The Effect of Mould Filling on the Mechanical Properties of Wall Tile Production

Abstract

This study is focused on the development of properties of ceramic wall tile bodies by changing the degree of mould filling under industrial conditions (Usak Seramik A.S., Usak, Turkey). The effects of spray dryer operating conditions and granule size distribution on the degree of mould filling have been investigated. The study measured the ceramic wall tile bodies water absorption, fired shrinkage, fired and dried strength, and porosity. The granule size and distribution were changed by adjusting the pressure and the nozzles’ diameter of the spray dryer. This study aimed to reduce grain size and quantity over 500 microns and to increase quantity between 500 microns and 75 microns by increasing the spray dryer pressure and reducing the nozzle disc diameter. It was also aimed to increase the degree of mould filling by decreasing granule size. 200 tone wall tile slips were prepared and 11,000 m2 of wall tile products were produced. The phase and microstructure analysis were investigated using an X-ray diffractometer (XRD) and scanning electron microscope (SEM). As a result of this study, it was found that a lower granule size of above 500 µm improved the technical characteristics of the tiles. Ceramic wall tiles produced with lower granule grain size have high strength values, mainly due to the higher degree of mold filling. The ceramic tile production parameters in the Usak Seramik Company have been rearranged according to the data obtained from this study. This granule size and distribution set is now an industrial production standard in Usak Seramik.