GLASS PROCESSING ( DCP 5262 ) By: Abu Bakar bin Aramjat Department of Ceramic Processing Technology Kolej Kemahiran Tinggi MARA Masjid tanah Melaka.

GLASS PROCESSING( DCP 5262 )

By: Abu Bakar bin AramjatDepartment of Ceramic Processing

TechnologyKolej Kemahiran Tinggi MARA Masjid tanah

Melaka

COURSE INFORMATION

Code: DCP 5262Course Name : Glass Processing

Learning/Week:1 hour : Theory ( lecture )3 hours: Lab/Practical

Assessment

Course work: 1. Test 1: 15 % ( UNIT 1 & 2 )2. Test 2: 15 % ( UNIT 3 & 4 )3. Practical Lab: 30 % ( JOB SHEET – 8 )

Final Exam: 40 %

LEARNING OBJECTIVESLEARNING OBJECTIVES

Students should be able to:

i. Identify various types and properties of common glasses.

ii. Formulate, and determine glass melting and forming process.

iii. Conduct glass testing and identify defects.iv. Differentiate glass decoration and finishing techniques

COURSE CONTENTCOURSE CONTENT

UNIT 1.0 INTRODUCTION TO GLASS 

1.1 History of Glass1.2 Glass Families1.3Types of Glasses1.4 Chemical Compositions of Commercial Glasses1.5 Glass Raw Materials1.6 General Glass Makings1.7 Applications of Glasses1.8 Basic Principles of Glass Processing: Batching, Mixing, Melting, Casting and Annealing

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COURSE CONTENTCOURSE CONTENTUNIT 2.0 PROPERTIES OF GLASS 2.1 Glass Formation & Structure2.2 Thermal Expansion2.3 Micro hardness and Strength2.4 Viscosity2.5 Chemical Durability2.6 Optical Properties

UNIT 3.0 GLASS MELTING 3.1 Preparation for Glass Melting3.2 Glass Melting Furnaces3.3 Glass Casting and Shaping3.4 Annealing and Tempering

COURSE CONTENTCOURSE CONTENTUNIT 4.0 TESTING OF GLASS 

4.1 Density and Molar Volume4.2 Thermal Expansion4.3 Micro hardness and Strength4.4 Chemical Durability4.5 Optical Properties4.6 Glass Defect

UNIT 5.0 GLASS DECORATION AND FINISHING 5.1 Glass Colorants5.2 Glass Etching5.3 Sand Blasting5.4 Stain Glass5.5 Laser Techniques

1. What is Glass2. Glass from Nature3. Composition of glass4. Types of glass5. Advantages & Disadvantages of

glass6. Glass Products7. Glass Malaysia Scenario

Introduction to Glass

What is Glass

An inorganic product of fusion which has been cooled to rigid condition without crystallising - ASTMoA state of matteroA glassy or vitreous surfaceoA solid with liquid like structureoA non-crystalline solidoAn amorphous solidoShort range order

What is Glass

“…a material form by cooling from the normal liquid state which has shown no discontinuous change at any temperature, but has become more or less rigid through a progressive increase in its viscosity.”

What is Glass

oUniform amorphous solid material.

oProduced when the viscous molten material cools rapidly to below its glass transition temperature, without sufficient time for a regular crystal lattice to form.

What is Glass - characteristics

oClear /transparentoBrittleoInertoDurableoLuster

Glass from Nature

oMagma – molten rockoFulgurite – lightningoObsidian – volcanicoTektites – fire/volcanic

Glass from Nature

magma fulgurite

obsidian tektites

Silica Sand

Silica Sand

Limestone (CaCO2)

Sodium Carbonate/soda ash

(Na2CO3)

Feldspar,

Borates

Phospate

Traditional Glass

Composition of Glass

Glass Additives

1. Boric oxide: B2O32. Barium Carbonate : BaCO33. Potassium Carbonate : K2CO34. AluminiumOxide : Al2O35. Zinc Oxide : ZnO6. Titanium Oxide : TiO27. Zirconium Oxide : ZrO2

ALUMINA in glass for :improved weathering and less devitrification (crystallisation),

BORATES for easier working and lower thermal expansion,

ARSENIC OR ANTIMONY OXIDE for fining (removal of bubbles).

