Ceramic Wall Research Articles

Automatic tiling method for mosaic ceramic art images based on subpixel edge fitting localization and collaborative operation of multiple manipulators

Mosaic ceramics are not limited to use solely as building materials, they also possess artistic value. Artists can create images by arranging and combining mosaic ceramics, resulting in a perfect fusion of large-scale public art for external walls and ceramic materials. However, the current approach for artists to create mosaic ceramic exterior wall art images involves manual laying and assembling of individual mosaic ceramics. This manual process suffers from issues such as low efficiency, eye fatigue, selection errors, and the risk of high-altitude operations. These challenges significantly impact the quality and efficiency of creating mosaic ceramic exterior wall art image images. To address these problems, this paper proposes an automatic mosaic ceramic art image stitching method based on subpixel edge fitting positioning and collaborative operation of multiple robotic arms. Additionally, a new U + I type conveying method is designed for efficient and space-saving transportation of mosaic ceramics. Experimental results demonstrate a high success rate of recognition, absorption, and placement of multi-color mosaic ceramics using this method reaching 95.45%, with a positioning error within 0.5 mm. The method can also adapt to varying levels of light intensity or noise interference. This approach effectively enhances the quality and efficiency of creating mosaic ceramic exterior wall art images and promotes the development of mosaic ceramic exterior wall public art creation.

Life Cycle Assessment of Construction Components of Schools in Southern Brazil

Introducing energy efficiency techniques in schools can significantly reduce energy consumption, as Brazil has a large public education system. The main objective of this work was to select the set of construction components with the lowest environmental impact for use in schools in Florianópolis, southern Brazil, through life cycle assessment (LCA). Two types of walls, four types of roofs, and two types of window frames were studied. Ceramic bricks measuring 14x9x19cm and 9x19x19cm were considered for the walls. Wood and aluminium were used for the window frames, with single glass panes on all windows. For the roofs, fibre cement tiles with a PVC ceiling, a drywall ceiling, and a concrete slab were considered, as well as ceramic tiles with a PVC ceiling. Computer simulations were conducted using the EnergyPlus program in order to determine the building’s energy consumption. SimaPro was used to run the LCA. The construction of the building and one year of its energy consumption were analysed to select the combination of components with the lowest impact on the building’s life cycle. Finally, the set consisting of 9x19x19cm ceramic brick walls, wooden frames, and roof with fibre cement tiles and PVC ceiling presented the lowest environmental impact. Keywords: Life Cycle Assessment; public schools; computer simulation; buildings; EnergyPlus; SimaPro

ЖЕРГІЛІКТІ ШИКІЗАТ НЕГІЗІНДЕ ҚАБЫРҒАЛЫҚ КЕРАМИКАЛЫҚ КІРПІШ ТЕХНОЛОГИЯСЫНДА ШЫНЫ ҚАЛДЫҒЫН ҚОЛДАНУ МАҢЫЗДЫЛЫҒЫ

Annotation. The results of experimental studies on the development of technological parameters of effective wall ceramics are presented. The main physical and mechanical properties of wall ceramics were studied. The possibility of obtaining effective wall ceramics using non-traditional raw materials has been established. Glass waste is the optimal raw material base for the production of ceramic wall materials. The use of by-products of glass waste in the production of wall ceramics is very relevant. In order to obtain such a high-quality product, it is necessary to carefully study its chemical composition and mineral composition. Based on the obtained information, it is necessary to design a new suitable, economical technology. Due to the abundance of modern energy-saving wall materials, brick always maintains its position by combining its valuable properties. Ceramic wall products are environmentally friendly, durable for a very long time, maintain a favorable climate and temperature and humidity in the residential area. However, a serious problem in the production of these products is the forced involvement in the field of production of low-grade raw materials - clays, drying and chemical and mineralogical composition are very sensitive, production-quality wall ceramics do not meet the technological requirements. In the industry of ceramic wall products, the main part is to increase the efficiency of production by introducing new facilities with advanced technologies, as well as using additives for various purposes and introducing advanced technologies and equipment into production.

