화학공학소재연구정보센터
Journal of the American Ceramic Society, Vol.84, No.4, 719-725, 2001
Feedstock formulations for direct consolidation of porcelains with polysaccharides
Direct-consolidation methods are becoming well-established forming techniques for advanced ceramics, because of their advantages in terms of shape capability. These advantages could also be exploited to consolidate traditional ceramics, such as stoneware or porcelain pottery requiring handles, which could be potentially manufactured in a single step. The most limiting factor in the transfer of these technologies from advanced to traditional ceramics is related to the moderate solids loading usually achievable with clay-based suspensions. In this work, new porcelain feedstocks are proposed that use either milled rejected pieces (MRP) of porcelain or a kaolinitic stoichiometric mixture of SiO2 and Al2O3, i.e., pseudokaolin (PK), The replacement of the clay component by MRP or PK makes it possible to obtain 60 vol% aqueous porcelain suspensions, which can be directly consolidated using a relatively low amount (1 wt%, based on liquid volume fraction) of a mixture of polysaccharides. Steady shear viscosity measurements show that these highly concentrated suspensions are fluid enough for pouring operations. The green and presintered bodies show similar values of shrinkage and relative density, because of the low amount of organic additives used. The total replacement of the clay component in the starting composition enables a decrease in the firing temperature. Otherwise, for a given firing schedule, the enhancement of quartz dissolution in the glass phase and the decrease of the aspect ratio of mullite needles lead to an increase of the pyroplastic deformation index.