Ceramic Products Research Articles

Zero-value dental mould waste: an innovative pathway for high purity calcium source enabling the production of akermanite ceramics

Zero-value dental mould waste: an innovative pathway for high purity calcium source enabling the production of akermanite ceramics

Combining thermodynamic modeling and experiments to characterize the effect of ceramic polishing powder in cement-based materials

Ceramic polishing powder (CPP), a by-product of ceramic tile production, has the potential to prepare building materials. While the hydration and thermodynamic properties of CPP remain largely unexplored, thereby limiting its widespread application. This study utilized R3 tests to demonstrate that CPP exhibits pozzolanic activity comparable to that of fly ash. Then it analyzed the effects of substituting 10–20 % of cement with CPP on the hydration products, microstructure, and mechanical properties of composite materials, utilizing a synergistic approach that combines thermodynamic simulations with experimental investigations. The findings showed that adding CPP does not generate new crystalline products but enhances the formation of C-S-H through the pozzolanic reaction, which consumes calcium hydroxide. However, adding over 25 % CPP significantly lowered the pH of the pore solution, altering hydration products and causing volume contraction. In addition, CPP improved the microstructure at later ages, particularly by increasing micropores, leading to enhanced mechanical properties at 28 and 90 days. For instance, at a w/b ratio of 0.5, the 90 days compressive strengths of composite mortars CPP10, CPP15, and CPP20 were recorded at 67.0 MPa, 63.3 MPa, and 65.1 MPa, respectively. These values represented increases of 17.3 %, 10.9 %, and 14.0 % over the control group (57.1 MPa). Conversely, this also resulted in increased autogenous shrinkage due to higher capillary pressure. Notably, the 6 days shrinkage of CPP15 and CPP20 was about 50 % higher compared to that of the pure cement mortar. These findings highlight the necessity of balancing CPP content for optimal performance.

Quality Control of Ceramic Wall Products Six Sigma Method with Dmaic Tools and Failure Mode and Effect Analysis (FMEA)

Considering the importance of increasingly rapid industrial development, business people must be aware of the orientation towards product quality. The manufacturing industry has an important role in industrial development. It is hoped that it will be able to grow and have advantages in industrial development, therefore it is necessary to improve and increase product quality. The company continues to strive to maintain and improve product quality and increase productivity so that customers are satisfied with the products produced. One way that needs to be done is to reduce the number of defective products in the production process. This effort is one way of continuous improvement carried out by PT. ABC and companies operating in the same field. The ceramic wall production process has relatively high demand but still has a high level of defects. Based on information on production data and data on the number of defects for the period January – September 2023, wall ceramic production has a defect rate of 3.86%. Companies must reduce the number of defects to achieve company targets. This research aims to improve the production process of wall ceramics by minimizing the number of defective products. This research uses the six sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) tool assisted by the FMEA (Failure Mode and Analysis) method. Corrective action to reduce defects based on the 5 Why analysis is to find out what the problem is and ask "why" and "what is the root of the problem". The research results show that there are 4 types of defects which have a large number of defects, namely Rupture Defects, Application Defects, Peeling Defects and Hole Defects. From the research results, solutions were obtained for the emergence of several types of defects in the wall ceramic production process, namely by providing planning suggestions and corrective actions which are discussed this time. At the defect calculation stage, Broken produces a DPMO value of 29.362 with a sigma level of 3.39 with a sigma level of 3.48, Defect Peeled produces a DPMO value of 28.044 with a sigma level of 3.38, and holes are defective. resulting in a DPMO value of 26,020 with a sigma value of 3.45 from the data calculation results, it is still not enough to meet the company's target at the sigma level, therefore the company must make quality improvements to achieve the main target at the sigma level.

Physical and Chemical Analyses of Shabu Clay for Stoneware Ceramics Production

Physical and Chemical Analyses of Shabu Clay for Stoneware Ceramics Production

Evaluation of influence of thermoplastic slurry flow conditions on heat transfer coefficient during beryllium ceramic formation

The article presents the results of calculation of the influence of thermoplastic slurry flow conditions on the total heat transfer coefficient when forming ceramic products. Methods of detailed description of casting processes and thermal calculations have been developed to ensure reliable correspondence of calculated data and experimental results implemented on the basis of calculational experiment. The modeling of physical processes occurring during the formation of products allows you to discover new opportunities for improving the quality of castings by allowing you to more closely track the change in the temperature-phase fields of the process and clearly present the solidification kinetics depending on the casting modes. The speed of heat removal from the casting during the solidification period determines the rate of movement of the slurry, along with the temperature field on which the width of the transition region depends. These factors have a direct influence on the formation of the structure of beryllium ceramics. The study of the heat exchange process in the formation of ceramic products depending on temperature, heat at phase transition is the main task, since they largely determine the technological and operational characteristics of beryllium ceramics. The design data allows to determine the optimal conditions of the ceramic casting process and to obtain a solidified product with a uniform structure at the outlet.

