Syllabus

Module 1 Introduction to the course
Introduction Ceramic Fabrication Science and the importance of studying the course correlating ceramic raw materials- their processing and size reduction, structure and properties How intrinsic properties of materials influences the extrinsic properties vis-a-vis the application. Importance of different processing steps- viz. comminution, size classification and distribution. Different comminution processes, laws, comminution efficiency, particle size and size distribution. How comminution process affects powder characteristics vis-à-vis the property and microstructural evolution. Processing – microstructure-property- end applications correlation. A brief overview of some advanced comminution/powder preparation technology- compression, impact and shear-cum- compression milling, 6 Contact Hours

Module 2 Powder Synthesis by solid state and liquid precursor routes
Decomposition Routes- mechanism, kinetics, Compound Formation- spinel formation and kinetics, Precipitation route- principle of homogneous and heterogeneous precipitation, powders with uniform particle size, coated powders, powder synthesis by liquid evaporation routes- spray drying, spray pyrolysis, freeze drying. Hydrothermal synthesis. Advanced powder preparation techniques – mechano-chemical synthesis, Gel route- Pechini process, combustion synthesis 5 Contact Hours

Module 3 Particle size, porosity and pore size
A brief discussion on particle size distribution models. Continuous particle size determination by sedimentation method- layer technique and homogeneous technique. Coulter counter and laser scattering technique. Specific surface area measurement by BET adsorption, pore size determination by gas adsorption method and mercury porosimetry methods 5 Contact Hours

Module 4 Packing of powders and consistency states

Ceramic fabrication and particle packing. Random packing of powders. One and two component particle packing. McGeary packing theory- binary and ternary packing. Furnas packing diagram, packing of continuous particle size- Andreasen model, Dinger-Funk model
Different consistency states of powder- bulky, granular, plastic, paste and slurry. The significance of each consistency states on ceramic processing and fabrication. Effect of particle-particle interaction, additives, binder, deflocculant on changes in the powder consistency state 5 Contact Hours

Module 5 Ceramic Fabrication Techniques
Ceramic forming and process reliability. Correlating consistency states and ceramic fabrication process. Shape forming of dry and semi-dry powder mixture. Uniaxial dry pressing and compaction stages. Additives and binders. Effect of RH on compaction and pore removal. Pressure gradient in uniaxial pressing. Pressing defects in uniaxial pressing. Isostatic pressing – dry and wet bag isostatic pressing. Problems in isostatic pressing- a brief review of tape casting, extrusion and injection moulding.
5 Contact Hours

Module 6 Particle charging, colloidal stability and rheology of ceramic slurries
Origin of particle charge in ceramic oxides, Stern double layer and diffuse double layer theory, flocculation and deflocculation, iso-electric point, zeta potential and significance of zeta potential in colloidal stability. Non-newtonian behaviour of ceramic slurries. Einstein equation, Doherty-Kreiger equation, solid loading and no-flow condition. Effect of particle size distribution on flow behaviour of concentrated ceramic slurries. 5 contact hours

Module 7 Filtration of slurry and slip casting
Filtration mechanism through a porous filter bed. Karmen- Cozeny equation. Filtration rate equation. Slip parameters affecting filtration. Relation between filtration and slip casting. Slip casting mechanism. Slip parameters affecting slip casting of slurries. Slip casting mechanism of triaxial porcelain and that of a deflocculated alumina slurry. Mould properties and slip casting rate. Good slip and poor slip properties – particle size distribution and slip casting behaviour. Tape casting- mechanism, slip preparation, casting specialities. 5 Contact Hours.

Module 8 Drying of green shapes- science and technology
The drying process, Drying systems, Drying mechanisms and mass transport and drying rate equation- influence of green body microstructure on drying technologies- adiabatic drying, humidity controlled drying, super- heated steam drying, Drying process, Drying shrinkage, defects and their prevention- maximum safe drying rate on the basis of green body microstructure. 4 Contact hours

To provide an in-depth understanding of the comminution process and ceramic fabrication process

To correlate material properties with powder and particle characteristics and to design appropriate processing method for ceramic fabrication for a specific use.

To correlate microstructure and the processing-fabrication related defects leading to defects, and rejection of shaped body.

To utilize the above knowledge to design, develop and upgrade products for different commercial and strategic applications.

CO1: To be well versed about different aspects of science and technology of ceramic comminution and abrication and processing routes and to use them to fabricate ceramic products for different applications.
CO2: To understand the importance of ceramic powder science as well as fabrication technology and to correlate the powder characteristics to the developed ceramic product.
CO3: To be able to decide the optimum fabrication technique for a ceramic product on the basis of available inputs, raw materials, and existing processing capabilities. The developed technology should be eco-friendly also
CO4: To be able to do analysis of defective and rejected components to ascertain the root cause of defective products.
CO5: To modify the existing ceramic fabrication process on the basis of customer feedback, analysis, survey and suggest an upgraded process/technology for improved product quality.

J. S. Reed, Introduction to the Principles of Ceramic Processing, John Wiley , 2nd Edition, ISBN: 978-0-471-59721-6, 1995, John Wiley

M. N. Rahaman, Ceramic Processing, CRC Press , 2nd Edition, 10.1201/9781315157160 , CRC Press, 2017

D. W. Richerson, Modern Ceramic Engineering, CRC Press , ISBN-13 9781498716932, 2nd Edition CRC Press 2018

L. L. Hench and G. Y. Onoda, Ceramic Processing Before Firing, Wiley- Intersciences , 1978, ISBN-13 978-0471654100

F. F. Lange, Powder Processing Science and Technology for Increased Reliability, Journal of the American Ceramic Society, Vol 72, Issue 1, Page 3-15, Year 1989