Optical microscopy of ceramic materials based on fly ash from thermal power plants

The data on the annual release of ash and slag waste as a result of the operation of thermal power plants (TPP) in Siberia and the Far East of the Russian Federation are presented. The main reasons for the insignificant use of ash in the construction industry (about 5-8% of the total waste output) and the problems hindering its use for the production of ceramic wall materials are considered. A brief description of the composition and properties of the raw materials used in this work for the manufacture of ceramic wall materials is given. The compositions of the developed fly ash-based charges and the method of manufacturing ceramic samples with a matrix structure are given. The results of the study of the structure of ceramic materials by optical microscopy are presented. It is established that during the firing process, a matrix (dispersion medium) is formed from the fusible shell of aggregated complexes, and granules from fly ash are transformed into cores (dispersed phase) of a ceramic matrix composite. It was revealed that the kernels have an oval shape due to the deformation of the granules during pressing. Clusters are formed in the nuclei, consisting of a large number of small crystalline grains connected by an amorphous substance and edged with thin chains of pores. It is shown that the developed pore space inside the cores is mainly represented by frost-proof and reserve pores, which ensures high frost resistance of ceramic samples based on fly ash.

Стеновая керамика, модифицированная тетраоксидом марганца

Стеновая керамика, модифицированная тетраоксидом марганца

Ceramic materials of low-temperature sintering from natural and technogenic rocks of the Tuva Republic

Abroad, they are actively engaged in “cold” sintering of materials, including ceramic, which is a mechanically and thermally conditioned mass transfer process that allows for low-temperature integration of various materials. The paper presents the results of research on low-temperature sintering and optimization of firing regimes for ceramic materials by introducing a salt complex with a liquidus temperature of 825оC into a charge based on natural and man-made rocks of the Republic of Tyva. The optimal concentrations of salt-containing additives in the ceramic mass, which affect the roasting properties of the resulting materials, have been determined. It was found that the introduction of a complex of salts into the ceramic charge promotes earlier sintering of the shard and the production of high-quality wall ceramics at lower temperatures, which leads to a reduction in energy costs during firing of products.

Experimental study of the out-of-plane mechanical properties of tall foam ceramic (FC) partition wall

Foamed ceramic (FC) partition wall is a non-structural component which has a broad application prospect. At present, most of the relevant specifications and studies on partition walls are limited to ordinary floor heights. In practical engineering applications, the partition wall exceeding the specification height limit often appears in scenes such as hotel halls and airport terminal. It would pose a life safety threat to the building in the event of out-of-plane damage of this type of partition wall under wind loads. Therefore, this paper aims to study the out-of-plane mechanical properties of tall FC partition walls under static loading. Experimental studies were conducted on the influence of different connection forms, as well as different construction column spacings on the out-of-plane mechanical performance of tall FC partition walls. It can be found that different connection forms had almost no effect on the cracking load. The cracking load decreased gradually with the increasing of the structural column spacings. The specimens with more rigid connection had better crack resistance ability during the service phase. With the increasing of the spacing of structural columns, the restraining effect of the steel skeleton on the FC wall panel, its out-of-plane bearing capacity and stiffness all decreased; The configuration of the steel skeleton reduced the brittleness of FC material; The weak part of tall FC partition wall was in the bonding area between FC wall panel and square steel tube, which should be paid attention to in practical engineering.

Applying TOPSIS and AHP Intrinsic Properties to Explore Consumers’ Preferences for Public Ceramic Relief Murals in Taiwan Region

Ceramic mural art is a contemporary landscape art, carefully designed based on human nature, culture, and architectural wall space; combined with social customs, visual sensibility, and art. It may also become the main axis of ceramic art in the future. The most distinctive feature of Taiwan region’s public ceramic relief mural (PCRM) was pioneered by Pan-Hsiung Chu in 1987. In addition to breaking through the limitations of traditional PCRM, Chu uses local culture and perceptual art as themes, giving Taiwan region’s ceramic wall art a unique style and innovative value. This study uses in-depth interviews with experts to analyze the intrinsic properties of AHP. At the same time, IPA is used as the public’s preference evaluation, and TOPSIS analysis is applied to understand consumers’ preferences for PCRM design imagery. It is hoped that this will sort out the key preferences of consumers and provide a reference basis and research methods for promoting PCRM in the Taiwan region.

