Seventy Ways To Make Ceramics PDF
Seventy Ways To Make Ceramics PDF
Seventy Ways To Make Ceramics PDF
Abstract
This is an attempt to classify ceramic manufacturing processes in such a way that the connections to related operations in other industries and
to the ancient crafts of antiquity become apparent. The aim is to make it easier for students of ceramic processing to move seamlessly across a
terrain that is conceptually integrated and therefore to find solutions to manufacturing problems through creativity informed by a pan-materials
taxonomy of processes. This approach veers towards the ‘systematic’ method of creativity as exemplified by TRIZ but it is important to recognise
that in some organisations the ‘chaos’ approach is also gaining recognition and what at first appears to be an oxymoron; ‘management for chaos’
is gaining acceptance. The relevance of an integrated approach to processing of materials is discussed in relation to the efficacy of the National
System of Innovation (NSI).
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doi:10.1016/j.jeurceramsoc.2007.12.015
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2. Taxonomy in ceramic processing which some texts on manufacturing forget to mention. They do it
rather cleverly by redefining the states of matter to give a chapter
Students of materials often learn manufacturing pathways in headed “Forming from the liquid and particle state”. The justi-
the form of lists of disconnected processes. There is no recogni- fication is obvious; powder suitable for compaction flows like a
tion that the processes might have some relationship to each other liquid (having a low angle of repose) into a die (cf. mould), has a
and to processes in other industries by a network of intersecting free volume comparable to that of a liquid and loses free volume
pathways. There is no idea that they may be connected rather like appropriately when it “solidifies” by compaction. Perhaps it is
a family tree to antiquity or indeed that they might share ‘genetic a meta-liquid? The student needs to remember that the analogy
defects’. Students learn these processes in the same way a child does not stretch very far; liquid flows more slowly in a pipe as
learns to spell and it must seem that they were plucked out of thin the pipe gets longer, powder flows more quickly.7
air unencumbered by antecedent and unconnected by principles. In the classification that follows, the four basic divisions are
To the student, processing is all about memory work; names to kept and treated as universal for all materials, as indeed they are
be learned for an exam, names soon to be forgotten. at a conceptual level. Compaction processes are placed in with
The real situation is not like that. Actually, ceramic pro- casting using the meta-material, free volume argument but fore-
cessing has learnt from and borrowed procedures from other warning students not to go treating powders as fluids in general.
industries. I use the term borrowed deliberately because ceram- The freeforming processes are separate but it is pointed out that
icists have often given those processes back with a far higher they can individually be loaded into the four classes (albeit with
level of understanding than attended them upon receipt. They some conceptual acrobatics).
have paid their interest on these loans in the form of enhanced
knowledge.
When it comes to textbooks on manufacturing processes, the 3. Inventiveness: serendipity or systematic thought?
choice of chapter headings reveals just how problematic is the
taxonomy even though these are mostly books that disclose no Shaping ceramics continues to provide challenges to the sci-
allegiance to a specific materials class in the title. One of the entific community especially as computer controlled methods
pitfalls of education is that if the same subject is taught under open up the capability for macro and microstructure design and
different course unit headings, the students tend to see it as two for computer control of 3D functional gradients. There is a pop-
separate subjects. The main aim of undergraduate students at ular idea that inventions are plucked out of thin air, unconnected
lectures is to get their notes into the right folders. So a course to previous ideas, uninformed by organised thought and equally
on materials processing delivered by a metallurgist can be seen accessible to all. The open access of the patent protection proce-
as quite a different subject to a course on materials process- dure, at least in principle, is a motivating force in our economic
ing delivered by a ceramicist. Undergraduates tend to perceive system and there is plenty of evidence to support the serendipity
knowledge as intrinsically fragmented because that is the way of invention. To argue from such examples towards a general
the assessment system is structured; students are tactically alert! rule of the dependence of invention on serendipity would, of
One of the most direct and standard classification of materi- course, be to use the fallacy of converse accident. Indeed, just
als processing is found in Ghosh and Mallik.1 After a chapter as there are some who claim that Shakespeare’s plays can be
on ‘Properties of Materials’ we get the straight unambiguous reduced to seven themes, so too there is an idea that inventions
four-way division into ‘Casting Processes, Forming Processes, have their own taxonomy. Booker8 puts forward the idea that
Machining Processes and Joining Processes’. There follows an most stories ever written can be reduced to seven plots (Over-
added chapter on ‘Unconventional Machining Processes’ which coming the Monster, Rags to Riches, The Quest, Voyage and
could have formed part of ‘Machining’ if the focus had not Return, Rebirth, Comedy, Tragedy). The arguments are compli-
been so heavily metallurgical. DeGarmo et al.2 follow the same cated and the book is substantial as Booker searches for order
approach except that casting and forming are thrown together in apparent chaos. What is relevant for us working in ceram-
in the same chapter. They differ at a fundamental level because ics processing is that others have done the same for the patent
casting involves a state change and deformation processing does literature.
