Deliverables
On the basis of own industrial practice and of costs evaluation CIFER chose, in agreement with the RTD performers, the raw materials to develop an alumina based composition with the Al2O3 content more than 96 wt %.
Then, by examining the results of rheological tests, the aqueous suspension preparation conditions were defined.
The suitable procedure to add the gelling binder to the developed suspension was set-up.
The prepared mix processing conditions were studied and optimised, at laboratory level, by injecting the mix into a mould for cylindrical components production.
Finally, pre-series of alumina thread guides with the Al2O3 content more than 96 wt % were realised by using the optimised conditions for low pressure injection moulding. Different components of the same composition could be produced, by the same technique, if the suitable mould is available.
On the basis of own marketing knowledge, LOUCANIA decided, in agreement with the RTD performers, the realisation of porcelain round "pan with handle".
By exploiting the previous RTD work on porcelain mix preparation, the optimised mix preparation procedure was set-up.
The processing conditions were studied and defined, at laboratory level, by injecting the prepared mix into the prototype mould.
On the basis of its own experience and of the other partners and RTD performers suggestions, BC Italiana has developed design criteria and guidelines for realisation of moulds for ceramics production by low pressure injection moulding of aqueous ceramic mixes.
The prototype moulds have been designed to be easily used in connection with the machine for low pressure injection moulding, developed by GOCERAM in the frame of the AQUIMCER project, but the used approach enable their assembling to different machines.
The prototype moulds have been purposely designed to produce, in agreement with the request of the industrial end-users involved in the project, respectively:
- A porcelain �cup with handle� in only one step (while the actual manufacturing process requires the separate production of cup and handle and subsequent handle attachment on cup);
- A porcelain round "pan with handle" in only one step (while the actual manufacturing process requires the separate production of pan and handle and subsequent handle attachment on pan);
- An alumina thread guide used in textile machines.
The gained experience, on these prototypes, enabled BC Italiana, to define general criteria for mould design and realisation.
The composition of aqueous mix (suspension + binder) and its processing conditions for low pressure injection moulding of a porcelain cup with handle were set-up.
The processing conditions were studied and defined, at laboratory level, by injecting the prepared mix into the prototype mould.
Since the porcelain producer, for which the mix was developed, ceased its activity during the project, the gained knowledge can be used to develop and tailor made a similar production for other producers.
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