CERAMIC

Group members• NAME:

1. Lee Jian Ru 0318132

2. Darren Loong Chi Yoong 0318029

3. Chong Kai Xiang 0322935

4. Kiing Kiu Chun 0318727

5. Hiew Li Ming 0319941

6. Hong Kai Yin 0323361

7. Chee Wei Shan 0319572

8. Michelle Lee Ern Hui 0319703

9. Lily Then 0313973

10. Lau Chin Sheng 0317899

11. Willliam Goh Ming Hann 0317949

History of Ceramics

-Ceramics that date back to at least 24,000 BC. Flourished

in Upper Egypt about 8,000 BC.

- In the Middle Ages, when the metal industry was in its

infancy. The industrial revolution was born, when synthetic

materials with better resistance to high temperatures

(called refractories) were developed in the 16th century.

These refractories created the necessary conditions for

melting metals and glass on an industrial scale, as well as

for the manufacture of coke, cement, chemicals, and

ceramics.

History of Ceramics (CONT’)

• -Another major development occurred in the second half

of the 19th century, when ceramic materials for electrical

insulation were developed. As other inventions came on

the scene-including automobiles, radios, televisions,

computers-ceramic and glass materials were needed to

help these become a reality, as shown in the following

timeline.

Ceramics: Composition of Clay

-main compositions are feldspar group of minerals

comprise around 60% of the earth's crust. They are

aluminium silicates, also incorporating alkali and/or alkaline

earth metals.

Ceramics: Composition of Clay(CONT’)

-Clays are divided to two types:

1) Primary clay:

-usually found in the same place as the feldspar from which

it originated

-is relatively rare and has particular properties with which

potters must work.(pure materials)

-earthen clay (the kind from the ground, which is often

glazed/sealed and "fired" in a kiln with very high heat after

air-drying)(less plastic)

-absorbs more water compared to the secondary type of

clay.

Ceramics: Composition of

Clay(CONT’)2) Secondary clay:

-have been transported by wind, water or both from their places of formation.

-are far more abundant and tend to be easier to form and fire.

-Polymer clay is oil-based (not water-based and "air-dry" like most other "clays") so it has no water to lose and can't "dry" out and is pretty impervious to water.(Higher plasticity)

- is pretty impervious to water.

- absorbed water and/or drying won't hurt the clay though or make it less strong.

Manufacturing Process of

Ceramics

Types of Moulding

• Injection moulding- Optimal process for manufacturing large series of relatively

small components. By mixing ceramic powder and suitable

binder systems it is possible to injection mould ceramic

components. The polymer binder is burned off in a separate

burn off stage before sintering.

Types of Moulding (cont’)

Types of Moulding (cont’)• Isostatic pressing

- Ceramic powder is fed into a

moulding bag inside an isostatic

press.

- The press is sealed and the

isostatic pressure is increased.

Types of Moulding (cont’)

- The powder compacts and

forms a solid in the form of the

moulding bag. The pressure is

released and the press can be

open to remove the formed

ceramic component.

Characteristics

• Bending Resistance

• High Hardness

• High degree resistance to moisture

• Resistance to impact and abrasion

• Excellent resistance to chemical attack

Characteristics (cont’)

• Temperature up to 2400 °C

• Can be design to various type of pattern

• Can be painted to various type of colors

• Roofing tiles contains more than 30% water which have

considerable drying contraction

• Wall and floor tiles contain 2-5% water have greater

accuracy in shape and size

Characteristics (cont’)

• All floor tiles can be used on walls and others surface but

not all wall tiles can be used on floors

• Installed in Portland cement setting bed or special epoxy

adhesives

• Rarely accurate in shape and size

• Most advanced ceramic materials are combination of

ceramics and others materials known as Ceramic Matrix

Composites

Advantages of Ceramic

• Durable

• -extremely hard.

• -last 10-20 years and longer.

• -handle extremes of heat and cold very well.

• Easy to clean

• -stain resistant.

• -hygienic, not absorb liquids, does not retain the residues and

smells of chemicals, foods or beverages.

• -simply vacuum and use damp mop.

• Design options

• -modern manufacturing techniques allow ceramic producers to

make materials which can be printed in numerous ways.

