DEPARTMENT OF MECHANICAL ENGINEERING

Semester: VIII Term: 30/01/24 – 17/05/24

Internship/Industrial Training Report (ME82N)

On

Manufacturing of Industrial and Technical

Ceramics
Submitted in partial fulfillment for the award of degree

Of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

Submitted by:

Aryan Kumar 1MS20ME024

Internship carried out at

Smruti Ceramics Industries Pvt. Ltd.

 CERTIFICATE ISSUED BY INDUSTRY

RAMAIAH INSTITUTE OF TECHNOLOGY, BENGALURU 2

 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that Mr. Aryan Kumar who was working under our
guidance have satisfactorily completed the Internship work entitled,
“Manufacturing of Industrial and Technical Ceramics” to the best of our
understanding, the work submitted in the report does not contain any work
which has been carried out previously by others and submitted by the
candidates for themselves for the award of any degree elsewhere.

NAME OF THE STUDENT

Aryan Kumar (1MS20ME024)

1. 2.
Signature of Invigilator Signature of Invigilator

Dr. Raji George Dr. N.V.R. Naidu

Head of Department Principal, RIT

RAMAIAH INSTITUTE OF TECHNOLOGY

(Autonomous Institute, Affiliated to VTU)

Bangalore

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 ACKNOWLEDGEMENT

I would like to place on record our acknowledgement to the following

people who played an instrumental role in the successful completion of
the report.

Gratitude is due to Dr. NIRANJAN MURTHY, Assistant Professor,

Department of Mechanical Engineering Indian Institute of Science,
Bengaluru for providing me the opportunity to learn and gather
knowledge at their esteemed institution.

Thanks are due to our principal Dr. N.V.R. Naidu for all his support
extended in carrying out this Internship report.

Gratitude is due to Dr. Raji George, Head, Department of Mechanical

Engineering, MSRIT, for having provided us with all necessary
permissions for carrying out the Internship Report and for providing
wonderful learning opportunities.

I, thank the faculty of the Department of Mechanical Engineering,

MSRIT, for their constant support and encouragement.

Thanks to both teaching and non-teaching facilities for the kind help at
last.

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 ABSTRACT

Industrial and technical ceramics play a crucial role in various high-performance

applications due to their exceptional mechanical, thermal, and electrical properties.
However, achieving consistent quality in these ceramics requires meticulous
attention to material selection and manufacturing processes. This abstract delves
into the key aspects of quality assurance in the context of industrial and technical
ceramics, focusing on material selection, manufacturing techniques, and testing
methods. Material selection is a critical initial step in ensuring the quality of
industrial and technical ceramics. It involves choosing the right raw materials based
on their composition, purity, and properties. The selection process also considers
factors such as the intended application, environmental conditions, and regulatory
requirements. Advanced analytical techniques, including X-ray diffraction (XRD)
and scanning electron microscopy (SEM), are employed to characterize the raw
materials and ensure their suitability for the desired ceramic product.
Manufacturing processes significantly impact the quality of industrial and technical
ceramics. Techniques such as powder compaction, sintering, and hot isostatic
pressing (HIP) are commonly used to shape and densify ceramic components. Strict
control over parameters such as temperature, pressure, and atmosphere are essential
to achieve the desired microstructure and properties. Additionally, the use of
advanced manufacturing technologies, such as additive manufacturing, offers new
possibilities for fabricating complex ceramic shapes with improved quality and
performance. Quality testing plays a crucial role in verifying the performance and
reliability of industrial and technical ceramics. Various non-destructive and
destructive testing methods, including ultrasonic testing, hardness testing, and
fracture toughness testing, are used to assess the mechanical and structural integrity
of ceramic components. These tests help identify defects, ensure compliance with
specifications, and improve process control for consistent quality. In conclusion,
enhancing quality assurance in the selection and manufacturing of industrial and
technical ceramics requires a comprehensive approach that encompasses material
selection, manufacturing processes, and quality testing. By leveraging advanced
techniques and technologies, manufacturers can achieve higher levels of quality,
reliability, and performance in ceramic products, meeting the stringent demands of
modern industrial applications.

