The Process Involved in Ceramic Molding
Ceramic molding by definition is a kind of process specifically designed for production of material that has precision and almost perfect finish by way of using high temperatures, which in turn results to a structure that’s perfectly shaped. The output or product made out of the process isn’t priced high and the process itself gives a low grade of toleration.
In general, the patterns used by ceramic mold include but not limited to wood, rubber, metal, plastic, and plaster. The pattern is actually the shape body of the intended part.
Ceramic molding is actually quite old, having been around for centuries. As soon as the first humans invented fire, they had all sorts of ideas on how to use it. One of the earliest things they tried was pottery, or the practice of using clay and fire to mold. Majority of ancient civilizations contain proof through their remains that they’ve created and utilized pottery before.
Ceramic molding is performed using two distinct methods. These are the original or true molding and the ethyl silicate slurry molding, or more commonly called as the Shaw process.
Understanding the Whole Process
Ceramics are described as a kind of material that is made of clay base with oxides and other types of ingredients. The raw version of the clay will be calcined, a process wherein it will be fired at a very high temperature, after which it’ll be mixed with water to be formed into mold components, and finally it will be subjected to fire once again.
For the true ceramic molding process, the refractory grain is going to be bonded using calcium or ammonium phosphate. The most effective method of making good ceramic molds is called dry pressing – a process in which molds are created by pressing the clay mixture with four to nine percent moisture under a pressure level of 1-10 ton per sq. inch. After the pressing is done, the molds will then be stripped from the dies and subjected to fire with temperature of at least 1650 degrees F.
The ethyl silicate variety on the other hand is performed in a completely unique way. The first process involves mixing ingredients including graded refractory filler, a liquid catalyst, and hydrolyzed ethyl silicate so as to come up with a slurry consistency. The slurry is intended to be poured on a pattern and be allowed to jell. The resulting slurry will be given time for gelation, and when that process is over, the mold will be stripped and subjected to fire by using a high pressure gas torch. After torching, the mold will be cooled and assembled, and then fired again before pouring.
The patterns to be used in ceramic molding are now available in different materials and the choice depends on the specific use of the product.