Advantages of Ceramic (cont’)

• Cost

-relatively inexpensive, cheaper than hard wood, carpet.

- Once you absorb the initial cost of tile you don’t have to

spend money on it again for the life of the product if it is

installed properly.

• Can be installed in nearly any application

-on floors, walls, in showers, backsplashes, ceilings

-countertops, table tops, fireplaces, columns and more

-water resistance, can be installed in wet environment.

• High scratch resistance

• Resistance to burns

Advantages of Ceramic (cont’)

• Resistance to fading

-not fade due to sunlight and electrical light.

• Environmental friendly

-100% natural materials.

Disadvantages of Ceramic

• Temperature

-Ceramic is cold when used as flooring and can be quite

uncomfortable during cold climate.

-density of ceramic.

-during hot climate, warm ceramic tile takes a long time

to cool.

• Ceramic installation

-intensive installation, hard and heavy and they need to

be

installed using a variety of mortars, grouts, and tools.

-higher labor cost.

Disadvantages of Ceramic

• Ceramic Tile Weight

-Ceramics are quite heavy, which means that they may not

always be appropriate for upper story installations.

• Hard Flooring

-difficult and uncomfortable to stand on.

-Unlike resilient floors, hard tile ceramics cannot be softened

using padded underlayments.

-not suitable at environments where people will be forced

to stand for long periods of time.

Properties of Ceramics

• Ceramics are best known as brittle solids particularly

suited for withstanding high temperatures but, in fact, the

different materials used in ceramics can gives them a

wide range of properties.

• The classic properties of ceramics include durability,

strength and brittleness, high electrical and thermal

resistance, and an ability to withstand the damaging

effects of acids, oxygen, and other chemicals because of

their chemical unreactive.

Properties of Ceramics (cont’)

• But not all ceramics behave in this way. For example,

graphite is a very soft ceramic and conducts electricity

well, whereas diamond is a very good good conductor of

heat.

• Ceramics called ferrites are particularly good conductors

of electricity and superconductors have almost no

electrical resistance at all.

General properties of ceramics

• Hard• Wear – resistant• Brittle • Refractory• Thermal insulators• Electrical insulators • Nonmagnetic• Oxidation resistant• Prone to thermal shock• Chemically stable

Daily Uses of Ceramics

• Bowls and plates

• Accessories or ornament for clothing

• Housing : floor tiles, bricks, roof tiles and so much more

TYPES OF CERAMIC

1. Terracotta

2. Stoneware

3. Fireclay

4. Earthware

5. Roofing

6. Porcelain

7. Vitreous China

TYPES OF CERAMIC

• 1. Terracotta

•This is a type of earthenware, is a clay-based unglazed or

glazed ceramic, where the fired body is porous.

•Uses include flower pots, water and waste water pipes,

bricks, and surface embellishment in building construction.

•Natural, brownish orange colour.

TYPES OF CERAMIC

• Faience : a glazed form of terracotta or stoneware

• Fired to the biscuit condition and then glazed before

refiring

• Alternatively, unfired faience may be glazed and ‘once

fired’

• Once fired : a process which improves resistance to

crazing of the glaze while reducing the range of colour

• When water can penetrate, crystallization of salts and

frost action will cause failure, thus faience with low water

absorption is preferable as it is resistant to frost.

1. Terracotta

TYPES OF CERAMIC

• 1. Terracotta

Uses of Terracotta :

• Easy to clean

• Crazing of inferior products collect grime

• Suitable for in–ground use to carry

pressurized water

• Garden ware

• Oil containers

• Ovens

• Building decorations in tropical environments

or in freezing environment ( need to be glazed

)

TYPES OF CERAMIC

• 1. Terracotta

Disadvantages of Terracotta :

• Expensive : it is rather costly when compared to the other

tiles useful for construction reasons.

• Sensitive : fragility, not suitable to receive heavy knocks

• Loss of colour : within the passage of time, these types of

tiles often fade and lose its original deep colour

TYPES OF CERAMIC

2. STONEWARE

1. Stoneware is a vitreous (glass) or semi-

vitreous ceramic made primarily from stoneware clay or

non-refractory fire clay.