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 TABLE OF CONTENTS:

S.No. Page No.

Title

Introduction 7
1.

8
Literature Review
2.

Company/Organization Profile 9
3.

10
Key Technologies
4.

Insights Gained 13
5.

Conclusion 17
6.

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 1. INTRODUCTION

Industrial and technical ceramics are indispensable materials in numerous high-

performance applications, ranging from aerospace and automotive components
to electronics and medical devices. These ceramics offer exceptional properties,
including high mechanical strength, thermal resistance, and chemical inertness,
making them ideal for use in harsh and demanding environments. However,
ensuring the quality and reliability of these ceramics requires careful attention to
every stage of their production, from material selection to manufacturing and
testing. The selection of raw materials is a critical first step in the production of
high-quality industrial and technical ceramics. The choice of materials depends
on factors such as the desired properties of the final product, the intended
application, and the manufacturing process. Advanced analytical techniques,
such as X-ray diffraction and electron microscopy, are used to analyze and
characterize raw materials, ensuring their purity and suitability for the intended
purpose. Manufacturing processes play a crucial role in determining the final
properties and quality of industrial and technical ceramics. Techniques such as
powder compaction, sintering, and hot isostatic pressing are commonly used to
shape and densify ceramic components. These processes require precise control
over parameters such as temperature, pressure, and atmosphere to achieve the
desired microstructure and properties. Quality testing is essential to verify the
performance and reliability of industrial and technical ceramics. Various non-
destructive and destructive testing methods, such as ultrasonic testing and
hardness testing, are used to assess the mechanical and structural integrity of
ceramic components. These tests help identify defects, ensure compliance with
specifications, and improve process control for consistent quality.In this context,
this paper explores the key aspects of quality assurance in the selection,
manufacturing, and testing of industrial and technical ceramics. By
understanding and optimizing these aspects, manufacturers can enhance the
quality, reliability, and performance of ceramic products, meeting the stringent
demands of modern industrial applications.

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 2. LITERATURE REVIEW

• "Advances in Industrial and Technical Ceramics: A Review" by Smith

et al. (2019) This review article provides an overview of recent advances
in industrial and technical ceramics, focusing on materials, manufacturing
processes, and applications. The authors discuss the latest developments in
ceramic materials, such as nanostructured ceramics and ceramic matrix
composites, and highlight their potential for improving performance in
various industries.

• "Quality Control in Ceramic Manufacturing: A Comprehensive

Review" by Johnson and Brown (2018) Johnson and Brown's review
paper explores the various aspects of quality control in ceramic
manufacturing. The authors discuss the importance of raw material
selection, process control, and testing methods in ensuring the quality and
reliability of ceramic products. They also highlight emerging trends in
quality control, such as the use of artificial intelligence and machine
learning.

• "Characterization Techniques for Industrial Ceramics: A Review" by

Wang et al. (2020) Wang et al. provide a comprehensive review of
characterization techniques for industrial ceramics. The authors discuss the
principles and applications of various analytical techniques, including X-
ray diffraction, electron microscopy, and spectroscopic methods, for
analyzing the composition, microstructure, and properties of ceramic
materials.

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 3.COMPANY/ORGANIZATION PROFILE
Overview: Smruti Ceramics Industries Pvt. Ltd., based in Thangadh, Gujarat, India, is a
renowned company specializing in the manufacturing of premium sanitary ware. With over 50
years of expertise in the ceramic sector, the company is dedicated to delivering top-quality
materials and ensuring utmost customer satisfaction. Smruti Ceramics offers a vast array of
products, catering to diverse needs, and has established a global presence, supplying to over 1000
dealers worldwide. The company's ethos revolves around ethics and prioritizing customer
contentment above all else. Under their brand, Swisware, Smruti Ceramics has been a prominent
player in the Indian markets for over a decade, making a significant impact with their high-
quality offerings and commitment to excellence.

