Vetrova V. Gaydaychuk E. Govorova L. Slim casting Vetrova V. Gaydaychuk E. Govorova L.

Plan of presentation Role of ceramic in every day life and in manufacture; Three main forming processes; Production of ceramic manufacture; Main stage of ceramic technology; Slim casting more detail; Our solution of problem in slim casting.

Role of ceramic in every day life and in manufacture Ceramic products used in the production of high precision engineering, in the construction of spacecraft, in the manufacture of electrical appliances and in the many other industries.

Main forming processes Dry pressing Extruding Slip casting

Production of ceramic manufacture Ceramic balls can be used to replace steel in ball bearings. Their higher hardness means that they are much less susceptible to wear and can offer more than triple lifetimes.

Production of ceramic manufacture Ceramic engines are made of lighter materials and do not require a cooling system and hence allow a major weight reduction.

Production of ceramic manufacture Bio-ceramics: hydroxyapatite, the natural mineral component of bone, has been made synthetically from a number of biological and chemical sources and can be formed into ceramic materials.

The technological scheme of manufacture of a ceramic tile Basic phases: 1. Preparation of slip; 2. Forming of products; 3. Drying; 4. Preparation of glaze and browning ; 5. Roasting.

Dry Pressing This is the process used to make almost all ceramic tiles. The reasons behind this preference mainly lie in the technical characteristics attainable on the product, the speed and simplicity of the shaping process and the inexpensiveness of the overall technological cycle.

Extruding This shaping technique is mainly used to manufacture ceramic items with a constant cross-sectional area. The extrusion process generally consists of passing a column of body through a shaped opening, known as the extrusion mouth.

Slip Casting Slip casting involves introducing liquid clay, or ‘slip’, into a mould and then removing it again. That may seem simple, but making properly shaped articles requires in-depth technical knowledge.

Main applications of the three basic techniques dry pressing extruding slip casting Floor tiles + Wall tiles Trims Roof tiles Bricks Sanitary wares Table wares (hollow) (*) Table wares (flat) Refractories Kiln rollers Insulators Technical ceramics Art wares

Slip casting Casting in Plaster Moulds Casting in Polymer Moulds

Casting in Plaster Moulds A plaster mould will only reproduce sharp detail for about fifty casting cycles or so. The ‘slip’, a mixture of finely ground stone and clay with water added to give it a creamy consistency, is poured into the mould from the rim. A percentage of the water is absorbed by the plaster or clay mould itself, thus depositing a layer of clay on the inside.

Pressure Casting in Polymer Moulds Sanitaryware manufacturers are increasingly turning to pressure casting in polymer moulds. Excellent mould life and excellent recovery are two additional benefits – 40,000 casts per mould is not unusual – and A-grade recovery over 95% from cast to boxed has been accomplished in several instances. Yet another advantage of this casting method is that a lower caster skill level is required.

Conclusion Old plant Plaster moulds New plant Polymer moulds

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