5 فروق بين السيراميك و البورسلين هاتساعدك لاتخاذ القرار - كورسات معمارية مجانية

 

Let's make ceramics

introduction :-

Because you are a new engineer and confused on the site or in the technical office; or if you are a new groom and confused about finishing your apartment, and you have many choices and are confused about the finishing items.
Follow us, God willing, all your questions will be answered here.
The first thing that comes to your mind is that you heard about ceramic and porcelain, but what are they even more important about?
What is the difference between them?
What is best to use in my apartment?
Or I recommend it to my client.

Material of manufacture?

What is Ceramic?

Ceramic is a group of inorganic and non-metallic materials that were formed due to the heat factor. Ceramic is considered a solid material, and when it is exposed to fire, it becomes soft and brittle. It is characterized by high chemical and physical properties, and its melting point is very high.

Ceramic industry from silica sand:

The manufacture of ceramics from silica sand goes through several stages:

1- Raw material processing:-

In the beginning, the raw materials needed for the ceramic manufacturing process are prepared and prepared. These equipment consist of three materials: -
Chondrites: They are hydrated aluminum silicates.
Feldspars: These are minerals formed as a result of the chemical decomposition of granite.
Silica sand: These materials are ground in places designated for grinding, and then a thick, sticky mixture is produced. This mixture is called quartz.

Pumping quartz into the atomizer:-

The atomizer is a cone-shaped structure that contains a stream of hot air, the temperature of which reaches more than 500 degrees Celsius.
The function of the atomizer: This very high temperature inside the conical structure dries the moisture present in the quartz (the mixture that has been ground), and a powder is produced through this process, the moisture of which ranges from 4 to 6%.

Ceramic formation:-

In the ceramic formation stage, the powder resulting from the quartz moisture drying process is poured and pressed (the quartz and powder process), and after pressing and pressing, it is placed in molds with different shape characteristics.

Burning and drying:

In order for the firing and drying process to take place, the molds in which the ceramic was formed are taken and placed in special dryers.

Decoration and coloring:-

Ceramic decoration and coloring is done by choosing the appropriate color and shape of the molds by using laser printers for the decoration process.

Final burning:-

After completing the decoration and coloring stage of the molds, they reach the final burning stage by placing them in furnaces at a temperature appropriate to each piece for approximately 30 to 45 minutes.

Examination and sorting:-

After the final burning process, the pieces are taken from the molds for examination, their quality is detected, and defects are discovered. If any defects occur during their sorting, they are sent to the factory again in order to repair them with special pastes, and they are placed in the oven again to be burned.

Packaging and packing:-
After ensuring that there are no defects in the pieces, the product is taken to private factories in order to package it and then sell it in the markets and use it.

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Porcelain:-

China, china, porcelain, or porcelain (read: porcelain) is a ceramic material made by heating materials, generally including a material such as kaolin, in a kiln to a temperature of between 1,200 and 1,400 °C (2,200 and 2,600 °F). The strength and translucency of the porcelain, compared to other pottery, comes mainly from the glazing and formation of the mineral mullite within the body at these high temperatures. Although definitions vary, porcelain can be divided into three main categories: hard-paste, soft-paste, and bone china. The category to which an object belongs depends on the composition of the paste used to make the object's ceramic body and the firing conditions.

Ceramics developed slowly in China and was finally achieved (depending on the definition used) at some point around 2000 to 1200 years ago, then slowly spread to other East Asian countries, and finally Europe and the rest of the world. Its manufacturing process is more demanding than that of earthenware and stoneware, the other two main types of pottery, and it is usually regarded as the most popular type of pottery due to its fineness, strength and white colour. It combines well with both glazes and paint, and can be very well designed, allowing for a wide range of decorative treatments in tableware and utensils. It also has many uses in technology and industry.

The European name, porcelain, is derived from the ancient Italian porcelain (kauri veneer) due to its resemblance to the surface of the veneer. Porcelain is also referred to as china or fine china in some English-speaking countries, as first seen in imports from China. Properties associated with porcelain include low permeability and flexibility; Great strength, hardness, whiteness, transparency and resonance; High resistance to chemical attack and thermal shock.

The porcelain has been described as fully glazed, hard, impermeable (even before glazing), white or artificially coloured, transparent (except when of great thickness) and resonant. However, the term "ceramics" lacks a universal definition and "has been applied unsystematically to materials of different types that have certain surface features in common." East Asia only classifies pottery into low-fired wares (porcelain) and high-fired wares (often translated as earthenware), the latter also including what Europeans call stoneware, which is high-fired but generally not white or translucent. Terms such as “primary porcelain,” “porcelain,” or “semi-porcelain” may be used in cases where the ceramic object is close to white and translucent.