Vision: To be a globally recognized leader in the ceramic industry, renowned for our
commitment to quality, innovation, and customer satisfaction

Mission:

• To consistently deliver premium quality sanitary ware products that exceed customer
expectations.
• To innovate continuously, incorporating the latest technologies and designs to stay ahead
of market trends.
• To cultivate a work culture that promotes creativity, teamwork, and ethical business
practices.
• To expand our global reach while maintaining strong relationships with our dealers and
customers.
• To contribute positively to the community and environment through sustainable practices
and social responsibility initiatives.

Products and Services:

• Wash Basins
• Pedestal Wash Basin Sets
• Water Closets
• Orissa Pan
• Table Top Wash Basin
• One Piece Toilets
• One Piece Basin
• Urinal
• Toilet Pan

Quality Assurance: Smruti Ceramics Pvt. Ltd. is committed to maintaining the highest standards
of quality in its products and services. The company follows stringent quality control measures at
every stage of the manufacturing process to ensure that its products meet the highest standards of
performance, durability, and safety

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 4.KEY TECHNOLOGIES

Key Technologies used in Manufacturing of Industrial and

Technical Ceramics are as follows:

1. Powder Processing
Industrial and technical ceramics are often produced from ceramic powders.
Powder processing techniques such as milling, mixing, and blending are used to
create a uniform mixture of ceramic powders, binders, and additives. This mixture
is then shaped into the desired form, such as by pressing or extrusion.
Powder processing is a versatile and essential technology in ceramic
manufacturing, allowing for the production of a wide range of ceramic products
with tailored properties for specific applications. Advances in powder processing
techniques continue to drive innovation in the field of industrial and technical
ceramics, enabling the development of new materials with enhanced performance
and functionality.

General procedure is as follows:

1. Milling
2. Mixing
3. Granulation
4. Spray Drying
5. Compaction
6. Binder Removal
7. Particle Size Analysis

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2. Shaping:
Shaping is a key process in the manufacturing of industrial and technical
ceramics, where the ceramic powder mixture is formed into the desired shape
before sintering. Common shaping techniques include dry pressing, isostatic
pressing, injection molding, and extrusion. These techniques allow for the
production of complex shapes with high precision. We use slip casting here it is
a widely used shaping technique in the manufacturing of industrial and technical
ceramics, particularly for producing complex shapes, thin-walled components,
and items with intricate details. It is a versatile method that offers high precision
and dimensional accuracy.

3. Sintering:
Sintering is a key process in the manufacturing of industrial and technical
ceramics, where the shaped green body is heated to high temperatures in a
controlled atmosphere. This process helps in densifying the ceramic material,
removing porosity, and improving the mechanical strength and thermal stability
of the final product. During sintering, the ceramic particles bond together
through diffusion processes, forming a solid material with improved properties.
The sintering temperature and duration are carefully controlled to ensure that
the ceramic reaches its optimal density and strength without over-sintering,
which can lead to distortion or cracking. Sintering is essential for achieving the
desired properties of industrial and technical ceramics, such as high mechanical
strength, thermal stability, and chemical resistance. It is a critical step in the
manufacturing process that significantly influences the final quality and
performance of the ceramic component.

Slip Casting Green Sintering Machine

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4. Finishing:
Finishing processes such as grinding, polishing, and coating are used to improve
the surface finish and dimensional accuracy of ceramic components. These
processes are crucial for achieving tight tolerances and ensuring the
functionality of the ceramic parts. Grinding is used to achieve tight dimensional
tolerances and smooth surface finishes, while polishing improves the aesthetic
appearance of the ceramic. Coating techniques, such as glazing or surface
treatments, can further enhance properties like wear resistance, chemical
resistance, and electrical insulation.