not. One text gives the four classifications in relation to metals The soviet engineer Genrich Altshuller believed that a
and then adds, to a chapter list of different processes, the head- ‘method for inventing’ must exist and during his work in the
ing “Plastics” as though this is a new process.3 Kalpakjian4 does 1940s for the Russian Navy, began to develop a method that
much the same thing, separating both ‘Processing of Polymers has become known as TRIZ (the acronym for Teoriya Resh-
and Reinforced Plastics’ and ‘Processing of Powder Metals and eniya Izobretatelskikh Zadatch) or ‘Theory of Inventive Problem
Ceramics’ as though these involve fundamentally different pro- Solving’.9,10 His finding was that invention is the removal of
cesses to those used for metals. Lindberg5 puts “Plastics and technical contradictions with the help of principles that can be
Adhesives” and “Powder Metallurgy” into separate headings. identified; he logged 40 such principles. TRIZ is one of several
This means that adhesive joining is seen as distinct from other systems for invention and is probably the most well-known. Vin-
joining processes which have already been described in a sep- cent et al.11 show how TRIZ can be used to adopt in technology,
arate chapter and that powder processing must sit on its own. methods used in nature, so-called biomimetics but they point out
Alexander et al.6 are keen to keep to the four standard divi- that the database contains limited biological knowledge. Vincent
sions but have a problem in how to include powder processing, et al.12 go on to show how the TRIZ system can be extended.
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The important idea for our work in ceramics processing is find a quick answer, even if it be a wrong answer. This is an idea
that Altshuller recognised that the principles he found when that also pervades John Holt’s ‘How children fail’.18 The second
analysing patents from one industry were applicable to problems is “internal locus of evaluation”; the creative person is deemed
in another. He presents an idea of the universality of techni- to be relatively unaffected by praise or criticism. It is sometimes
cal problem solving which shows a striking similarity to the said that their ‘centre of judgement’ lies within the ‘bound-
ethos expressed in Richard Feynman’s well-known ‘tapestry’ aries of self’. In some assessments this appears as ‘disregard
metaphor: “Nature uses only the longest threads to weave her for authority’ which can be misleading; the authority exerted
patterns, so that each small piece of her fabric reveals the orga- by peers can be forceful yet imperceptible. An example might
nization of the entire tapestry”.13 The issue for those of us in be the way in which research funding ‘priorities’ sometimes
education is whether these tenets can be used to guide the career lurch from one theme to another under the ‘authority’ of collec-
development and peer structures of our systems of scientific tive thought and by analogy with fashion. The third is “ability
and engineering education and professional advancement, part to play with elements or concepts”; On this, Rogers17 waxes
of the aim of which is to contribute indirectly to the NSI. It lyrically and is worth quoting in full. “. . . the ability to play spon-
can sometimes seem that our systems favour intellectual isola- taneously with ideas, colours, shapes, relationships, to juggle
tionism. Since we embrace the principle of excellence through elements into impossible juxtapositions, to shape wild hypothe-
specialisation and we have a well-trenched system of disciplines ses, to make the given problematic, the express the ridiculous, to
supported both by the universities and professional institutions, translate from one form to another, to transform into improbable
structures not noted for their fluidity, it is quite possible for prac- equivalents.”.17 The literature on creativity is so vast and often so
titioners in one subject area to become progressively separated bizarre that conventional science and engineering departments
from those in another adopting the caricature of a tribal identity. are reluctant to introduce it at undergraduate level but it is rapidly
The need to ameliorate these schisms is now recognised and the accessing the research schools.
interdisciplinary efforts of the professional institutions and the
initiatives of research funding councils go some way to broad- 4. Intellectual integration and the NSIs
ening our outlooks. It is fair to say that the ceramics processing
community has, over the last two decades, embraced the organic Part of the reason for the state of materials processing is his-
and physical chemistry of surfactants, dispersants and polymers torical and is to do with the essential difference between the aims
in its quest to control particle behaviour; some ceramicists have and objectives of university scientists and manufacturers when
become colloid and polymer scientists and the community has they engage to do ceramics processing research. The scientist is
benefited. primarily interested in causation and is asking questions of the
TRIZ and similar ‘systematic’ approaches to creativity appeal external world; “Why does it happen?”, “Why is it cracked?”
to the science and engineering community partly because of their Why is it full of holes?”. The manufacturer is primarily inter-
organised nature but there is another putative route to inven- ested in goals and purposes and is making statements like; “We
tiveness and originality that is gaining popularity; the ‘chaos’ need to make this happen and we need to stop this happening”,
approach. The transfer of ideas or principles between subjects “We want this to happen faster”. There is a tragic sense in which
and between industries is considered to be due to serendipity the scientist is listening to an external world but can hardly hear
and to depend on a host of unpredictable prompts and interac- it while the manufacturer is instructing an external world which
tions. This does not mean that we are helpless to accelerate the is recalcitrant in inattentiveness. It is no wonder that when these
process. Advocates of ‘chaos in organisations’,14–16 promote two meet there are often difficulties in devising a joint research
the guiding principle of “management for chaos” in contrast to strategy that will fulfil the business and professional goals of
the obsolete “management of chaos”. Changing work patterns, each. On the one hand, these are matters of personal interac-
a flux of new interactions between people, the appearance of tion to be resolved by individuals but viewed collectively, they
meeting rooms and tea rooms, the emergence of UK research define the effectiveness of the National System of Innovation
council’s ‘sandpits’ are signs that the organisation recognises (NSI).
