Pottery Process and Stages

I forgot that a lot of people do not have much knowledge of the process and stages of ceramics. So I found some helpful information to help you out and provide some knowledge of these steps and processes I use in my artwork.

Pottery is the ceramic ware made by potters. Major types of pottery include earthenware, stoneware, and porcelain. The places where such wares are made are called potteries. Pottery is one of the oldest human technologies and art-forms, and remains a major industry today. Ceramic art covers the art of pottery, whether in items made for use or purely for decoration.

Background
Pottery is made by forming a clay body into objects of a required shape and heating them to high temperatures in a kiln to induce reactions that lead to permanent changes, including increasing their strength and hardening and setting their shape. There are wide regional variations in the properties of clays used by potters and this often helps to produce wares that are unique in character to a locality. It is common for clays and other minerals to be mixed to produce clay bodies suited to specific purposes.
Prior to some shaping processes, air trapped within the clay body needs to be removed. This is called de-airing and can be accomplished by a machine called a vacuum pug or manually by wedging. Wedging can also help to ensure an even moisture content throughout the body. Once a clay body has been de-aired or wedged, it is shaped by a variety of techniques. After shaping it is dried before firing. There are a number of stages in the drying process. Leather-hard refers to the stage when the clay object is approximately 75-85% dry. Clay bodies at this stage are very firm and only slightly pliable. Trimming and handle attachment often occurs at the leather-hard state. Clay bodies are said to be "bone-dry" when they reach a moisture content at or near 0%. Unfired objects are often termed greenware. Clay bodies at this stage are very fragile and hence can be easily broken. Once an object has been fired for its first time it is called bisqueware. Once clay has become bisqueware it is ready to be glazed and then fired again finally becoming glazeware.

Firing
Firing produces irreversible changes in the body. It is only after firing that the article can be called pottery. In lower-fired pottery the changes include sintering, the fusing together of coarser particles in the body at their points of contact with each other. In the case of porcelain, where different materials and higher firing-temperatures are used the physical, chemical and mineralogical properties of the constituents in the body are greatly altered. In all cases the object of firing is to permanently harden the wares and the firing regime must be appropriate to the materials used to make them. As a rough guide, earthenwares are normally fired at temperatures in the range of about 1000 to 1200 degrees Celsius; stonewares at between about 1100 to 1300 degrees Celsius; and porcelains at between about 1200 to 1400 degrees Celsius. However, the way that ceramics mature in the kiln is influenced not only by the peak temperature achieved, but also by the duration of the period of firing. Thus, the maximum temperature within a kiln is often held constant for a period of time to soak the wares, to produce the maturity required in the body of the wares.
The atmosphere within a kiln during firing can affect the appearance of the finished wares. An oxidising atmosphere, produced by allowing air to enter the kiln, can cause the oxidation of clays and glazes. A reducing atmosphere, produced by limiting the flow of air into the kiln, can strip oxygen from the surface of clays and glazes. This can affect the appearance of the wares being fired and, for example, some glazes containing iron fire brown in an oxidising atmosphere, but green in a reducing atmosphere. The atmosphere within a kiln can be adjusted to produce complex effects in glaze.
Kilns may be heated by burning wood, coal and gas, or by electricity. When used as fuels, coal and wood can introduce smoke, soot and ash into the kiln which can affect the appearance of unprotected wares. For this reason wares fired in wood- or coal-fired kilns are often placed in the kiln in saggars; lidded ceramic boxes, to protect them. Modern kilns powered by gas or electricity are cleaner and more easily controlled than older wood- or coal-fired kilns and often allow shorter firing times to be used. In a Western adaptation of traditional Japanese Raku ware firing, wares are removed from the kiln while hot and smothered in ashes, paper or woodchips, which produces a distinctive, carbonised, appearance. This technique is also used in Malaysia in creating traditional labu sayung.

Glazing
Glaze is a glassy coating applied to pottery, the primary purposes of which include decoration and protection. Glazes are highly variable in composition but usually comprise a mixture of ingredients that generally, but not always, mature at kiln temperatures lower than that of the pottery that it coats. One important use of glaze is in rendering pottery vessels impermeable to water and other liquids. Glaze may be applied by dusting it over the clay, spraying, dipping, trailing or brushing on a thin slurry composed of glaze minerals and water. Brushing tends not to give an even covering but can be effective as a decorative technique. The color of a glaze before it has been fired may be significantly different than afterwards. To prevent glazed wares sticking to kiln furniture during firing, either a small part of the object being fired (for example, the foot) is left unglazed or, alternatively, special refractory spurs are used as supports. These are removed and discarded after the firing. Special methods of glazing are sometimes carried out in the kiln. One example is salt-glazing, where common salt is introduced to the kiln to produce a glaze of mottled, orange peel texture. Materials other than salt are also used to glaze wares in the kiln, including sulfur. In wood-fired kilns fly-ash from the fuel can produce ash-glazing on the surface of wares, and the use of an ash and clay mix can result in alkaline glazes, as used in Catawba Valley Pottery in the eastern United States.