¿Estamos interpretando el lenguaje de los tiestos?

Some existing methodological approaches for the analysis of archaeological ceramics are evaluated, and the need to standardize criteria is reflected on. Ceramics are understood as a goods derived from a production process in which each product contains technological knowledge reflected in its quality. Furthermore, each object or artifact also reveals the formal and identity expression of a community from a particular era, externalizing a style. Likewise, as a consumer good it adopts intangible values intrinsic to social work such as, for example, satisfying a need in its functional, ideological, economic or social expression. These three dimensions of analysis: technological, cultural identity and social valuation define its essence. In the technological dimension, ceramic production involves a succession of technical steps. Therefore, ceramic study must analytically reproduce this succession of steps to understand the technical particularities of each production process.

Estimation of Chemical and Mineral Composition, Structural Features, and Pre-Firing Technological Properties of Waste Coal Heaps for Ceramic Production

The relevance of the investigation and creation of a new non-traditional raw material base for wall ceramics for the south of Russia is shown in connection with the decreasing availability of traditional raw materials—loams. Characterizations of the mineral and chemical constituent rock formations of the rocks composing the dumps of coal waste heaps and enrichment plants are given. A serious constraint for the industrial development of coal wastes is the requirement for a great variety of mineral constituents. The chemical and mineralogical compositions and the pre-firing ceramic properties of the waste coal heaps are studied and presented in detail. It is mentioned that fine and thin materials contain coal in an increased amount; due to this, they cannot be considered as the main raw material for the production of wall ceramics. The materials of the medium-sized grain group (2.0–5.0 mm, sifting) can contain up to 2–3% of coal and are most often represented by a mixture of mudstones, siltstones, and sandstones, with the predominance of one or another type of rock. The granulometric composition and the content of large-grained inclusions, molding moisture, plasticity, cohesiveness, desiccation properties, and air shrinkage were studied and determined. It is concluded that the middle group of waste coal heaps in particular are of the greatest interest as a basic raw material for the production of wall ceramic products.

Effect of SiO2/MgO ratio on the properties of diopside-based ceramics

Diopside-based ceramics were successfully synthesized by utilizing recovered extracted titanium slag, asbestos tailings, and quartz tailings as raw materials. The objective of this approach is to explore novel sources of raw materials for ceramic production and optimize the utilization of industrial solid waste. The effects of SiO2/MgO mass ratio (S/M) on the properties of the ceramics were studied by investigating the bulk density, bending strength, water absorption and corrosion resistance. The microstructure and crystallization process of the ceramics were analyzed by SEM-EDS and XRD. The results revealed that the increase of S/M is beneficial to the formation of low viscosity liquid phase, the promotion of ion migration and crystallization process, the decrease of sintering temperature, the decrease of water absorption and the increase of bulk density and bending strength of ceramics. In addition, the increase of S/M helps to increase the acid resistance of ceramics. The most optimal parameters (bulk density of 2.97 g·m−3, bending strength of 118.73 MPa, water absorption of 0.29 %, and acid resistance of 98.98 %, respectively) were achieved at the S/M of 2.50 and the sintering temperature of 1175 °C. The increase of S/M ratio also affects the phase reconstruction process. At lower S/M (1.75–2.08), Melilite is transformed into diopside, and at higher S/M (2.50–4.71), Melilite is transformed into diopside and anorthite. The present study aims to optimize the utilization of industrial solid waste (100 %), which not only protects the environment, but also provides a novel approach for resource recovery from such wastes.