Function additive in glass

Type of Glass

The main types of glass are:Commercial Glass also known as Soda-lime-silicate glass

Lead Glass Borosilicate Glass Glass Fibre

Type of Glass

Types of special glass include:Vitreous silica Aluminosilicate glass Alkali-barium silicate glass Technical Glass Glass Ceramics Optical glass Sealing glass

Important class of compositions is the BOROSILICATES.

lower thermal expansion better thermal shock resistance, improved chemical durability,

for such applications as automobile head-lamps, cooking wares and laboratory apparatus

Types of Glass

ALUMINO SILICATE GLASSES for :

chemical durability, resistance to devitrification, higher temperature, and greater strength in cooking wares,

glass ceramics, fiber glass and seals.

Types of Glass

FUSED SILICA is especially valuable for :

high-temperature stability, low thermal expansion andhigh thermal shock resistance, excellent chemical durability, purity and good optical transmission in the ultraviolet.

Types of Glass

LEAD GLASSES are used for high refractive index, easier working and greater density for lamp envelopes, seals, optical glass

CRYSTAL GLASS for art and tableware

Types of Glass

Advantages of Glass

InertDoes not corrodeDurableOptical transparencyMany forming methodMany compositionCheap

Disadvantages of Glass

BrittleBreakableHeavy

Glass ProductsWindow glassGlass containersFiber glassOptical glass / lensTechnical glass / laboratory glassSafety glass / windscreen glassGlass panels / buildingTableware / cooking wareBulb/chandelier/lighthingLaser glassGlass mirrorsGlass ceramic

Glass Products

The word glass is derived from a late-Latin term glaesum, used to refer to a lustrous a transparent material

Another word often used to refer to glassy substances is vitreous, originating from the Latin word vitrum.

Luster or shine and in particular its durability when exposed to the elements of nature, were probably the most significant properties of glass recognised by early civilisations.

History of Glass

The history of the origin of glass can be categorized by periods according to the methods of the manufacturing process as follows:

The First Period: 1700 BC through 100 ADPrimitive method of making glass

using molds. The Second Period: 100 AD through 400-

500 ADGlassblowing technique discovered,

and glass manufacture becomes a more practical process.

The Third Period: 4-500 AD ~ 1200 ADMiddle Ages, characterized by

Byzantine glass.

History of Glass

The Fourth Period: 1200 AD ~ 1900 ADVenetian glass, foundation for

modern glass making is set. The Fifth Period: 1900 AD ~ present

Glass objects used as everyday goods; large scale manufacturing.

The science and engineering of glass as a material was much better understood, and in the late 1950's Sir Alastair Pilkington introduced a new revolutionary production method (float glass production), by which 90% of flat glass is still manufactured today.

History of Glass

The word glass is derived from a late-Latin term glaesum, used to refer to a lustrous a transparent material

Another word often used to refer to glassy substances is vitreous, originating from the Latin word vitrum.

Luster or shine and in particular its durability when exposed to the elements of nature, were probably the most significant properties of glass recognised by early civilisations.

History of Glass

The history of the origin of glass can be categorized by periods according to the methods of the manufacturing process as follows:

The First Period: 1700 BC through 100 ADPrimitive method of making glass

using molds. The Second Period: 100 AD through 400-

500 ADGlassblowing technique discovered,

and glass manufacture becomes a more practical process.

The Third Period: 4-500 AD ~ 1200 ADMiddle Ages, characterized by

Byzantine glass.

History of Glass

The Fourth Period: 1200 AD ~ 1900 ADVenetian glass, foundation for

modern glass making is set. The Fifth Period: 1900 AD ~ present

Glass objects used as everyday goods; large scale manufacturing.

The science and engineering of glass as a material was much better understood, and in the late 1950's Sir Alastair Pilkington introduced a new revolutionary production method (float glass production), by which 90% of flat glass is still manufactured today.

