978 94 017 5259 6 Book 1 PrintPDF pdf INDUSTRIAL CERAMICS INDUSTRIAL CERAMICS FELIX SINGER Dr Ing , Dr Phil , M I Chem E , F I Ceram and SONJA S SINGER M A , B Sc SPRINGER SCIENCE+ BUSINESS MEDIA, B V[.]
INDUSTRIAL CERAMICS INDU STRI AL CERA MICS FELIX SINGER Dr Ing., Dr Phil., M.I.Chem.E., F.I Ceram and SONJA S SINGER M.A., B.Sc SPRINGER-SCIENCE+ BUSINESS MEDIA, B.V 1963 Additional material to this book can be downloaded from http://extras.springer.com © SONJA S SINGER 1963 Originally published by Chapman & Hall in 1963 Softcover reprint of the hardcover 1st edition 1963 First published 1963 ISBN 978-94-017-5259-6 DOI 10.1007/978-94-017-5257-2 ISBN 978-94-017-5257-2 (eBook) PREFACE ALTHOUGH many new books have appeared in recent years dealing in detail with individual sections of ceramics, it was felt that there was a need to try to draw together the threads, and discuss as many aspects of ceramics as possible, in one volume The word ' ceramics' from the Greek 'keramos ', 'the Potter' has, however, come to mean a l'ather ill-defined number of subjects The field considered in this book has therefore to be defined at the outset, and our definition is as follows : Ceramics are products made from inorganic materials which are first shaped and subsequently hardened by heat This definition embraces the European use of the word, meaning ware made with clay, while allowing inclusion of non-clay new developments It does, however, exclude the chemically related subjects of glass, enamels and cements which may be included in the term ceramics in the United States The word 'industrial' in the title is generally taken to mean any ceramic product made in a factory, and usually made in considerable numbers The hand making of individual pieces by artists is not included, although some of the illustrations are perhaps borderline cases The text has been compiled largely from my father's large and well classified library, collected over fifty years, and also embodies his long practical experience as a ceramic consultant It is very sad that after so many years of collecting data followed by several years of selecting from it he did not live to see the final completion of the manuscript, but I assure readers who remember him well that the choice of matter to be included was very largely his, and that he personally approved the bulk of the text On the other hand I take responsibility for any errors that have not been eradicated, due to my desire to have the book published as quickly as possible in memory of him It would be impossible to list here the many people and firms who have helped us by allowing us to quote from their work, sent us information, or made illustrations available Their names are given in the bibliography, which is arranged alphabetically, thus combining it with the author index Where machines, apparatus or products are described or illustrated these are not necessarily the best for the purpose, but it is hoped that they are representative of the types under consideration Availability of information has often been a factor governing what has been included Vl PREFACE The units used throughout are the British ones with the metric units in brackets (except where Continental items are described when the metric unit may be given first) This applies also to pyrometric cone numbers, and where a foreign cone does not correspond exactly to a British cone the two neighbouring ones are given A few tables that not belong exclusively to any particular chapter are given at the end in the appendix Finally I want to thank most particularly my late mother and my husband for their encouragement, assistance and also their prolonged tolerance of the large amount of books and papers that have been amassed in their respective homes during the writing of this book South Croydon March 1960 SONJA S SINGER CONTENTS Page Preface v Introduction Xl PART I THE GENERAL PRINCIPLES OF CERAMIC MANUFACTURE Chapter The Raw Materials Introduction to silicate chemistry Plastic raw materials-Clays Non-clay plastic raw materials-Talc Non-plastic raw materials- Refractories- FluxesColouring agents Auxiliary raw materials 96 150 The Action of Heat on Ceramic Raw Materials Changes and reactions in the solid state Melting, crystallisation and glass formation Phase diagrams Thermal stresses, fatigue, thermal shock Colour 167 167 198 215 223 227 Chapter Chapter Winning and Purification of Clays China clay and kaolin Sedimentary clays Machinery used in clay winning Treatment of clays 3 89 236 237 253 258 263 CONTENTS Vlll Chapter The Ceramic Laboratory Chemical analysis Physical tests Investigation of: 0~ Fired properties Glazes Process control Chapter Ceramic Bodies Page 265 266 275 ~ 338 369 380 393 Chapter Glazes Glazes Salt glazes Ceramic colourants 525 525 598 605 Chapter The Mechanical Preparation of Ceramic Bodies and Glazes Crushing and grinding Size grading Mixing Filtering Wedging 661 661 686 696 701 708 Chapter Shaping Shaping of plastic bodies Dry and semi-dry pressing Casting 717 741 754 Chapter Glazing and Decorating 777 Chapter 10 Drying of Shaped Ware Dryers 832 834 Chapter 11 Firing and Kilns Firing of ceramic wareKilns for firing ceramic ware Choice of fuel 854 854 884 899 716 CONTENTS Instruments for observing, recording and controlling kiln and other works conditions Saggars and kiln furniture The setting of ware in kilns Periodic or intermittent kilns Continuous kilns (fire moving) Tunnel kilns Frit kilns PART lX Page 934 954 956 967 985 1002 1047 II CERAMIC PRODUCTS Chapter 12 Ceramic Building Materials 1065 Chapter 13 Ceramics in the Home 1089 Chapter 14 Chemical and Technical Ceramics 1103 Chapter 15 Specialised Laboratory and Engineering Ware 1135 Chapter 16 Ceramics in the Electrical Industry 1170 Chapter 17 Constructional Refractories 1212 Chapter 18 Thermal Insulators 1284 Appendixes Periodic Table I Comparison of Standard Fine Test Sieves II Weight solids, % water, % solids for given slip weight per pint III Thermoscopes or heat work reco.rders IV Ambiguous words V British Standard Specifications Normes Francaises Deutsche Industrie Normen American Society for Testing Materials, Standards VI Health hazards and Factory Acts 1300 1301 1302 1304 1307 1308 1311 1313 1317 1322 Bibliography and Authors Index 1327 Subject Index 1431 Introduction word ceramics is taken to cover those articles that are made from inorganic substances first shaped and then hardened by fire In ancient times this meant articles made from clay In this century we have found out how to use ceramic production methods for a number of physically and chemically different substances, but the ceramic industry is still founded on a working knowledge of clay Chemically, the classical raw materials, clays, flint and feldspar, are compounds of silica The properties which make them suitable for ceramics are precisely those by which they differ from other substances It is therefore well worth considering the basic structures and properties of silicates before proceeding to the raw materials themselves THE