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The effect of raw materials type and content on the properties of clay–feldspar–quartz compositions was studied using the statistical design of mixture experiments. Based on wall and floor tile industrial practice, 10 mixtures of three raw materials were selected and processed. Characterization results were used to calculate statistically significant and valid regression equations, relating fired body properties with clay, feldspar, and quartz contents in the unfired mixture. Such statistical modeling is discussed against quantitative X‐ray diffraction and scanning electron microscopy results. The glassy phase present was found to control the microstructure and the mechanical strength of the fired ceramic body.

a b s t r a c tA fresh green sand, spent green sand, and a weathered spent green sand (wSGS) from a foundry landfill were analyzed using diffractometry, electron microscopy, fluorometry, granulometry, spectrometry, and thermogravimetry (TG). Our objective was to understand how the physicochemical properties of the foundry green sands change from their original form after being subjected to the casting process, then after weathering at the landfill. A quantitative phase composition model was also postulated for each material based on the TG results and it was found to be the most reliable and informative quantitative data for this type of residue. The weathered sample, that remained in a landfill for two years, was found to be composed of almost pure sand. Because of the weathering process, it may be possible to use the wSGS as a virgin sand replacement in the regeneration system or in geotechnical applications where bentonite would affect the properties of the final product.Published by Elsevier B.V.

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