Die Pressing

Die pressing
It is important that the unfired or green compact has adequate strength for handling
before the firing operation, during which the organic additives are decomposed.
Fired components
showed shrinkage
after firing process
due to consolidation
and pore closure.
https://doi.org/10.1007/s40145-019-0318-4 1
Isostatic pressing
Isostatic pressing increases the no of contact points between the particles,
facilitating the compaction process. In addition, this method minimizes frictional
resistance with the wall surfaces.
Advantages
• Produces body in complex shapes.
• Reduces variation in physical properties.
Isostatic pressing involves applying

pressure from multiple directions through a
liquid or gaseous medium surrounding the
compacted part.
In hot-isostatic pressing, gas
A flexible (commonly polyurethane) mold (nitrogen or argon) is used.
immersed in a pressurized liquid medium
(commonly water) is used to transmit the It combines pressing and sintering,
force in cold-isostatic pressing. causing consolidation of powder
particles, healing voids and pores.
The work pressures are commonly between 15,000 psi to 44,000 psi 2
Isostatic pressing
The mold deforms to compress the powder and regains its original shape, when the
pressure is released.
Examples of isostatic pressed ceramic products: spark plugs, grinding media and
hollow tubes, and the operating pressures up to 200 MPa are typically used.
Mold for iso-static pressing can be polyurethane or silicone rubber.
Modern spark plugs contains approximately 90%

Al2O3 and remaining is SiO2, CaO, and MgO,
respectively.
3
2 1
The insulator is exposed to rapid temperature
changes in the internal combustion engine. The
insulator should have high dielectric strength and
chemically inert. Hence, ceramic is the ideal
choice.
1 – Alumina ceramic insulator; 2 and 3 - Alumina ceramic with metal fitting and sleeve 3
Slip casting
A fine powder of the ceramic material in solution phase containing 30% of water or any other
solvent is first prepared, which is known as slip or slurry.
The slip/slurry is poured into a mould. Plaster of Paris mould is used, if water is the solvent.
The mold wall will extract the liquid from slip in contact with it, forming a green compact, at
the vicinity of the wall.
After a finite time, the process is interrupted and the excess slip is drained from the mold, and
the object is removed. This method yields molded objects of fixed thickness. The distinctive
features of slip casting is the accuracy of the objects that can be cast.
4
Slip casting and solid casting
In slip casting, the material is allowed to dry for sufficient time, to obtain
reasonable mechanical strength for handling, removal from mould and
subsequent processing.
Finally, the ceramic is fired to get the required microstructure and mechanical
properties of the formed/shaped product.
Solid casting: To obtain solid shapes, the process will NOT be interrupted, till
the whole mold is solidified. This process is called as the solid casting.
Alternatively, the shaping can be done in pressure or vacuum, called vacuum or

pressure casting.
Slip casting is advantageous for forming thin walled and complex shapes of
uniform thickness.
Life span and precision of Plaster of Paris mould is important to get

dimensionally accurate ceramic products.
5
Injection molding
Injection molding allows high productivity forming of products, with a thin
wall/complicated shape, in contrast to slip casting.
In injection molding, ceramic powder particles and binder system is mixed and
the mixture is de-aerated and pressed into pellets (Die-pressing).
Next pellets are introduced into the molding device, heated within the heating
tube/cylinder, then forced/injected at high speed into the mold.
The forming process and equipment used are almost identical with those used in
injection molding of plastics.
The formed object must be fired, after the binder is extracted/decomposed.
The binder system usually consists of the major binder, a minor binder, a
plasticizer/lubricant and surfactant for particle wetting.
Productivity refers to efficiency, in other words, number of products manufactured in a day. 6
Injection molding – Screw-fed system
Ceramic powders are fed into a
mold cavity by means of a screw
rotating inside a cylinder.
Steps involved in injection molding.
1. Mixing – Ceramic powders with

