IELTS READING – Sheet glass manufacture: the float process S42AT1

| IELTS Reading Sheet glass manufacture: the float process reading practice test has 10 questions belongs to Industrial Process & Manufacturing subject.. |

Glass, which has been made since the time of the Mesopotamians and Egyptians, is little more than a mixture of sand, soda ash and lime. When heated to about 1500 degrees Celsius (°C) this becomes a molten mass that hardens when slowly cooled. The first successful method for making clear and flat glass involved Q1 spinning. This method was very effective as the glass had not touched any surfaces between being soft and becoming hard, so it stayed Q2 perfectly unblemished, with a ‘fire finish’. However, the process took a long time and was Q3 labour intensive.
Nevertheless, demand for flat glass was very high and glassmakers across the world were looking for a method of making it continuously. The first continuous ribbon process involved squeezing molten glass through two hot rollers, similar to an old mangle. This allowed glass of virtually any Q4 thickness to be made non-stop, but the Q8 rollers would leave both sides of the glass Q5 marked, and these would then need to be ground and polished. This part of the process rubbed away around 20 per cent of the glass, and the machines were very expensive.
The float process for making flat glass was invented by Alistair Pilkington. This process allows the manufacture of clear, tinted and coated glass for buildings, and clear and tinted glass for vehicles. Pilkington had been experimenting with improving the melting process, and in 1952 he had the idea of using a bed of molten metal to form the flat glass, eliminating altogether the need for rollers within the float bath. Q9 The metal had to melt at a temperature less than the hardening point of glass (about 600°C), but could not boil at a temperature below the temperature of the molten glass (about 1500°C). The best metal for the job was tin.
The rest of the concept relied on gravity, which guaranteed that the surface of the molten metal was perfectly flat and horizontal. Consequently, when pouring Q6 molten glass onto the Q7 molten tin, the underside of the glass would also be perfectly flat. If the glass were kept hot enough, it would flow over the molten tin until the top surface was also flat, horizontal, and perfectly parallel to the bottom surface. Once the glass cooled to 604°C or less it was too hard to mark and could be transported out of the cooling zone by rollers. The glass settled to a thickness of six millimetres because of surface tension interactions between the glass and the tin. By fortunate coincidence, 60 percent of the flat glass market at that time was for six-millimetre glass.

Pilkington built a pilot plant in 1953 and by 1955 he had convinced his company to build a full-scale plant. However, Q11 it took 14 months of non-stop production, costing the company £100,000 a month, before the plant produced any usable glass. Furthermore, once they succeeded in making marketable flat glass, the machine was turned off for a service to prepare it for years of continuous production. When it started up again it took another four months to get the process right again. They finally succeeded in 1959 and there are now float plants all over the world, with each able to produce around 1000 tons of glass every day, non-stop for around 15 years.
Float plants today make glass of near-optical quality. Several processes — melting, refining, homogenising — take place simultaneously in the 2000 tonnes of molten glass in the furnace. They occur in separate zones in a complex glass flow driven by high temperatures. It adds up to a continuous melting process, lasting as long as 50 hours, that delivers glass smoothly and continuously to the float bath, and from there to a coating zone and finally a heat treatment zone, where stresses formed during cooling are relieved.
The principle of float glass is unchanged since the 1950s. However, Q12 the product has changed dramatically, from a single thickness of 6.8 mm to a range from sub-millimetre to 25 mm, from a ribbon frequently marred by inclusions and bubbles to almost optical perfection. To ensure the highest quality, inspection takes place at every stage. Occasionally, a bubble is not removed during refining, a sand grain refuses to melt, a tremor in the tin puts ripples into the glass ribbon. Automated on-line inspection does two things. Firstly, it reveals process faults upstream that can be corrected. Q13 Inspection technology allows more than 100 million measurements a second to be made across the ribbon, locating flaws the unaided eye would be unable to see. Secondly, it enables computers downstream to steer cutters around flaws.
Float glass is sold by the square metre, and at the final stage computers translate customer requirements into patterns of cuts designed to minimise waste.
Easily Get Required Score I am interested in IELTS Pass with Confidence, Dehradun Small Batch Size with Flexible Time, professional faculty.
![]()
8439000086
8439000087
7055710003
7055710004
IELTS Simulation 323 GMS Road, Near Ballupur Chowk, Dehradun, India
email: info at ieltsband7.com
Boost Your Score: Practice IELTS Online with IELTS Simulator Prepare for IELTS Effectively Using IELTS Simulator Ace the IELTS: Try Realistic Practice on IELTS Simulator IELTS Simulator: Online Practice to Improve Your IELTS Score Rocky Bay field trip listening practice test has 10 questions belongs to the Leisure & Entertainment subject. Prepare for IELTS IELTS Test International Experienced Teacher Best Training By CELTA Trainer. Best Results Easily Get Required Score IELTS Exam Dates Available, Small Batch Size with Flexible Time, Professional. Easily Get Required Score I am interested in IELTS Pass with Confidence, Dehradun Small Batch Size with Flexible Time, professional faculty. Learn From Experienced Teacher Best IELTS Coaching Dehradun Best IELTS in Dehradun Uttarakhand GMS Road BEST coaching in Dehradun Apply for Class Courses Today Good Results. Small Batch Size, Flexible Time and Professional IELTS Teacher Best IELTS coaching classes IDP certified British Council trained and CELTA certified experienced trainer. Easily Get Required Score Tel:8439000086 Tel:8439000087 Tel:7055710003 Tel:7055710004 Tel:7055710009









