Course Details
Subject {L-T-P / C} : CR3404 : Whiteware Technology { 3-0-0 / 3}
Subject Nature : Theory
Coordinator : Prof. Santanu Bhattacharyya
Syllabus
Module 1 Introduction to the course
Pottery and Whiteware- the oldest technology of human mankind. Classification of pottery- porous pottery and dense pottery- common pottery, majolica, earthenware. Classification based on raw materials.Classification of dense pottery- delft, faience, vitreous china, soft porcelain. Difference between pottery and whiteware. Explanation on the development of different triaxial bodies and their characteristics using triaxial diagram of clay-quartz-feldspar. 5Contact Hours
Module 2 Review of Processing and compositions with respect to whiteware bodies
Primary raw materials – clay, quartz, feldspar and their roles in body formulation. Flux, Fillers and Auxiliary fluxes. Recognizing the role of water in Whiteware processing. Critical issues in the porcelain processing- a brief review of dry and wet processing routes. Theory of plasticity- stretched membrane theoryContact Hours
Module 3 Particle charging, colloidal stability and wet processing of whiteware
Origin of particle charge in clay- card house structure and flocculation-deflocculation. Particle characteristics and effect on Slip rheology. Particle size distribution and cohesive strength of triaxial body mix- Filter pressing, pugging, de-airing pugging and plastic body preparation. Particle size and size distribution decides the mix cohesiveness and thus the optimum plastic shaping routes-Ram press, Roller head,-automated jigger and jolley. 6Contact Hours
Module 4Triaxial Porcelain- Reactions at high temperature and phase formation Raw material parameters and process parameters effect on high temperature phase formation in clay-quartz-feldspar triaxial body. Liquid phase formation, viscoelastic deformation and viscous phase sintering. Effect of time, temperature, heating rate, raw materials characteristics and atmosphere on maturing of triaxial porcelain. Mullite phase formation and strengthening of porcelain. Translucency and strengthening of porcelain 7 Contact Hours
Module 5 Bone China –Processing, phase evolution and properties
Bone China – origin, phases and developments in bone china processing. Bone ash/clay ratio and phase formation sequence. Heating rate, and distortion of bone china body. Translucency and strength of bone china body 8 Contact Hours
Module 6 Ceramic Tiles
Classification and gradation of ceramic tiles on the basis of porosity, application and number of defects present on tile surface. Classical tiles and fast fired tiles - why fast firing required composition change? Special effect tiles. Vitreous tiles, glazed porcelain tiles, unglazed porcelain tiles. 8 contact hours
Module 7 Sanitaryware casting
What are sanitaryware? Sanitaryware market and prospect in India. Key characteristics of ceramic sanitarywares. Vitreous china sanitaryware, fireclay sanitaryware. POP mould preparation and mould properties. Testing of sanitaryware. Sanitaryware manufacturing process – bench casting, battery casting, high pressure casting machine.
Flow chart of sanitary slip production- virgin slip, run off slip, scrap slip. Casting rate control- slip rheology control. Stages of HPC of sanitaryware. Sanitaryware defects- casting defect, slip rheology defect, defect due to mould.8Contact Hours
Module 8 Glazing of whiteware
Need for glaze- types of glaze- raw and fritted glaze, fritting rules, glaze receipe. Scattering of light and glaze opacity. Gloss and reflectance of glaze. Types of glaze- glossy, matt, satin glaze. Special effect glaze- crackle glaze, crystalline glaze, aventurine glaze. Glaze-body interaction and glaze stability. Colours in glaze- solution colour, precipitation from glaze batch on cooling- opacifiers, colours through colour pigments, unusual colour effect. Glaze decoration- under glaze, over glaze, on glaze.
Course Objectives
- To provide an in-depth understanding of the science of Whiteware technology and Fabrication
- To correlate end use properties with available raw materials characteristics and to design appropriate processing method for whiteware body fabrication intended for specific uses.
- To correlate microstructure, raw materials and the processing to minimize processing related defects and rejection of shaped body and to think of innovative eco-friendly processing and shaping technologies.
- To utilize the above knowledge to design, develop and upgrade products for different commercial applications.
Course Outcomes
CO1: To be well versed about different aspects of whiteware processing routes and to use them to fabricate different commercial whiteware products for different applications. <br />CO2: To understand the importance of processing science with raw materials characteristics to the developed whiteware product. <br />CO3: To be able to decide the optimum processing for a whiteware product on the basis of available inputs, raw materials and existing processing capabilities. <br />CO4: To be able to do analysis of defective and rejected components to ascertain the root cause of defective products and to modify the existing process or to suggest and upgraded process to minimize defective products
Essential Reading
- W Ryan and C Radford, Whitewares: Production, Properties and Quality Control,, Pergamon Press, Oxford, 1987
- F H Norton, Fine Ceramics, McGraw Hill, 1970
Supplementary Reading
- R. A. Eppler and M. Obstler, Understanding Glazes, The American Ceramic Society
- Digitalfire, Website of Digitalfire, https:/digitalfire.com
Journal and Conferences
- Y Iqbal and W Lee, Microstructural Evolution in Triaxial Porcelain J Am Ceram Soc 2000
- Porcelain- Raw Materials, Processing, Phase Evolution by William Carty and Udayan Senapati JACS- 10.1111/j.1151.2916.1998.tb02290.x