DCP 2143 CERAMIC MATERIAL: NON-CLAY

1. DCP 2143 CERAMIC MATERIAL: NON-CLAY • CODE: DCP 2143 • COURSEWORK: 60% • TEST 1 : 15% • TEST 2 : 15% • LAB : 30% • FINAL EXAM : 40%

2. SCOPE OF SUBJECT UNIT 1.0 Introduction to Non-Clay Materials - what is non-clay material - function of non-clay material UNIT 2.0 Feldspar – mineralogy, properties, application, type of feldspar (plagioclase,orthoclase,nephelinesyenite) UNIT 3.0 SILICA - mineralogy, properties, application,type of silica group, - quartz,tridymite, cristobalite UNIT 4.0 OTHERS NON-CLAY MATERIALS - talc, bauxite,dolomite,limestone,magnesite ,bone ash, wollastonite UNIT 5.0 GPYSUM - chemical, type and characteristics of plaster, consistency , setting time, water/plaster ratio, UNIT 6.0 ADVANCED CERAMIC MATERIALS - alumina, zirconia, silicon carbide, silicon nitride and others UNIT 7.0 OTHERS COMPONENT RAW MATERIALS - binder,deflocculant, pigment

3. INTRODUCTION • This subject provides strong theoretical overview on understanding and fundamental of non-clay ceramic materials, its properties and characteristics incorporating laboratory and hand-on work on the behavior and characteristics of some of the materials. • The subject present basic theories and hands-on facts concerning such non-clay materials like feldspar, silica, alumina, talc, dolomite, zirconia, plaster of paris and etc. with respect to their uses ceramics science and technology

4. LEARNING OBJECTIVES • Explain the function of non-clay materials for ceramic applications • To provide the students with the fundamental and hands-on knowledge on usage of non-clay material for ceramic manufacturing process • Explain the characteristics and identification of non-clay material

5. UNIT 1 INTRODUCTION TO NON-PLASTIC MATERIALS

6. LEARNING OUTCOMES • At the end of the lesson, student should be able to: • Explain the definition of non-clay materials • Explain the function of fluxes • Explain the function of fillers • List raw materials of non-clay materials

7. COMPOSITION OF COMMON CERAMIC BODIES

8. COMPOSITION OF COMMON CERAMIC BODIES

9. INTRODUCTION TO NON-PLASTIC MATERIALS • What is non-plastic or non-clay materials? • This group of ceramic materials involves rocks, minerals and artificial or synthetic minerals that when mixed with water does not exhibit plasticity.

10. ROLES OF NON-PLASTIC MATERIALS • Non-clay materials provide the desired influence on the green and fired properties of ceramics. • Some non-clay materials do not need to be mixed with clay to form ceramics; examples are alumina, zirconia, etc. • A part of non-clay acts as: • >fillersin the ceramic body, • > some act asfluxes • > improve the refractoriness of the body. • > some non-clay materials are also used as • coloring substances. • .

11. ROLE OF NON-PLASTIC MATERIALS: FLUXES What are Fluxes ? • A flux is substance that lowers the melting or softening temperature of the mix or compound in which it is present • In ceramics it is used to lower the temperature at which liquid form during firing. This liquid when cooled formed glass that bind the grains of the body together. • Therefore by adding flux stronger body or product can be formed at lower firing temperature. • For example most ceramic such as porcelain can be fired between 1100-1300 oC by adding feldspar.

12. Fluxing effect in microstructure of ceramic Grains in ceramic before formation of glass Formation of glass phase: individual grains fused together

13. REACTIONS OCCURING DURING FIRING IN CERAMIC BODY

14. PROPERTIES OF FLUXING MATERIAL Fluxes are usually made up of: • Alkali or alkali earth containing minerals which melt on firing and react with other body constituents to form glass. • Fluxing oxides such as those of the RO group like K2O, Na2O, CaO, Li2O, MgO, B2O3. • The higher the alkali content of the material the more effective the fluxing action.

15. Others the important criteria of flux : • Impurity: • Fe2O3 contents will give color to the flux • The particle size: • The smaller the particle size the more effective the fluxing action.

16. Example of common flux used in ceramics: • feldpars, • cornish stones, • nephelinesynite, • sericitic stones

17. ROLE OF NON-PLASTIC MATERIALS: FILLERS Fillers are non-plastic materials used in body composition which are not fluxes. Example • Silica, • Alumina • Calcium carbonate • Etc…….

18. The functions of filler are: • > Ceramic bodies • to open up the body/ framework/structure of ceramic body • to facilitate drying process • reduce shrinkage and • reduce plasticity. • Fillers contribute a significant proportion of body composition, therefore particle size distribution is important in determining particle packing in the body. • Example: silica, alumina, grog, flint, etc.

19. The functions of filler are: • > Paints, plastic, rubber • Good dispersability, • High chemical inert • pH stability • High resistance to abrasion • Low viscosity at high filler loading. • Example: felsdpar, calcium carbonate

20. REVIEW…. WHAT IS THE NON-PLASTIC MATERIALS ? GIVE EXAMPLE OF FLUX AND FILLER MATERIALS ? WHAT IS THE FUNCTION OF FLUXING MATERIALS IN CERAMIC BODIES ? WHAT IS THE FUNCTION OF FILLER ?

21. Kualitidiriseseorangbisadiukurdarikemampuannyamenjagalidah. Orang-orangberimantentuakanberhati-hatidalammenggunakanlidahnya. "Wahaiorang-orangberimantakutlah kalian pada Allah danberkatalahdengankata-kata yang benar." (QS Al-Ahzab:70).Sementaraitu, Rasulullah saw bersabda, "Siapa yang berimanpada Allah danhariakhir, makahendaklahdiaberkatabaikataudiam". (HR Bukhari-Muslim).