that new ideas nucleate on the edge of chaos. Encouraging and The efficiency of National Systems of Innovation (NSI) is
exploiting chaos is seen by some as a positive challenge to the a controversial issue because in western cultures, NSIs can
established organisational structures. Surprisingly, the universi- only be debated against a background context of state control
ties have been quite slow to adapt, often being hamstrung by rigid vs. the free-market, some arguing that government agencies
budgetary structures and, in the UK, by national competitive should not interfere with the way businesses develop their
research assessment “exercises”. technologies. This dualism makes it difficult to achieve the
Fascination with the source of creativity has spawned a large co-operation needed for effective functioning of an NSI. In
and diverse literature among which one of the more cautious some of the advanced free-market economies that are less ide-
analyses has identified three important characteristics.17 The ologically driven, NSIs are highly integrated and productive.
first is “openness to experience” or “extensionality” in which The NSI in the UK comprises an association of Manufactur-
a person accepts stimuli without distortion caused by emo- ers, Investors, the Department of Innovation, Universities and
tional defensiveness. This category includes the well-known Skills, the Universities, the Research Councils, Charitable Trusts
‘toleration of ambiguity’ concept, namely the ability to accept such as the Leverhulme, the Professional Institutions and the
contradiction without the discomfort that stimulates a need to Research Associations each of which has its own remits and
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Table 1
Casting/solidification processes for ceramicsa
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targets. Various knowledge transfer (KT) initiatives attempt to 5. Classification of the 70 ways
bring these diverse organisations together.
It is well known that NSIs in western developed nations have Tables 1–5 are not intended to be exhaustive of the multiplic-
limited efficacy in stimulating manufacturing growth and the ity of processes that have and are being used to shape ceramics
Peters study19 highlights this by using as a case study, the route but they do aim to portray a classification that can be used to iden-
to market of TFT-LCD displays, a journey that took nearly 40 tify similarities. Furthermore, the classification can be arranged
years. It is an interesting case study because the development to lead to new methods of forming.
of both thin film transistors and fast liquid crystals were nec-
essary but neither was sufficient. The aetiology of failure for 5.1. Casting/solidification processing
several western companies that participated in the early work
is the so-called ‘Hayes and Abernathy syndrome’20 ; short term What most textbook authors on processing omit is that all the
cost reduction in existing product lines rather than long term processes listed under casting in Table 1 follow the same prin-
development of technological competitiveness, an emphasis on ciple but that the method of state change can vary. It does not
early return on investment and a distancing of senior manage- much matter that the state change mechanism differs because
ment from the technological base giving rise to ‘management by in each case we have usually one surface (the mould) which
numbers’. It is likely that in assessing the history of high tech- can even be a flat sheet, which will define the final shape;
nology, those names, Hayes and Abernathy, will pop up again and that is casting. This is why replication foaming appears in
and again in an attempt to account for missed opportunities. this section; topologically, there is one surface upon which the
Japanese and Korean NSIs were more integrated and it is from slurry is cast as in tape casting. In the classification, the state
those nations that displays emerged into the market place. There change is a second order identifier but it should be remembered
is a sense in which the Peters study holds up a mirror to show that in each state change method, free volume at some level of
the extent of fragmentation of some NSIs. structural hierarchy generally (but not always) decreases. Free
Table 2
Deformation processes
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Table 3
Machining/material 97–108 removal
Table 4
Joining
the polymer is subsequently converted to a ceramic. Many of is a good example to which practically all ceramic–ceramic
the foaming processes for ceramics involve elongational flow of and ceramic–metal joining methods have been applied during
a powder suspension and are thus distinguished from replication development.
foaming which is casting upon a free surface.
5.5. Solid freeforming
5.3. Machining/material removal
Solid freeforming (Table 5) can be defined as the creation of a
shape by point, line or planar addition of material without confin-
The common feature in this class of processes (Table 3) is
removal of material from a blank to leave any one of an infinite Table 5
number of shapes. These are subtractive processes and anything Solid freeforming
that cuts, abrades, ablates or corrodes provides a potential new
process.
5.4. Joining
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Fig. 3. A model of the maze at Hampton Court Palace made with a Xaar inkjet
printer using zirconia and fired at 1400 ◦ C. The distance marker is 1 mm. The
likely applications are for high temperature gas phase microreactors.
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6. Concluding remarks
Acknowledgements
ceramic processing to students and the attempt here has been
to ameliorate them by dealing in concepts of processing before The author is grateful for the support of EPSRC under Plat-
introducing individual precisely defined processes. This method form Grant No. EP/E046193 and Leverhulme Trust Grant No.
of delivery still retains lacunae because the processes of interest F/07 476/V.
tend to be ‘high technology’ or ‘state of the art’ and these are
the ones that command the most interest for students. Their his-
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