Formula optimization and mechanical properties of thin porcelain ceramic plates mainly containing smoky quartz tailings

Abstract

As sustainable mineral waste resources, smoky quartz tailings are regarded as potential raw materials for ceramic, but they are not efficiently utilized in thin porcelain ceramic plates. To improve the utilization value, the smoky quartz tailings were innovatively used to prepare thin porcelain ceramic plates. The potential ceramic formulas were explored by a formula optimization method with a triangle ingredients diagram. Besides, the functions of key components to the properties of thin porcelain ceramic plates, such as bulk density, water absorption, apparent morphology, mechanical properties, and mechanical mechanisms were respectively investigated. It was found that the densification tendency could be accurately represented in a triangle ingredients diagram, and the contour lines of 0.5% water absorption value by regression equation fit well with experimental data. The densification behaviors and microstructure evolutions were synergistically influenced by driving forces, mass transfer carriers, and chemical components. The ceramic plates from optimized ceramic formulas reached the highest bulk density of 2.85 g/cm3 and bending strength of 132.24 MPa, respectively. In addition, the excellent mechanical properties were mainly attributed to the mechanical mechanisms of micro-crack deflections and particle diffusion enhancements. This formula optimization method narrowing from optimized region to accurate ceramic formulas was proved to be efficient in gaining potential ceramic formulas and fully compatible with standard stoneware processing.