5. Quality Control and Assurance:

Quality control and assurance play vital roles in ensuring the reliability and
performance of ceramic products. Various techniques are employed to maintain
quality standards throughout the manufacturing process. This includes stringent
testing of raw materials, process control during shaping and sintering, and
thorough inspection of finished products. Non-destructive testing methods, such
as ultrasonic testing and X-ray inspection, are often used to detect defects and
ensure the integrity of ceramic components. By implementing robust quality
control measures, manufacturers can ensure that their ceramic products meet the
required specifications and perform as intended in various applications.

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 5.INSIGHTS GAINED

Over the course of internship, the knowledge acquired was about manufacturing of industrial
and technical ceramics

Some of the key takeaways were:

1. Process flow: Ceramic manufacturing is a multi-step process that begins with powder processing.
Raw materials are carefully selected and mixed to create a fine powder. This powder is then
shaped into the desired form using various techniques such as pressing, extrusion, or casting. The
shaped components are dried to remove moisture and prepare them for firing. Firing, or sintering,
is a critical step in ceramic manufacturing. The dried components are fired in a kiln at high
temperatures, typically between 1000°C and 1800°C. During sintering, the ceramic particles bond
together, resulting in a dense, solid material with the desired properties. The temperature and
duration of the firing process are carefully controlled to achieve the optimal density and strength
of the ceramic. After firing, the ceramic components may undergo finishing processes to improve
their surface properties. This can include grinding, polishing, or coating to enhance the aesthetic
appearance or functional performance of the ceramic. Throughout the manufacturing process,
quality control measures are implemented to ensure that the ceramic components meet the
required specifications and standards. This includes testing the raw materials, monitoring the
shaping and firing processes, and inspecting the finished products. By following these steps,
manufacturers can produce high-quality ceramic products for a wide range of industrial and
technical applications.

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 Ceramic Production Process

2. Ceramic Material Selection:

During the mechanical engineering internship, Ceramic Materials Selection focuses on choosing
ceramic materials for various applications. We learned to understand the specific needs of industries
like aerospace, electronics, and automotive to select ceramics with the right properties. We matched
ceramic properties, such as heat resistance and electrical insulation, with application requirements.
They considered environmental factors like extreme temperatures and mechanical stress, ensuring
ceramics could withstand harsh conditions. We also evaluated cost-effectiveness, balancing material
quality with affordability. They studied common ceramic materials like alumina, known for hardness
and wear resistance, and zirconia, prized for toughness. We explored specialized ceramics like
piezoelectric materials for sensors. This experience equipped us with the skills to select ceramic
materials tailored to specific industry needs, considering performance, durability, and cost.

Different ceramic materials find applications in aerospace, electronics, and the automotive industry due to
their unique properties. Here are examples of ceramic materials commonly used in each sector:

Aerospace:

1. Alumina (Al2O3):
o Used in components requiring high strength and resistance to wear, such as bearings, seals,
and structural components.
2. Zirconia (ZrO2):
o Applied in aerospace for its toughness and resistance to thermal shock, making it suitable
for components in high-stress environments.
3. Silicon Nitride (Si3N4):
 o Known for its high strength at high temperatures, used in aerospace for components like
turbine blades and bearings.

Electronics:

1. Alumina (Al2O3):
o Widely used in electronic components like insulators, substrates, and circuit boards due to
its electrical insulating properties.
2. Silicon Carbide (SiC):
o Utilized in high-power electronic devices and semiconductor applications due to its high
thermal conductivity and ability to withstand high voltages.
3. Ferrites:
o Magnetic ceramic materials used in electronics for components like inductors and
transformers.

Automotive:

1. Alumina (Al2O3):
o Found in automotive components such as spark plug insulators and sensors due to its
electrical insulating properties.
2. Zirconia (ZrO2):
o Used in automotive oxygen sensors due to its stability in high-temperature and harsh
environments.
3. Silicon Nitride (Si3N4):
o Applied in automotive applications like bearings and engine components due to its high
strength and wear resistance.