Materials:-

Choline is the basic substance from which porcelain is made, although clay minerals may represent only a small percentage of the whole. The word paste is an old term for both fired and unfired materials. The most common term for unpublished material is “body”; For example, when purchasing materials, a potter may order a quantity of ceramics from a vendor.
The composition of porcelain varies greatly, but the clay mineral kaolinite is often the raw material. Other raw materials can include feldspar, ball clay, glass, bone ash, limestone, quartz, bitonites, and alabaster.
The clays used are often described as long or short, depending on their flexibility. Long clay is cohesive (sticky) and has high elasticity; Short clay is less consistent and has less elasticity. In soil mechanics, plasticity is determined by measuring the increase in water content required to change a clay from a solid, bordering-plastic state to a plastic-liquid state, although the term is also used less formally to describe the ease with which clay can work.

Chemical raw materials:-

1) Feldspar: MOAL2O3.6SiO2
2) Glutens: kaolin
3) Flint (sand) SiO2
4) Dolomens MgCa(CO3)2:
5) Calcite CaCO3
Where M are: K, Na, Ca
Feldspar: a raw material that forms ceramics and helps in melting. It reduces the firing temperature from 1700 to 1450 degrees Celsius as a result of it containing alkali oxide.
It results from the erosion of feldspar:{\displaystyle {\ce {K2Al2O3.6SiO2+CO2+2H2O->K2CO3+Al2O3.2SiO2.2H2O+4SiO2}}}
Kaolin features:
- Soft when in water and hard when dry.
- Glassy in appearance and very hard when grilled.
- It suffers from shrinkage in size and length due to the release of water from it.
Resistant to melting and shrinkage.
The ratio of Mg to calcium carbonate is 1:1 if ideal. The maximum percentage of magnesium is 50 or less. This percentage should not exceed during grilling. It shrinks due to the release of CO2 from it and is considered one of the materials that aid in melting.
Helping to melt and shrink during grilling to release CO2.

Its manufacture:-

The industry takes place in two stages:-

1- Structure manufacturing

2-Glass transition stage

1. Kaolin + feldspar + sand.

2.Currant wet mill.

3. Fan tank (crushed sand + crushed feldspar)

4. A comb tank whose task is to remove bubbles from the air.

Forming: - By pouring (asymmetrical shapes).

-With templates (symmetrical shapes).

Structure thing:

150°C

- Physical water is released.

Pores are formed as a result of the physical release of water.

Shrinkage: 20% in size and 7% in length.

600 - 650 °C

- Chemical dewatering.

- Pore formation and loss of hydroxyl ions (Hydroxyl is the product OH bonded to Al)

-The transformation of kaolin into metakaolin.

1000-900°C

- CO2 release.
Pores are formed as a result of the release of CO2.
- Metakaolin dissociates and forms mullite 3Al2O3.2SiO2.
The pores are important as they absorb the vitrification liquid to make the vitrification layer rooted deep in the structure of the basic structure, giving it strength and durability.
The degree of glass transition depends on:
1- The ratio of resistant oxides to auxiliary oxides. 2- The temperature reached by the grill is 1600 °C - 1500
3- Grilling time: As the time increases, the temperature decreases.
You start by preparing the glazing liquid, as its components are the same as the body mixture materials, but the smoothness here is higher. With a higher percentage of feldspar, the grilling temperature is 145 °C, and the grilling process takes 24-36 hours.
Methods of coating it: The basic structure of the product is coated with this liquid, either by dipping it in this liquid, by spraying it, or by painting it with a brush.

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Glazing furnace:-

Thermal zones:
- 150 °C drying zone: where physical water is removed.
- 600 °C chemical dewatering.
-800–1000 °C Calcination and CO2 is released.
- 1100 - 1200 °C oxidation zone:
We give it O2 by heating, which produces acidic CO2 and affects the brick. Therefore, the brick must be silicone to resist acidity, and in this area we get rid of the organic materials present in the dirt.
-°C 1200- 1300 Return zone O2 reduction Iron forms black dots in the vessel after vitrification, so there should be no vitrification liquid
- 1400-1450 Vitrification zone (Shi).

Temperature reduction:
So that the cost does not increase when high heat is needed in the grilling process, this is done by:
-Either by adding alkaline materials to a certain extent because it affects the mullite (such as dolomite - calcium carbonate - sodium carbonate
-Or increase the duration of the thing.

Decorating and coloring ceramics-

It usually takes place after the vitrification stage is completed in an electric furnace at a temperature of 600-800 degrees, so that no oxidation process or return of transitional elements occurs, resulting in a change in color, for example.

Liquid gold:

It is a colloidal solution that we spread in and then add to the grill as well.

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