Development of Cordierite Based Carrier Refractory Sagar Bodies for Bone Porcelain Firing Process

During the firing process of porcelain tableware; Biscuit firing takes place at low temperatures (980-1000°C), while glazed firing takes place at high temperatures (1250-1280°C for soft porcelain, 1350-1380°C for hard porcelain). Biscuit firing in bone porcelain products, which is in the soft porcelain class, is done at higher temperatures than glazed firings. Due to the presence of bone ash in the Bone China recipe formulation, it causes the bodies to undergo vitrification in a narrow range and thus the final product to deform during sintering. Bone porcelain products are fired on carrier refractories called sagar so that they do not deform during sintering. Sagars are designed to support that model for each product model and do not shrink or deform during firing thanks to its low thermal expansion coefficient. In this study, a refractory body with a porous structure with the code of "PS1-Std" was developed by performing the characterization analyzes of refractory products with different technical properties supplied from different companies. In order to improve the mechanical properties by changing the ratios of talc, alumina, quartz and zircon in the recipe composition; A refractory product containing 8.47% zircon in its recipe composition and containing indialite, corundum, mullite, quartz and zircon phases after sintering has been developed. The microstructure images of the developed refractory product were examined with the support of SEM analysis. It has been observed that refractory products obtained as a result of recipe development studies offer a 10% longer service life than equivalent refractory products.

Keywords:

Biscuit, bone porcelain, cordierite sagar, vitrification,

PDF

___

[1] P. Rado, An Introduction to the Technology of Pottery, 2nd edition du., England: Oxford, 1988.
[2] The British Standards Institution, “Domestic and hospitality use ceramic tableware articles intended for contact with foodstuffs.“ BS8654:2015.
[3] P. Rado, Bone China, Ceramic Monographs Handbook of Ceramics, Verlag Schmid GmbH Freiburg, 1981.
[4] F. Gungor, «Investigation of pyroplastic deformation of whitewares: Effect of cyrstal phases in the "CaO" based glassy matrix,» Ceramics International, vol. 44, no. 11, pp. 13360-13366, 2018.
[5] O. Turkmen, A. Kucuk, S. Akpınar, “Effect of wollastonite addition sintering of hard porcelain“ Ceramics International, cilt 41, no. 4, pp. 5505-5512, 2015.
[6] S. Ke, X. Cheng, Y. Wang, Q. Wang, H. Wang, “Dolomite, Wollastonite, and Calcite as Different CaO Sources in Anorthite based Porcelain“ Ceramics International, cilt 39, no. 5, pp. 4953-4960, 2013.
[7] S. Kurama, E. Ozel, “The Influence of Different CaO Source in the Production of Anorthite Ceramics“ Ceramics International, cilt 35, no. 2, pp. 827-830, 2009.
[8] F. Ceylan, “Anorthite Phase Production and Industrial Applications” Graduate School of Natural and Applied Sciences, Kütahya, 2011.
[9] M. Kosecavus, "Anorthite Synthesis and Characterization from Volcanic Tuff" Graduate School of Natural and Applied Sciences, Ankara, 2007.
[10] S. K. Das, K. Dana, N. Snight, R. Sarkar, "Shrinkage and Strenght Behaviour of Quartzitic and Kaolinitic Clays in Wall Tile Compositions" Applied Clay Science, cilt 29, pp. 137-143, 2005.
[11] J. S. Reed, Introduction to the Principles of Ceramic Processing, Newyork, John Wiley & Sons Inc, 1995, p. 486.
[12] D. Stookey, N. Y. Corning.Patent: U. S. Patent 3241935, 22 March 1966.
[13] H. Soyhan, "Investigation of Shape Changes of Ceramics During the Sintering Process" Graduate School of Natural and Applied Science, İstanbul, 2007.
[14] B. P. Saha, R. Johnson, "Thermal Anisotropy in Sintered Cordierite Monoliths" Materials Chemistry and Physics, no. 67, pp. 145-150, 2001.
[15] T. Bahtlı. Turkey Patent: 2017/10403, 2017.
[16] American Society for Testing and Materials, Standart Test for Drying and Firing Shrinkages of Ceramics Whiteware Clays., ASTM, 2018.
[17] American Society for Testing and Materials, Standart Test for Flexural Properties of Ceramics Whiteware Materials- ASTM-C674, ASTM, 2018.
[18] The British Standards Institution, Materials and Articles in Contact with Foodstuffs - Test Method for Water Absorption of Ceramics Articles, BSI, 1998.
[19] Mayer and Havas, "Coefficient Expansion of Enamels and Their Chemical Composition" Sprechsaal, 42, 497; 44, 188, 207, 220.
[20] J. P. F. Grilo, H. P. A. Alves, A. J. M. Araujo, R. M. Andrade, R. P. S. Dutra, D. A. Macedo, "Dielectric and electrical properties of a mullite/glass composite from a kaolinite clay/mica-rich kaolin waste mixture" Cerâmica, vol. 65, pp. 117-121, 2019.
[21] E. Gunay, "Sintering Behavior and Properties of a talc-based cordierite composition with boron oxide additions" Journal of Ceramic Processing Research, vol. 11, no. 5, pp. 591-597, 2010.
[22] E. Gunay, "Sintering Behavior and Properties of Sepiolite Based Cordierite Compositions with added Boron Oxide" Turkish Journal of Engineering and Environmental Sciences, vol. 2, no. 35, pp. 83-92, 2011.
[23] L. J. Trumbulovic, Z. Acimovic, S. Panic, L. J. Andri, "Synthesis and Characterization of Cordierite from Kaolin and Talc for Casting Application" FME Transactions, vol. 31, no.1, pp. 43-47, 2003.
[24] M. S. Kumar, "Processing and Characterization of Pure Cordierite and Zirconia-doped Cordierite Ceramic Composite by Precipitation Technique"" Bulletin of Material Science, vol. 38, no. 3, pp. 679-688, 2015.
[25] R. Avedikian, C. His, T. Champion, M. Bobo. France Patent: EP06808197.5, 2017.