze.
21.2
Describe soft glaze.
21.3
Describe hard glaze.
21.4
Describe medium glaze.
21.5
Describe the opaque glaze.
21.6
Describe the transparent glaze.
21.7
Describe the translucent glaze.
Understand the type of kiln.
22.1
Explain kiln and furnace.
22.2
Classify the kiln on different factor.
22.3
Describe the brief history of kiln.
22.4
Describe the innovation of kiln from old age to today.
Understand the saggar and kiln furniture.
23.1
List the names of 10-kiln furniture.
23.2
Describe the characteristic of saggar and kiln furniture.
23.3
Describe the shaping, drying and firing of kiln furniture.
23.4
Describe the advantages of saggar.
23.5
Explain the composition of saggar and kiln furniture.
Understand the concept of firing.
24.1
Define firing.
24.2
Describe the different types of firing process.
24.3
Explain the necessity of finishing for ceramic ware.
Understand the basic theory of firing.
25.1
Define radiation of heat.
26
25.2
Explain the theory of radiation.
25.3
Describe the flow of heat in down draft kiln without baffle wall.
25.4
Describe the flow of heat in down draft kiln with baffle wall.
25.5
Describe biscuit, glost and decoration firing.
25.6
Describe the method of gas firing of shuttle kiln.
Understand the oxidation & reduction firing and their controlling system.
26.1
Define oxidation and reduction firing.
26.2
Describe the controlling system of oxidation firing of shuttle kiln and tunnel kiln.
26.3
Describe oxidation firing.
26.4
Mention the theory of reduction firing.
26.5
Describe how to control of reduction/Oxidation firing in shuttle kiln and tunnel
kiln.
26.6
27
28
29
Describe the advantages and disadvantages of reduction firing.
Understand the biscuit firing and its controlling system.
27.1
Define biscuit firing.
27.2
Describe the necessity of biscuit firing.
27.3
Describe the controlling system of biscuit firing in down draft kiln and tunnel kiln.
27.4
Discuss the firing range of different types of body.
Understand the glost firing and its controlling system.
28.1
Define glost firing.
28.2
Describe the glost firing controlling system in a down draft kiln and a tunnel kiln.
28.3
Describe the physical and chemical changes in glost firing.
28.4
Describe the planning of the ware in kiln.
Understand the Decoration firing and its controlling system.
29.1
Define Decoration firing.
29.2
Describe the necessity of Decoration firing.
29.3
Describe the controlling system of Decoration firing in down draft kiln and tunnel
kiln.
29.4
Discuss the Decoration firing range of different types of body.
30
Understand the porosity.
30.1
Define porosity, apparent porosity, true porosity, apparent volume and true
volume.
31
30.2
Determine the apparent porosity by suspended method.
30.3
Describe the effect of porosity on fired body.
30.4
Prove that percentage of porosity = (1-Da/Dt)  100
30.5
Solve the problem on porosity.
Understand the defects in the firing process.
31.1
Describe the defects due to firing temperature.
31.2
Describe the defects due to firing speed.
31.3
Explain the defects due to firing atmosphere.
31.4
Describe the defects due to loading work.
31.5
Describe the defects due to rough handling.
Practical :
1.
Demonstrate skill in ceramic Body preparation.
2.
Demonstrate skill in slip preparation.
3.
Determine the viscosity of slip.
4.
Determine the Density of slip.
5.
Demonstrate skill in ceramics ware making in casting process.
6.
Demonstrate skill in ceramic ware making in jiggering process.
7.
Demonstrate skill in ceramic ware biscuit firing process.
8.
Demonstrate skill in determination of ceramic ware glost firing.
9.
Demonstrate skill in making bone china products.
10.
Demonstrate skill in making sanitary ware.
11.
Demonstrate skill in making tile.
12.
Demonstrate skill in ceramics glazes preparation.
13.
Show skill to find the linear drying and firing shrinkage.
14.
Show skill to find the porosity of fired ceramic body.
Reference book:
1.
Ceramic vol I. II & III –by Mac Nannere.
2.
Ceramic Hand book –by Robison J.M.
3.
Ceramic Technology and processing –by king Alam G.
4.
Ceramic processing-by Terpstea RA.
5.
Industrial ceramics –by Singer.