Properties of Unglazed Ceramics Containing Aluminum Dross as a Major Component

Abstract

Aluminum dross residue is a by-product produced at secondary re-melt plants where aluminum scraps are recycled. In this study, aluminum dross residue was utilized as a major component in the fabrication of unglazed ceramics for wall tile applications. The use of this by-product can reduce the landfill and environmental problems. The amount of aluminum dross residue used in the ceramic compositions varied in the range 50-90 wt.%. Other components utilized in the ceramic compositions included recycled glass alumino-silicate based clays. Firing was carried out between 1140 and 1200°C with 4h holding time which resulted in strong ceramic samples. Alpha-alumina, α-Al2O3 was the main crystalline phase found in all sintered ceramic samples. The appearance of mullite phase, Al6Si2O13 was evident in all fired samples. Overall, the synthesized ceramics had excellent densification characteristics when the amount of aluminum dross residue was less than 70 wt% in the ceramic composition.