Ceramic production relies heavily on the quality of raw materials, which serve as the foundation, while molding and firing are crucial steps in the process. Selecting and analyzing raw materials scientifically is essential for maintaining product quality and production efficiency. This article explores the key properties and testing methods of ceramic raw materials, as well as considerations for their standardization.
First, let’s look at the key performance characteristics of ceramic raw materials. Building sanitary ceramics manufacturers typically evaluate several aspects, including appearance quality, chemical properties, and physical properties. Appearance analysis includes hardness, brittleness, gloss, texture, and visual inspection. Chemical composition analysis involves determining elements such as SiO₂, Al₂O₃, Fe₂O₃, TiO₂, K₂O, Na₂O, CaO, and MgO, along with loss on ignition, mineral composition, and pH levels. Physical properties include whiteness, particle size distribution, thermal behavior, plasticity, bonding ability, dry flexural strength, viscosity, and linear shrinkage.
Next, we turn to the detection methods used to analyze these properties. For appearance quality, simple tests like touch, color change after firing, and surface examination can provide initial insights into the material’s chemical composition and processing performance. Chemical analysis can be conducted using traditional wet chemistry, spectrophotometry, X-ray fluorescence (both tablet and frit methods), and other techniques to determine color, refractoriness, firing range, and mineral type. Mineral composition analysis may involve optical microscopy, polarized light, electron microscopy, X-ray diffraction, infrared spectroscopy, and thermal analysis.
For liquid raw materials, a pH meter is commonly used, while powders are tested by suspending them in distilled water and measuring the supernatant. Particle size is measured through various methods such as microscopy, sieving, sedimentation, and laser diffraction. Thermal analysis, including differential thermal analysis and thermogravimetry, helps understand material behavior during heating, aiding in process optimization and defect prevention.
Plasticity is measured according to standards like GB/T 26742-2011, while bonding capacity is determined by how much non-plastic material a clay can bind. Dry flexural strength ensures that the green body remains intact during handling and firing, and can be tested using a three-point bending method. Viscosity is assessed using tools like the Tu-4 flow cup or rotational viscometer. Shrinkage rates—both drying and firing—are calculated based on dimensional changes before and after treatment.
Finally, the concept of standardization plays an important role in managing raw material variability. In China, fluctuations in raw material quality pose challenges for consistent production. Some experts have suggested establishing standardized ceramic raw material plants, similar to models in Spain and Italy, but these initiatives have faced obstacles. Reasons include the flexibility of process adjustments, higher costs of centralized supply, and differing procurement strategies among companies.
Standardization should not mean rigid control over supply but rather the use of common tools and standards to ensure consistency. Enterprises can apply product and testing standards to manage raw materials effectively, implement standardized storage and handling, and adjust formulas based on material variations. For example, many ceramic factories use multiple raw materials, so even if one fluctuates slightly, it doesn’t significantly affect the overall composition. The goal of standardization is to improve efficiency and adaptability, not to enforce strict uniformity in supply.
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