2. Stoneware is fired at high temperatures and it is

nonporous.

TYPES OF CERAMIC

• 1. STONEWARE

Composition :

Stoneware is made up of 3 major component, which is clays, fluxes and fillers.

Clay:

- The basic clays found in stoneware clay body formulas are high-

temperature refractory clays. Each group of clays provides specific attributes to the

total clay body formula, including fired strength, shrinkage and plasticity.

Fillers:

- Fillers reduce clay body shrinkage and warping in the drying and firing

stages. If the amount of filler is too high, the clay body's plastic qualities will be

decreased.

TYPES OF CERAMIC

• Fluxes:

Fluxes help lower the melting point of heat-

resistant clays and fillers and increase the glass

formation in a clay body. Using the wrong flux or

an incorrect amount can have disastrous

consequences.

1. STONEWARE Composition :

TYPES OF CERAMIC

• 1. STONEWARE

FUNCTION :

• Artware

• Chemical ware

• Cookware

• Drainpipe

• Kitchenware

• Tableware

• Tile

TYPES OF CERAMICManufacturing process

of stoneware pipes1. STONEWARE

TYPES OF CERAMIC

2. Fireclay

1. Fireclay is a type of clay that is able to withstand

intense heat.

2. It is suitable for making articles which will not melt, nor

even perceptibly soften when exposed to a high

temperature.

TYPES OF CERAMIC

• 2. Fireclay

Composition :

Fireclay consists alumina and silica.

Alumina:It is also named alumminium oxide. It has high thermal conductivity and good

electrical insulator which makes it suitable for making ceramics.

Silica:It is also named silicon dioxide. It is a major constituent of sand. It has high

thermal stability and is a good electrical insulator, same as alumina.

TYPES OF CERAMIC

• 2. Fireclay

FUNCTION :

• Sink

• Bathtub

• Tiles

• Crucible

• Firebricks

TYPES OF CERAMIC

• 2. Fireclay

Manufacture process of fireclay

TYPES OF CERAMIC

3. Earthenware

• Earthenware is also called low fired clay because it is normally matured

at low temperature

• Finer than stoneware

• Porosity, high water absorbtion of 5-8%

• Must be glazed to prevent water absorbtion

• small cracks in glaze is permeable to water

• Less suitable for sanitary ware compared to vitreous china

• Not translucent and are more easily to chipped, less strong than

stoneware

• There are two main types of glazed earthenware:

1 ) creamware 2) tin-glazed

TYPES OF CERAMIC

• Roofing

• Low water absorbtion

• High slip resistant

• This allows rainwater to flow downwards without leaking between tiles

• Durable chemical and frost resistance

• protects you from water during the rain, heat in summer and cold in winter

• last for about 400 years without losing its beauty and effectiveness

• Come in traditional red, brown or antique which are unglazed with a plain

finish

TYPES OF CERAMIC

• Porcelain

• A special type of clay either white or grey, to which kaolin (a

white firing stiff clay) and white China stone (finely decayed

granite, washed and prepared as small white blocks) is

added.

• Primary components - clays, feldspar or flint and silica

TYPES OF CERAMIC

• Porcelain

Manufacture process of Procelain :

1. Crushed using jaw crushers, hammer mills, and ball mills.

2. Cleaning to remove improperly sized materials

3. The mixture is subjected to one of four forming process —soft plastic

forming, stiff plastic forming, pressing, or casting—depending on the type of

ware being produced.

4. The ware then undergoes a preliminary firing step, bisque-firing.

TYPES OF CERAMIC

• Vitreous China

• Mixture of clay, feldspar and quartz which is molded, glazed

and "baked" at extremely high temperatures

• material which is strong, nonporous and impervious to

absorption.

TYPES OF CERAMIC

• Vitreous China

The word “vitreous” means “glass-like,”

glaze makes ordinary ceramics look shiny and

reflective while maintaining & strengthening their

durability.

The glaze itself is usually made of composite minerals

and powdered glass.1. It is typically sold as a powder that artisans and manufacturers must

melt down, in a kiln or specialized oven, before using.

2. Once the glaze has reached its melting point it can be painted, or

“glazed,” onto the surface of the ceramic piece.