The Cultural Connotation of Literati Space During the Qianlong Period of China: Designing Contemporary Ceramic Products for Literati with Innovation

The Cultural Connotation of Literati Space During the Qianlong Period of China: Designing Contemporary Ceramic Products for Literati with Innovation

Iron Age ceramics from Thracian rock-cut complexes from Bulgaria – Mineral magnetic relics of technological production and use

The Gluhite kamani Thracian rock-cut complex in the Eastern Rhodopes Mountain is famous with its more than 500 rock niches carved in the rock at heights up to 20 m. Continuous habitation starting from the final Chalcolithic (the second quarter of the 4th millenium BCE) until the Late Classical – Early Hellenistic period (late 5th – 4th century BCE) provides unique opportunity for studying diachronic changes in pottery production and use. In this contribution, systematic analysis of a collection of 135 ceramic sherds from five archaeological periods at the site was carried out using a combined mineral magnetic and geochemical approach. Magnetic susceptibility (χ), frequency-dependent magnetic susceptibility (χfd%) and firing temperature (Tfire), determined using the magnetic susceptibility method, were combined with data from elemental XRF analyses. Thermomagnetic measurements, employed for identification of magnetic minerals revealed the dominant presence of (titano)magnetite with low Ti-content and/or a fraction of single-domain magnetite and in few cases hematite. Although varying in a wide range, median χ values of ceramic sherds from the Early Iron Age (EIA) periods show similar distribution, while for Late Iron Age (LIA) with the introduction of the wheel-thrown pottery, χ values are higher, presumably due to decreased amount of silica-rich clastics in the clay. Concurrently, χfd% values decrease in ceramics from the LIA, indicating predominant presence of stable single-domain magnetite in the iron oxide composition of the ceramics. Firing temperatures (Tfire) estimations display a systematic pattern of two groups – higher (Tfire between 760 and 800 °C) and lower (Tfire ∼ 400–––600 °C). During the EIA periods both Tfire groups are present, characterized by systematic gradual decrease of the median value of the low Tfire when going from EIA1 towards the EIA2. Wheel-thrown pottery from the LIA show low Tfire ∼ 400 °C only. Based on the differences in thermomagnetic properties of ceramics, their magnetic parameters and Tfire estimates, two possible hypotheses are suggested to explain the observed changes in EIA ceramic characteristics: i) utilization of two differently sourced clay materials (illite-dominated and montmorillonite-dominated) for production of ceramics fired at higher and lower temperatures, respectively; and ii) utilization of one raw clay source, while using two firing regimes – firing at higher temperature for prolonged time, and fast firing to high temperature with successive stage of longer firing at lower temperature. Differences in thermomagnetic properties of wheel-thrown pottery from the LIA period leads to the assumption for utilization of diverse clay source for their production, as compared clay sources for the Early Iron Age periods.

The high-hardness ceramic glazes based on basalt from Bali Province for ceramic body coatings

The ceramic glaze method is not only done to add color aesthetics but also to increase the hardness of the glaze. Basalt is one of the raw materials developed as a ceramic glaze material because it is cheap, easy to find, and has good characteristics. This research aims to determine glaze characteristics by varying the concentration of basalt rocks from the Ababi area, Karangasem Regency, Bali Province. The experiment used basalt at 45%-61%, Feldspar 27%-37%, Kaolin 3%-8%, and ZnO 7%-10% as raw materials for glaze, not frit glaze. Heating the glaze material layer at 1,250 °C for 3 hrs. The product characteristics of glaze ceramics include chemical composition, crystal phase, microhardness, porosity, density, thermal expansion coefficient, and surface morphology. Basalt from Bali is characterized by its high Fe2O3 content, reaching 20.07 wt%. Compared to basalt in generally, it has a different impact on the physical and mechanical characteristics of the ceramic glaze produced. Based on the observation of ceramic glaze products, the glaze composition with 56% basalt, 32% feldspar, 5% kaolin, and 7% ZnO showed the best coating, with a yellowish-brown color and an average thickness of 79.82µm. The hardness value of the glaze layer is 6.5 GPa, exceeding the standard hardness value of glazes on the market. Glazed ceramics contain the minerals Gahnite (ZnAl2O4) and Coesite (SiO2), which can increase the hardness of the glaze. This research demonstrates the tremendous potential and added value of using basalt from Bali Province as a raw material for glazed ceramics.

