Effect of fluxing raw materials on moisture expansion of monoporosa wall tile bodies
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Effect of fluxing raw materials on moisture expansion of monoporosa wall tile bodies Kagan Kayaci1 Received: 17 May 2020 / Accepted: 20 October 2020 © Akadémiai Kiadó, Budapest, Hungary 2020
Abstract In the production of wall tiles, trends are moving toward larger-format wall tiles. Moisture expansion of larger-format wall tiles is one of the most important technological parameter that determine the quality of their service life. Clay, kaolin, quartz, carbonate and less fluxing materials are generally used in monoporosa tile recipes. In this study, alkali containing raw materials such as perlite, rhyolitic tuff, granite and nepheline syenite, were used instead of quartz and kaolin in the recipes. The investigated bodies are fired under industrial fast firing cycle at 1150 °C—50 min. Firing shrinkage, water absorption and color values (L*, a*, b*) of alkaline raw materials and bodies were measured. Thermal expansion coefficient and moisture expansion values of the bodies were determined by dilatometer and the sintering behavior of the representative formulations was evaluated using a double-beam non-contact optical dilatometer (ODHT). Phase and microstructural analyses were performed by XRD and SEM, respectively. As a result, the analytical data obtained from this study revealed that the alkaline/ flux materials which have more or less similar chemical compositions, represent distinctly different physico-mechanical behavior. According to the petrographical examinations, whereas the holocrystalline textured alkaline materials such as nepheline syenite and granite decrease moisture expansion, the use of amorphous-glassy textured raw materials such as perlite and rhyolitic tuff increase moisture expansion in monoporosa tile body manufacturing. Using of the alkali raw materials as a partial replacement of quartz also enables the development of lower thermal expansion bodies. Keywords Moisture expansion · Fluxing · Sintering · Wall tile
Introduction Ceramic wall tiles are characterized as building materials with high porosity and water absorption compared to other building materials. Wall tiles are produced with more than 10% water absorption, either by single or doublefiring method at temperature range of 1100–1150 °C for 35–45 min [1–3]. Fast-firing methods and the manufacture of single-fired (monoporosa) wall tiles require careful attention regarding the selection of raw materials and composition design in order to attain required technological properties. In addition, a recent trend toward larger sized wall tiles measuring up to 400 × 1200 mm with thickness down to 8 mm makes compositional design further complicated,
* Kagan Kayaci [email protected] 1
Kaleseramik Research and Development Center, 17400 Çan, Çanakkale, Turkey
particularly with respect to the attainment of low moisture expansion. Ceramic wall tile raw materials are primarily composed of kaolinitic clay, calcium carbonate, quartz and some other filling materials. During firing, calcium carbonate decomposes to CaO and kaolinite transforms
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