1. GLASS

2. Glass Definition Preparation Composition Variety Uses

3. Definition Glass is an amorphous, hard, brittle, transparent or translucent super cooled liquid of infinite viscosity, having no definite melting point obtained by fusing a mixture of a number of metallic silicates or borates of Sodium, Potassium, Calcium, and Lead. It possess no definite formula or crystalline structure. “An inorganic product of fusion which has cooled to a rigid condition without crystallizing” Does not have a specific melting point Softens over a temperature range

4. Properties of glass Glass is: Amorphous Brittle Transparent / Translucent Good electrical insulator Unaffected by air, water, acid or chemical reagents except HF No definite crystal structure means glass has high Compressive strength Can absorb, transmit and reflect light

5. Raw materials used in manufacturing glass Raw Materials Sodium as Na 2 Co 3 (used in soft glass). Potassium as K 2 Co 3 (used in Hard Glass). Calcium as lime stone, chalk and lime. Lead as litharge, red lead (flint glass). Silica arc quartz, white sand and ignited flint. Zinc is zinc oxide (Heat and shock proof glass). Borates are borax, Boric acid (Heat and shock proof glass). Cullets or pieces of broken glass to increase fusibility.

6. Glass Components Formers – Network Formation SiO 2, B 2 O 3, P 2 O 5, GeO 2, V 2 O 5, As 2 O 3, Sb 2 O 5 Fluxes – Softeners Na 2 O, K 2 O, LiO, Al 2 O 3, B 2 O 3, Cs 2 O Stabilizers – Provide Chemical Resistance CaO, MgO, Al 2 O 3, PbO, SrO, BaO, ZnO, ZrO

7. Manufacturing steps  Melting  Forming and Shaping  Annealing  Finishing

8. Melting process Raw materials in proper proportions are mixed with cullets. It is finely powdered and intimate mixture called batch is fused in furnace at high temperature of 1800°C this charge melts and fuses into a viscous fluid. CaCO 3 + SiO 2  CaSiO 3 + CO 2  Na 2 CO 3 + SiO 2  Na 2 SiO 3 + CO 2  After removal of CO 2 decolorizes like MnO 2 are added to remove traces of ferrous compounds and Carbon. Heating is continued till clear molten mass is free from bubbles is obtained and it is then cooled to about 800°C.

9. Forming, shaping, and annealing Forming and Shaping The viscous mass obtained from melting is poured into moulds to get different types of articles of desired shape by either blowing or pressing between the rollers. Annealing Glass articles are then allowed to cool gradually at room temperature by passing through different chambers with descending temperatures. This reduces the internal Strain in the glass.

10. finishing Finishing is the last step in glass manufacturing. It involves following steps.  Cleaning  Grinding  Polishing  Cutting  Sand Blasting

11. Varieties of glass Soda lime or soft glass Potash lime or hard glass Lead glass or flint glass Borosilicate or Pyrex glass Alumino- Silicate glass 96% Silica glass99.5% Silica glass(Vitreosil) Safety glass Optical or Crook’s glass Poly-crystalline glassToughened glassColored glass Wired GlassGlass WoolFiber glassPhotosensitive glass Photo-chromic glassNeutral glassLaminated glassInsulating glass

12. Sodalime or soft glass About 90% of all glass is soda-lime glass made with silica (sand), Calcium carbonate and soda ash. The approximate composition is Na 2 CO 3.CaO.6SiO 2. They are low cost, resistant to water but not to acids. They can melt easily and hence can be hot worked. Uses: Window glass, Electric bulbs, Plate glass, Bottles, Jars, cheaper table wares, test tubes, reagent bottles etc

13. Potash lime or hard glass Potash lime glass is made with silica (sand), Calcium carbonate and potassium carbonate. The approximate composition is K 2 CO 3.CaO.6SiO 2. They posses high melting point, fuse with difficulty and are less acted upon by acids, alkaline and other solvents than ordinary glass. Uses: These glasses are costlier than soda lime glass and are used for chemical apparatus, combustion tubes and glassware which are used for heating operations.

14. Lead glass or flint glass It is made up of lead oxide fluxed with silica and K 2 CO 3 is used instead of sodium oxide. Its approximate composition is K 2 Co 3.PbO.SiO 2. To get dense optical glasses about 80% lead oxide is used. Lead glasses has a lower softening temperature than soda glass and higher refractive index and good electrical properties. It is bright lustrous and possess high specific gravity. Uses: High quality table wares, optical lenses, neon sign tubing, cathode ray tubes, electrical insulators, crystal art objects or cut glass, Windows and Shields for protection against X-rays and Gamma rays in medical and atomic energy fields etc.

15. Borosilicate / pyrex / jena glass It is common hard glass containing silica and boron with small amount of alumina and less alkaline solids. It contains SiO 2 (80.5%), B 2 O 3 (13%), Al 2 O 3 (03%), K 2 O(3%) and Na 2 O(0.5%). These glass have low thermal coefficient of expansion, and high chemical resistance i.e..shock proof. Uses: Industrially used for pipeline of corrosive liquids, gauge glasses, superior laboratory apparatus, kitchen wares, chemical plants, television tubes, electrical insulators etc.