LEVEREGING TECHNOLOGICAL HEREDITY TO INCREASE PRODUCTION EFFICIENCY OF FERROCERRAMIC PRODUCTS DURING FINAL MACHINING

The quality state of grinded surface of ferro ceramic products is formed under the influence of thermomechanical phenomena which occurs during final machining and depends on the technological conditions for workpiece procurement. The mathematical model was formulated to regulate and optimize thermomechanical processes during the acquisition of ferroceramic workpieces. This mathematical model describes thermomechanical processes during workpieces sintering. Thermomechanical processes have a direct influence on defects formation in the workpieces. Grinding can cause the appearance of burns, cracks, tensile stresses in the surface layers of the products. These defects can significantly spoil the quality of products during their operation. High thermal stress of diamond-abrasive processing brings thermophysical aspects as a dominating factor for quality characteristics of processed surface. Existing grinding methods for products made from ferrocerramic materials are not able to fully eliminate the defects in the surface layer. Such defects are inherited from preceding machining operations, particularly from workpiece procurement. Material structure itself is prone or defect occurrence due to micro-heterogeneities, packaging defects, dislocations, and structural transformations. Analysis of the thermomechanical processes that run inside the surface layer made it possible to formulate calculation dependencies for defining technological conditions for eliminating burns and cracks during grinding of ferrocerramic products. Device for automatic stabilization of thermomechanical characteristics that accompany grinding of ferrocerramic products. This is achieved through the selection of optimal technological conditions for machining of the products that have heredity inhomogeneities inside the surface layer. Thus, this approach helps to achieve maximum efficiency within required quality citeria.

Seriating Trincheras Bichrome Pottery and Understanding Nearly a Millennium of Regional Ceramic Production

Nearly a century ago, pioneering investigations in northern Sonora led to the first discussion of Trincheras tradition ceramics. Since then, only cursory attempts have been made to understand the temporal and spatial variability of Trincheras bichrome pottery. A recent detailed attribute analysis of pottery from sites across Sonora and southern Arizona has resulted in the region’s first ceramic seriation and a revised decorated ceramic typology. In this paper, I synthesize the results of this study, highlight key technological differences which occurred over nearly a millennium, and argue that the Trincheras tradition was one of the earliest producers of bichrome ceramics in the Southwest/Northwest. A revision of Trincheras ceramic typologies has been much needed and is invaluable for archaeologists working in both Sonora and Arizona.

Limiting the lattice oxygen impurities to obtain high thermal conductivity aluminum nitride ceramics

Currently, the lattice oxygen is the key factor affecting the thermal conductivity of AlN ceramics. In this paper, three methods are proposed to limit lattice oxygen, namely reducing the original powder oxygen content, changing the debinding atmosphere, and extending the sintering time. The results show that the low powder oxygen content and protective debinding atmosphere alter the carbon and oxygen content, and further promote the formation of the Y4Al2O9 (YAM) phase. The generated YAM phase can effectively reduce the lattice oxygen in terms of thermodynamics. Prolonged high temperatures can provide kinetic conditions to reduce the lattice oxygen to 0.0343 wt%. In addition, morphological changes of the phase at the grain edges and their influence on the mechanical properties were noted. Finally, AlN ceramics with a thermal conductivity of 220 W m−1 K−1 and a flexural strength of 340 MPa were obtained. This study can provide a valuable reference for the industrial production of AlN ceramics.

The Influence of Perceived Value, Cultural Identity, and Product Familiarity on Consumers' Purchase Intention of Jingdezhen Ceramic Products

The Influence of Perceived Value, Cultural Identity, and Product Familiarity on Consumers' Purchase Intention of Jingdezhen Ceramic Products

Processes occurring during the synthesis of wollastonite‑containing refractory used in non‑ferrous metallurgy

This article presents the results of research on the processes occurring during the synthesis of wollastonite‑containing ceramics obtained from various clay components. The peculiarities of crystalline phase formation in the material are described. The obtained information lays the foundation for the organization of ceramic production that is in demand in the metallurgical industry.

Conditioning Influence of Kaolinite Matrices on Flexural Strength of Raw Pressed Slurry Collected from Ceramic Tile Production Wastewater

Kaolinite is able to assure the high binding affinity of the filler particles of raw ceramic bodies. It acts as a matrix that strongly holds the other constituents’ particles in a compact structure. The slurry samples were characterized by XRD, mineralogical microscopy and SEM coupled with an EDX elemental analysis. The slurry collected from the ceramic tile production wastewaters had a significant amount of kaolinite (36%), mostly fine particles of 3 µm, less surrounding quartz (37%) and mullite (19%) particles of 5–100 µm in diameter and traces of lepidocrocite (8%). It is a dense paste with a relative moisture of 25%. The square bar of the slurry as received, pressed at a load of 350 N, had a flexural strength of 0.61 MPa. Increasing the moisture to 33% using regular water, followed by mechanical attrition at 2000 rpm for 5 min, resulted in a porous bar with a flexural strength of 0.09 MPa; by increasing the attrition speed to 6000 rpm, the microstructural homogenization was improved and the flexural strength was about 0.68 MPa. It seems that regular water does not assure an optimal moisture for the kaolinite matrix conditioning. Therefore, we used technological water at pH = 10, a moisture of 33% and attrition at 6000 rpm for 5 min, and the bar pressed at a load of 350 N had a flexural strength of 1.17 MPa. The results demonstrate that the bar moistened with technological water and an attrition regime assured a proper conditioning for the kaolinite matrix, achieving the optimal binding of the quartz and mullite particles under the pressing load. Bars with the optimal mixture were pressed at several loads, including 70, 140, 210 and 350 N, and the flexural strength was progressively increased from 0.56 MPa to 1.17 MPa. SEM fractography coupled with atomic force microscopy (AFM) revealed that the optimal moisture facilitated a proper kaolinite particle disposal regarding the quartz and mullite filler particles, and the progressive load assured the strong binding of the finest kaolinite platelets onto their surface.