10-20% of binder system.
2. Injection into mould.
3. Removal from mould.
The molding cycle in the injection molding 4. De-binding

method is around 2-3 mins.
5. Sintering
Thermal de-binding – the binder is heated above the volatilization temperature. 7

Injection moulding – Binder system
Binder system can be two types (i) Thermoplastic resins and (ii) Thermosetting resin
System Major binder Minor binder Plasticizer/Lubricant

Thermoplastic Polystyrene Resin (low MW) Petroleum oil
type (high MW )
Paraffin Wax Stearate
Polyethylene
(high MW )
Thermosetting Phenol Wax
Epoxy resin
type formaldehyde
• The minor binder should burn out at a lower temperature and provide pore
channels for the escape of gas produced on decomposition of the major binder.
• The major binder provides strength, while gaseous products from the minor
binder diffuse through the low-permeability structure.
• Ash content and carbon residue after burn-out is an important consideration in
selecting a binder system.
• The plasticizer/lubricant is added to control/improve flow and moldability.
*MW – Molecular weight 8
Injection molding
Binder is removed by vaporization, sublimation or thermal or oxidative
decomposition.
Main advantages of injection molding

• High quality parts can be produced at a high production rate.
• Good surface finish.
• Process can be highly automated.
• Intricate shapes can be produced.
Disadvantages
• High capital cost/machine cost.
• The process must be closely controlled to produce a quality product.
9
Tape casting
A thin film of ceramic slurry is spread over a flat surface/substrate.
The slurry film thickness is controlled by a knife edge/doctor blade located above
the moving tape carrier surface.
The solvent in the slurry, evaporates, resulting in formation of ceramic sheet, which
may be stripped from the supporting surface.
Tape casting is used for manufacturing multilayer ceramics for capacitors,

dielectric insulators and batteries.
10
Tape casting
Substrate: Slurry is cast on a clean, smooth, impervious, insoluble surface such as Mylar,
Teflon or cellulose acetate.
The as-cast film is dried to an elastic, leathery state, slit (to cut length wise) for proper
handling, and shaped by punching.
The casting speed is dependent on the thickness of the tape, evaporation rate, and the length
of the machine, all of which controls the drying time (Casting speed is typically 2 cm/sec).
Lithium sulphide thin films for solid-state batteries for electric vehicles
https://doi.org/10.1016/j.mtphys.2021.100397 11
Processing of ceramics-
Stage – 2 – Sintering of green compacts
12
Sintering/firing
Sintering (firing) involves the consolidation of ceramic powder particles by heating
the “green” compact part to a high temperature, but below the melting point, to
facilitate diffusion (Note: High temperature favors diffusion).
During the diffusion process, the
pore size diminish or closes and Green compact
metallurgical bonding between the
ceramic particles occurs.
The driving force of sintering

process is reduction of surface Complete closure
energy of the particles caused by of pores
decreasing their vapor-solid

interfaces.
Densification of the part results in superior mechanical properties of the material.
Note: Sintering occurs simultaneously with pressing during hot pressing.

13
Fact : Mohs scale of hardness
14

Die Pressing

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Die Pressing

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Die pressing

Isostatic pressing involves applying

Mold for iso-static pressing can be polyurethane or silicone rubber.

Modern spark plugs contains approximately 90%

Alternatively, the shaping can be done in pressure or vacuum, called vacuum or

Life span and precision of Plaster of Paris mould is important to get

The formed object must be fired, after the binder is extracted/decomposed.

Steps involved in injection molding.

1. Mixing – Ceramic powders with

2. Injection into mould.

3. Removal from mould.

The molding cycle in the injection molding 4. De-binding

Thermal de-binding – the binder is heated above the volatilization temperature. 7

System Major binder Minor binder Plasticizer/Lubricant

Main advantages of injection molding

Tape casting is used for manufacturing multilayer ceramics for capacitors,

The driving force of sintering

decreasing their vapor-solid

Densification of the part results in superior mechanical properties of the material.

Note: Sintering occurs simultaneously with pressing during hot pressing.

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