The aim of this work was to test CFB-derived fly ash for its potential to get utilised in ceramic tilesmanufacturing by applying the sintering technique. The tested specimens were moulded using extrusion and fired at 1,050°C; a laboratory pilot-plant simulation of the industrial brick fabrication process was applied and the produced materials were afterwards tested for their microstructure and physical properties. Different types of clays were selected and characterised and various clay-ash mixtures were prepared. Plasticity after mixing with water as well as extrusion of the compact specimens and their drying behaviour were evaluated. Water absorption and mechanical strength of fired specimens were determined and evaluated as a function of the percentage FA content. Results showed that large-scale production of CFB FAcontaining bricks is feasible, as their mechanical properties were not significantly harmed, while any possible detrimental effect on the other properties of the synthetic bricks appeared to be relatively restricted.
Although structural kaolin based ceramics are attractive and useful materials, having
good mechanical characteristics, low density, good corrosion and high temperature resistance, their
use is restricted by their brittle behaviour. In order to improve their properties and mainly strength,
toughness and high temperature performance, fibre composite ceramics have been developed. In the
present work a series of kaolin-short random dispersed Grafil carbon fibre composites were
produced and sintered in an inert atmosphere of Argon at 1000oC and 1300oC and characterised
using various techniques. XRD analysis of the kaolin matrix at 1000oC showed that the crystalline
phases were decomposed without the formation of mullite a fact which also reconfirmed by SEM
examination. However at 1300oC mullite formation was well evidenced. XRD analysis of the fibres
in “as received” showed that they have graphite structure which was also retained, as SEM
examination revealed, after sintering. Examination of the Grafil fibres showed that they were quite
uniform in length and diameter and retained their integrity after sintering at the examined
temperatures. Examination the fractured composite surfaces showed only a weak bond between
fibres and matrix and at the pull out areas the fibres were replicated in the matrix.
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