16. Alumino-silicate glass The typical approximate composition of this type of glass is SiO 2 (55%), Al 2 O 3 (23%), MgO(09%), B 2 O 3 (07%), CaO(05%) and Na 2 O, K 2 O(01%). This type of glass possess exceptionally high softening temperature. Uses: It is used for high pressure mercury discharge tubes, chemical combustion tubes and certain domestic equipments.

17. 96% silica glass It contains 96% Silica, 03% B 2 O 3 and traces of other materials. It is translucent, the coefficient of thermal expansion is very low hence it has high resistance to thermal shock, have high chemical resistance to corrosive agents and are corroded only by Hydrofluoric acid, hot phosphoric acids and concentrated alkaline solutions. Uses: Used only where high temperature resistance is required (800°C). They are used in construction of chemical plants, laboratory crucibles, induction furnace lining and electrical insulators.

18. 99.5% silica glass / vitreosil It contains pure silica heated to its melting point. It is translucent, the coefficient of thermal expansion is very low hence it has high resistance to thermal shock, have high chemical resistance to corrosive agents. If Vitreosil glass is heated above its melting point, it becomes transparent and is known as clear silica glass. Uses: They are used in construction of chemical plants, laboratory crucibles, induction furnace lining, electrical insulators and heaters and have high light transmission properties.

19. Safety glass It is made by fusing two to three flat sheets of glass and in between them alternate thin layer of vinyl plastic is introduced. It is heated where both the layers merge together and glass is toughened. Uses: It is used as wind shield in automobiles and airplanes. On breaking it pieces does not fly apart because of the presence of the plastic layer in between the glass layers.

20. Optical or crook’s glass It contains Phosphorus, PbCO 3, silicates and Cerium oxide which has the property to absorb harmful ultra-violet light. This glass is given through homogeneity by heating it for a prolonged period of time. These glasses have low melting point and are relatively soft. Uses: They are used for making optical lenses.

21. Poly-crystalline glass It is new type of glass which is produced by adding nucleating agents to a conventional glass batch and then shaped into desired form. It is then subjected to heating where nucleating agents forms large number of micro crystallites. It is not ductile. It exhibits high strength and considerable hardness. Uses: For making specialized articles.

22. Toughened glass It is made by dipping articles still hot in an oil bath, so that chilling takes place. This results in outer layer of articles shrink and acquire a state of compression while inner layer are in state of tension. Such glass is more elastic to mechanical and thermal shock. It breaks into a fine powder. Uses: For making window shields of fast moving vehicles, windows of furnace and automatic opening doors.

23. Coloured glass Addition of transition metal compounds to glass gives color to the glass. They are outlined below. Yellow: Ferric SaltsGreen: Ferrous and Chromium salts Purple: Magnese dioxide salt Red: Nickel and cuprous salts Cu 2 O Lemon Yellow: Cadmium sulphide Fluorescent greenish yellow: Uranium oxide Blue: Cobalt Salts, CuOGreenish Blue Color: Copper Sulphate Brown: Iron Opaque milky white: Cryolite of Calcium phosphate Ruby : Auric Chloride

24. Wired glass Wired glass does not fall apart into splinters when it breaks and is fire resistant. It is made by fusing wire in between the two glass layers. Uses: For making fire resistant doors, roofs, skylights and windows

25. Fibre glass It is transformed into a fine thread of filament and has got a high tensile strength. Uses: Found extensive use for the manufacture of fabric, reinforcing plastics and production of thermal insulation materials etc

26. Photosensitive glass These are glasses by which a colored picture may be developed by exposing the glass to black and white negative in ultra violet light. The appropriate proportions of potash-alumina glass, mixed with LiSO 3, cerium and Silver salts have also been used as photosensitive glass. Uses: Photographic development

27. Glass wool Glass wool consists of tiny fibers formed by action of steam jets on dripping molten glass down from very fine hole. Uses: Heat Insulation, for filtration of Corrosive chemicals, sound insulation etc

28. Photo-chromic glass The three dimensional silicate network contains large no. of microscopic particles of silver halide which on exposure to light produce color. Uses: In making tinted car glasses and goggles.

29. Neutral glass These glasses are highly resistant to chemical attacks and they are specialized soda lime glass where alkali has been replaced by alumina, boron oxide and zinc oxide. Uses: Making Syringes, Injection Ampoules and vials etc.

30. Laminated glass The sheets of glass fiber or glass wool are soaked in a solution of thermosetting plastic like phenol formaldehyde resin and placed one above the other and then cured under heat or pressure. It is strong as steel. Non flammable and insulating. In bullet resistant glass vinyl resins are added in alternate layers. Uses: Shatter, shock and Bullet proof Glass

31. Insulating glass Two or more plates of glass are filled with dehydrated air and the edges are sealed air-tightly. Uses: Provides thermal insulating and so houses remain cool in summer and warm in winter.

32. Fracture / failure of glass Glass does not have crystal lattice structure hence it breaks. Fracture is caused by small imperfections, flaws and irregularity on the surface of the glass. Flaws are very fine cracks cause concentration of stress and the crack proceeds quickly causing a fracture.

33. THE END