Low cost ceramic moulding compound/composites are composed of inorganic metal silicates, fillers and different types of chopped fibre reinforcements, such as glass fibres. This research investigated manufacturing process of a series of ceramic moulding compounds that could be moulded at modest temperature(~ 150 °C) and pressure. The process replicates the polymer dough moulding compounds as fibre reinforced polymeric moulding composites(FRP). The conventional polymeric matrix of the DMC has been replaced by a soluble metal silicates based on an inorganic system which can be compounded with fibres, minerals or synthetic fillers and hardening additives to produce a thick paste or a doughy substance(ceramic DMC/CDMC). The CDMC compounds demonstrated a good handle-ability and can be adjusted by the viscosity of the matrix through the use of amount of fillers and additives. The mechanical properties of the compounds have been tested and additional formulation changes have been introduced to maintain desirable processing characteristics... Low cost ceramic moulding composites: -Materials and manufacturing technology G Ren*, P J Hogg* and D H Woolstencroft** Low cost ceramic moulding compounds/composites (CMC) are composed of inorganic metal silicates, fillers and different types of chopped fibre reinforcements, such as glass fibres. This research investigated manufacturing process of a series of ceramic moulding compounds that could be moulded at modest temperature (~ 150 °C) and pressure (0~8 MPa). This manufacturing process replicated the polymer dough moulding compounds as fibre reinforced polymeric moulding composites or Dough Moulding Compounds (DMC). The conventional polymeric matrix of DMC has been replaced by a soluble metal silicates based on an inorganic system which can be compounded with fibres, minerals or synthetic fillers and hardening additives, to produce a thick paste or a doughy substance -so called Ceramic Dough Moulding Compounds (CDMC). The CDMC demonstrated a good handle-ability and can be adjusted by the viscosity of the matrix through the use of various amounts of fillers and additives. The mechanical properties of the compounds have been tested and additional formulation changes have been introduced to maintain desirable processing characteristics.Dr Ren (g.ren@qmul.ac.uk) was in the Department of Materials, Queen Mary, University of London. He is now in the University of Hertfordshire, Hatfield AL10 9AB, UK. Professor P J Hogg is now in the University of Manchester, Manchester M60 1QD. Dr Woolstencroft is with Matrice Technology, Poulton, Lancs. FY6 8GD, UK.Keywords: ceramic silicates, moulding, composites, compounding, processing, glass fibre, fillers, viscosity.
IntroductionIt is well known that ceramic materials can provide good fire resistance and thermal stability at elevated temperature. However, due to their nature of the bonding within the composition and molecular structures, they are very brittle and considered as unreliable or inappropriate in many engineering applicatio...