History of Glass

Quick Question

Name four of the major technological achievements in glass which have had the most profound impact on mankind

Quick Question - Answer

1. Glass window – which enables sunlight to come into dwelling unit

2. Lenses – opthamics for improved vision,microscope,telescope optics

3. Light bulb envelope - lighting4. Semiconducting glasses – for

computer memory, solar cell, photocopiers

The word glass is derived from a late-Latin term GLAESUM, used to refer to a lustrous a transparent material

Another word often used to refer to glassy substances is vitreous, originating from the Latin word vitrum.

Luster or shine and in particular its durability when exposed to the elements of nature, were probably the most significant properties of glass recognised by early civilisations.

History of Glass

The history of the origin of glass can be categorized by periods according to the methods of the manufacturing process as follows:

The First Period: 1700 BC through 100 ADPrimitive method of making glass

using molds. The Second Period: 100 AD through 400-

500 ADGlassblowing technique discovered,

and glass manufacture becomes a more practical process.

The Third Period: 4-500 AD ~ 1200 ADMiddle Ages, characterized by

Byzantine glass.

History of Glass

The Fourth Period: 1200 AD ~ 1900 ADVenetian glass, foundation for

modern glass making is set. The Fifth Period: 1900 AD ~ present

Glass objects used as everyday goods; large scale manufacturing.

The science and engineering of glass as a material was much better understood, and in the late 1950's Sir Alastair Pilkington introduced a new revolutionary production method (float glass production), by which 90% of flat glass is still manufactured today.

History of Glass

Byzantine Glass Venetian Glass

Blowing Glass

Float Glass

Glass Industry in Malaysia: present Industry ScenarioThe present production capacity of the flat and container glass industry is capable of supporting the domestic market demand and subsequently a substantial amount of output is exported. The output is currently in the rgion of 650 tonnes of glass containers and 500000 tonnes of flat glass annually

Glass Malaysia ScenarioGlass Categories Products

Silica-based chemical Sodium silicate

Construction –related products tempered & laminated glass

Industrial glass Fiberglass, float glass, panel & funnel, cullet

Advanced & specialty glass Silicon wafer, optical & pharmaceutical glass, glass substrate, handphone screen

Household glass product Tableware, container/bottles, microwave turntable

Glass Malaysia Scenario

Glass Categories Production Qty

Silica-based chemical 5000-70000 tonnes

Construction –related products 3500 -22000 tonnes

Industrial glass 3 – 54m tonnes

Advanced & specialty glass 10m – 20m pcs

Household glass product 30000 – 71000 tonnes

Source: Mineral &Geoscience Department Industry Survey 2007

Existing Local manufacturers based on product Grouping

Product Groups Manufacturrers

Clear Flat glass Malaysian Sheet Glass Bhd (MSG)Malaysia n Mirrors Sdn Bhd

Colourless & Coloured Container Glass

KIG Glass Industrial Sdn BhdJG Container Sdn BhdKL Glass Mfr Co Sdn Bhd

Tableware Glass Malaya Glass BhdAsia Glass Sdn BhdHamay Glass Sdn Bhd

Clear Flat Glass (laminated) MSG Safety Glass Sdn BhdMCIS Safety Glass Sdn Bhd

Existing Local manufacturers based on product Grouping

Product Groups Manufacturrers

Clear Flat Glass (tempered) Malaysian Sheet Glass sdn bhd

MCIS Safety Glass sdn bhd

Funnels & Panels for CRT Samsung Corning sdn bhdNippon Electric Glass sdn bhdMatsushita Electric Corp sdn bhd

Chemical/Lab glassware Sri K.K Industry sdn bhd

Insulating glass wool and fibreglass Johore fiberglass sdn bhdPolyglass Fibre sdn bhdFoster Insulation sdn bhdArt Fiber Industry sdn bhdB.I.T Fiber Glass sdn bhd

Existing Local manufacturers based on product Grouping

Product Groups Manufacturrers

Optical Glass Policore Optical sdn bhdSchott Glass sdn bhdOhara Optical Sdn Bhd

Glass Substrate/ electronic glass Konica Minolta Glass Tech Sdn Bhd

Crystal Glass Rembau Crystal SBFaizy Crystal Glass Blowing SBPL Crystal Village SB

Thank you…

End of lecture