Glass–ceramic frits for porcelain stoneware bodies: Effects on sintering, phase composition and technological properties
Ceramics International (2007) in press
C. Zanelli a, G. Baldi b, M. Dondi a, G. Ercolani a, G. Guarini a, M. Raimondo a
a CNR-Institute of Science and Technology for Ceramics, Via Granarolo 64, 48018 Faenza, Italy
b CERICOL, Colorobbia Research Centre, Via Pietramarina 123, 50053 Sovigliana Vinci, Italy
In the present work, the effects of glass–ceramic frits (10 wt.%) added to a porcelain stoneware body in replacement of non-plastic raw materials were evaluated simulating the tile-making process. Each glass–ceramic frit plays its own peculiar effect on the compositional properties and only some precursors behave as real glass–ceramic materials. The positive influence of glass–ceramic precursors in promoting the sintering stands out when temperature onset densification and sintering rate are considered: both of them are improved with respect to the reference body. The presence of glass–ceramic frits allows to preserve good technological properties, complying with the latest requirements of the industrialnpractice.
Porcelain stoneware tiles are characterized by a very low water absorption (<0.5% according to standard ISO 13006; <0.2% in current production) and excellent mechanical, tribological and functional properties for a building material.
Porcelain stoneware is a glass-bonded material manufactured in large size (up to 1 m 2) with fast cycles and a wide range of decorative techniques in order to bestow outstanding aesthetical effects.
Therefore, pressing exigencies for the tile-making industry are: (a) enhancing the sintering kinetics; (b) actually controlling firing shrinkage to achieve a uniform densification; (c) keeping adequate mechanical strength in large size tiles; (d) obtaining colour of fired stoneware as lightest as possible. In fact, ceramic pigments used to decorate porcelain stoneware present a relevant cost; a light-coloured body, especially if even translucent, allows to lower significantly the amount of pigment necessary to get the desired coloration .
In order to fulfil these exigencies, some kinds of glass–ceramic materials have, in the latest years, come in a wide use in porcelain stoneware production. They are vitreous precursors, prepared like ceramic frits, that are expected to devetrify during the fast firing cycle of the tile-making industry (typically 50– 60 min cold-to-cold, with heating rates up to 80 8C/min and cooling rate up to 110 8C/min, maximum temperature 1200– 1240 8C for 5–10 min soaking). The glass–ceramic systems entered in use are silicate and alumino-silicate of Na, Mg, K, Ca,Zn, Ba and Zr, though some further components may be present in the most complex formulations.
The effects played by these glass–ceramic frits in the firing process have been essentially studied by the technological viewpoint . The role of glass–ceramic precursors on sintering kinetics, phase transformations and microstructure of porcelain stoneware is still to a large extent unknown.
The aim of the present paper is to fill this gap by investigating the firing behavior of seven glass–ceramic systems. The rationale is to introduce each frit in a typical porcelain stoneware body, simulating the industrial manufacturing in controlled laboratory conditions and assessing the changes induced by the glass–ceramic precursors on sintering and technological behaviour as well as microstructure and phase composition.
# 2006 Elsevier Ltd and Techna Group S.r.l. All rights reserved. |
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