Chemical fractionation and mobility of Cd, Mn, Ni, and Pb in farmland soils near a ceramics company.

Soil contamination due to industrial activity in ceramics production is of concern because of the risk of heavy metal pollution. Successive extraction was used to measure and identify the concentrations of Cd, Mn, Ni, and Pb in farming soils near a ceramics company in Nigeria. Furthermore, soil pH and particle size analyses were determined. The concentration of Pb was the highest, followed by that of Ni, Mn, and Cd (lowest), and the mean level of Cd exceeded the regulatory allowed limit of 1.4mgkg-1. The order of the metals' mobility factors was as follows: Cd > Mn > Ni, Pb. While the Fe-Mn oxide phase had 37% (Mn) and 20 to 83% (Ni), the residual fraction had approximately 30% (Cd) and 19 to 50% (Pb). Soil pollution evaluation was performed using enrichment factor (EF), contamination factor (CF), pollution load index (PLI), and geoaccumulation index (Igeo). Values of EF indicated significant enrichment for all metals, as the EF mean values for Cd, Ni, and Pb in soil were > 1.5. Total EF is of the order Cd > Pb > Ni > Mn. CF results revealed moderate to very high contamination (CF < 1: 3 ≤ CF ≥ 6). Similarly, the PLI indicated moderately to severely polluted soil. The order is 100m > 200m > 300m > 400m. The Igeo ranged from 1.46 to 2.76 (Cd), 0.07 to 1.62 (Ni), and 0.05 to 2.81 (Pb). The PCA, CA, and EF analyses suggest that the metals are a consequence of anthropogenic activities.

Material Extrusion Additive Manufacturing of Ceramics: A Review on Filament-Based Process.

Additive manufacturing is very important due to its potential to build components and products using high-performance materials. The filament-based 3D printing of ceramics is investigated, revealing significant developments and advancements in ceramic material extrusion technology in recent years. Researchers employ several typologies of ceramics and binders to achieve fully dense products. The design of the filament and the necessary technological adaptations for 3D printing are fully investigated. From a material perspective, this paper reviews and analyzes the recent developments in additive manufacturing of material-extruded ceramics products, pointing out the performance and properties achieved with different material-binder combinations. The main gaps to be filled and recommendations for future developments in this field are reported.

Preparation of high-density green body based on binder jetting 3D printing using spheroidized SiC powder

Silicon carbide (SiC) ceramic stands as a critical material in the realm of high-performance engineering ceramics. However, Crafting SiC ceramics with intricate structures and superior mechanical properties presents notable challenges in shaping, sintering, and processing. Binder jetting (BJ) additive manufacturing has the outstanding advantages of high forming efficiency and no thermal deformation, especially suitable for printing complex structure SiC components.; however, BJ printed green bodies often exhibit low density, resulting in high residual silicon content and diminished strength of the final components. In this work, we introduce a novel strategy to fabricate high-strength SiC components with complex geometries by improving the density of printed SiC green bodies. This method involves modifying the morphology of SiC powder through the molten salt method to increase the density of BJ 3D printed green bodies from 1.24 ± 0.13 g/cm³ to 2.01 ± 0.03 g/cm³, followed by a reactive melt infiltration process. The resulting RB-SiC ceramics display exceptional flexural strength, averaging 280.60 ± 33.05 MPa, and an elastic modulus of 294.67 ± 4.90 GPa. These values represent some of the highest for flexural strength and elastic modulus reported among 3D-printed SiC composites. With its robust mechanical performance and streamlined fabrication process, this strategy holds substantial promise for the production of structural SiC ceramics.