3. The enamel must usually be left to dry for a time, then the piece re-

fired to seal the coating.

4. Past this point, the item can usually be itself described as “vitreous

china.”

TYPES OF CERAMIC

• Similarities :

• Vitreous China

• Substances formed by firing clay and other

minerals at high temperature

• Have extremely low porosity

• Can be glazed and unglazed

TYPES OF CERAMIC

Porcelain Vitreous china

is fired, 1,454 degrees

Celsius

is fired, 1,204 degrees

Celsius

Has great hardness known as soft-paste or

tender porcelain, is softer

translucent opaque

Vitreous China

Differences :

TYPES OF PRODUCTION

• 3 Types of ceramic based on production processes:

a) Glazed

b) Mosaic

c) Quarry

TYPES OF PRODUCTION

• GLAZED TILES

• used for interior and exterior

• produced in modular size with matching trim piece for

comers, wall bases and nosing

• heavier coat glazing for floor tiles than wall tiles

TYPES OF PRODUCTION

• GLAZED TILES

ADVANTAGES OF GLAZED TILES FOR FLOORING :

• extremely strong

• easy to clean and maintain being stain free, acid and alkali resistant

• has a very high abrasion resistant

• does not attract dust

• bacteria free

• good insulators

• fire proof

• easy to lay and ready for live in use in a matter of 48 hours after laying

• available in many shades

• anti slip unlike white glaze tiles ceramic floor tiles are salt and are slip

and non skid

TYPES OF PRODUCTION

• GLAZED TILES

DISADVANTAGES OF GLAZED TILES FOR FLOORING :

• high cost

TYPES OF PRODUCTION

• GLAZED TILES

ADVANTAGES OF GLAZED TILES FOR ROOFING :

• create distinctive style on home or building

• fire safety

• non-combustible

• maintain color permanence

• durability

• unique resistance to the elements of Nature

TYPES OF PRODUCTION

• GLAZED TILES

DISADVANTAGES OF GLAZED TILES FOR ROOFING :• unsuitability for climates with fluctuating weather

• prone to erosion under these conditions

• while the tiles are durable, they are also fragile

• can be damage by high wind

TYPES OF PRODUCTION

• MOSAIC TILES

Mosaic is the art of creating images with an assemblage of

small pieces of coloured glass, stone, or other materials. It is a

technique of decorative art or interior decoration. Most mosaics

are made of small, flat, roughly square, pieces of stone or glass

of different colours, known as tesserae; but some, especially

floor mosaics, may also be made of small rounded pieces of

stone, and called "pebble mosaics".

TYPES OF PRODUCTION

• MOSAIC TILES

CHARACTERISTICS :

• Used for exterior and interior.

• Produced in modular size with matching piece for corners, wall

bases and nosing.

• Heavier coat glazing for floor tiles than wall tiles.

• Made in small sizes for composing intricate patterns for use in mural

on floors and walls.

• Smoother, brighter and more impervious than glazed tiles.

• Glazed or unglazed.

TYPES OF PRODUCTION

• MOSAIC TILES

ADVANTAGES :

• Hard wearing

• Frost proof

• Resistant to chemical

• Unglazed mosaic used for wet area eg: swimming pools

• Good slip resistance

TYPES OF PRODUCTION

• MOSAIC TILES

Mosaic tiles muralUnglazed Mosaic tiles for

swimming pools

TYPES OF PRODUCTION

• Quarry

-Made of shales and fine clays.

- A type of unglazed tile.

-The bottom side of a quarry tile is ridged to encourage adhesion to

grout.

-The top of the tile has a coarse surface because it is not glazed .

- This surface encourages traction, which can be very useful in

environments like pathways and kitchens.

TYPES OF PRODUCTION

Quarry tiles

Indoor Outdoor

TYPES OF PRODUCTION

• Quarry tiles

outdoor

Garden Step-tiled

TYPES OF PRODUCTION

• Quarry tiles

Indoor

Kitchen Toilet

Quarry Tile

Advantages Disadvantages

1)Slip –resisting 1) easy being

2)Inexpensive stained

(does not require glaze) (no glaze,

3)Durable liquid

penetrates

easily)

2) mold and

fungus occurs

Quarry tiles