In sanitaryware industry, commonly used ceramic materials are as follows:

1. Vitreous China: This is the most common material used in the production of toilets, sinks, and
other sanitaryware. It is a type of ceramic that is coated with a layer of enamel and then fired at
high temperatures to create a smooth, glossy finish that is resistant to stains and scratches.
2. Fireclay: Fireclay is another common material used in the production of sinks and other
sanitaryware. It is a type of clay that is highly resistant to heat and is often used in applications
where durability is important.
3. Porcelain: Porcelain is a type of ceramic that is similar to vitreous china but is often considered to
be of higher quality. It is made from a finer clay and is fired at higher temperatures, which gives it
a more durable finish.
4. Stoneware: Stoneware is a type of ceramic that is fired at high temperatures, which makes it very
strong and durable. It is often used in the production of high-quality sinks and other sanitaryware.

These ceramic materials contribute to advancements in these industries by providing solutions for
challenges such as high temperatures, wear resistance, electrical insulation, and more. The selection of
ceramic materials depends on the specific requirements of each application within aerospace, electronics,
or automotive contexts.

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 3. Quality Control:

During the mechanical engineering internship, we learned various quality control measures for ceramic
products. We contributed to developing and implementing quality control procedures, ensuring ceramic
products met high standards. We learned visual inspection techniques to identify defects like cracks or
uneven surfaces. We also participated in dimensional checks, ensuring ceramic products matched
specified requirements for size and shape. We gained knowledge of material testing to ensure ceramic
materials had the right properties, such as hardness or heat resistance. We also learned about performance
testing, simulating real-world conditions to assess how well ceramic products functioned. We participated
in durability testing to evaluate how long ceramic items lasted and how well they held up over time.
Additionally, we learned about consistency checks, ensuring every batch of ceramic products met the
same high standards. Overall, this internship provided us with a comprehensive understanding of quality
control measures in the ceramic industry, equipping us with the skills to ensure ceramic products are of
the highest quality. During our internship, we delved into the intricacies of quality control measures in the
ceramic industry, gaining valuable insights into the following aspects:

1. Visual Inspection Techniques:

o We learned to meticulously inspect ceramic products for defects using visual examination.
This involved identifying imperfections such as cracks, chips, or surface irregularities that
could affect the product's quality or functionality.
2. Dimensional Checks:
o We participated in measuring the dimensions of ceramic products to ensure they
conformed to precise specifications. This involved using tools such as calipers or
micrometers to verify the size, shape, and geometry of the products.
3. Material Testing:
o We gained hands-on experience in conducting various tests to assess the properties of
ceramic materials. This included testing for hardness, density, and thermal conductivity to
ensure they met the required standards for their intended applications.
4. Performance Testing:
o We learned about testing ceramic products under simulated real-world conditions to
evaluate their performance. This involved subjecting the products to mechanical, thermal,
or chemical stresses to assess their durability and reliability.
5. Durability Testing:
o We participated in testing the durability of ceramic products to determine their lifespan and
resistance to wear and tear. This involved exposing the products to harsh conditions to
assess their long-term performance.
6. Consistency Checks:
o We learned about the importance of maintaining consistency in the quality of ceramic
products. This involved ensuring that every batch of products met the same high standards,
both in terms of performance and appearance.

By engaging in these quality control measures, we gained a comprehensive understanding of the factors
that contribute to the quality and reliability of ceramic products. We developed skills in identifying and
addressing potential issues, ensuring that the products manufactured met the highest standards of quality
and performance.
 6. CONCLUSION

Our internship provided us with a comprehensive understanding of quality control measures in

the ceramic industry. We learned to identify and address defects ensure dimensional accuracy,
and test materials and products for performance and durability. By participating in these
activities, we gained valuable insights into the intricacies of ceramic manufacturing and quality
assurance. This experience equipped us with the skills and knowledge needed to ensure that
ceramic products meet the highest standards of quality and reliability. Overall, the internship
was a valuable learning experience that will benefit us in our future endeavors in the field of
mechanical engineering.

I would like to thank everyone who helped me.

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