Short Jute Fiber Reinforced Cement Mortar for Out-of-Plane Strengthening of Masonry Prisms

The retrofitting process contributes to the sustainability of the construction sector, since adopting measures to increase the lifespan of buildings reduces the need for new constructions. However, many of the materials used in this process come from nonrenewable sources and require significant water and energy consumption for production. The aim of this study is to assess the viability of using a more environmentally friendly mortar coating reinforced with short jute fibers (SJFRM) to reinforce ceramic brick masonry walls. Both coated and uncoated prisms were subjected to compression and flexural tests under two-point (line) out-of-plane loading. The reinforcement layer comprised mortar without fibers and mortars reinforced with jute fibers at levels of 2% and 4%, with lengths of 20 mm and 40 mm. Physical and mechanical tests were conducted to evaluate the properties of SJFRM in both fresh and hardened states. Results indicate that the compressive and flexural strengths were enhanced with SJFRM reinforcement due to alterations in the failure mode of the prisms. The fibers impede crack propagation in the reinforcement layer, enabling better redistribution of internal stresses in the prisms. This results in an increase of 6 to 9 times in stiffness under direct compression and up to 42 times in toughness under flexion in the prisms reinforced with SJFRM when compared to uncoated prisms.

Quality Control of Ceramic Wall Products Six Sigma Method with Dmaic Tools and Failure Mode and Effect Analysis (FMEA)

Considering the importance of increasingly rapid industrial development, business people must be aware of the orientation towards product quality. The manufacturing industry has an important role in industrial development. It is hoped that it will be able to grow and have advantages in industrial development, therefore it is necessary to improve and increase product quality. The company continues to strive to maintain and improve product quality and increase productivity so that customers are satisfied with the products produced. One way that needs to be done is to reduce the number of defective products in the production process. This effort is one way of continuous improvement carried out by PT. ABC and companies operating in the same field. The ceramic wall production process has relatively high demand but still has a high level of defects. Based on information on production data and data on the number of defects for the period January – September 2023, wall ceramic production has a defect rate of 3.86%. Companies must reduce the number of defects to achieve company targets. This research aims to improve the production process of wall ceramics by minimizing the number of defective products. This research uses the six sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) tool assisted by the FMEA (Failure Mode and Analysis) method. Corrective action to reduce defects based on the 5 Why analysis is to find out what the problem is and ask "why" and "what is the root of the problem". The research results show that there are 4 types of defects which have a large number of defects, namely Rupture Defects, Application Defects, Peeling Defects and Hole Defects. From the research results, solutions were obtained for the emergence of several types of defects in the wall ceramic production process, namely by providing planning suggestions and corrective actions which are discussed this time. At the defect calculation stage, Broken produces a DPMO value of 29.362 with a sigma level of 3.39 with a sigma level of 3.48, Defect Peeled produces a DPMO value of 28.044 with a sigma level of 3.38, and holes are defective. resulting in a DPMO value of 26,020 with a sigma value of 3.45 from the data calculation results, it is still not enough to meet the company's target at the sigma level, therefore the company must make quality improvements to achieve the main target at the sigma level.

Estimation of Chemical and Mineral Composition, Structural Features, and Pre-Firing Technological Properties of Waste Coal Heaps for Ceramic Production

The relevance of the investigation and creation of a new non-traditional raw material base for wall ceramics for the south of Russia is shown in connection with the decreasing availability of traditional raw materials—loams. Characterizations of the mineral and chemical constituent rock formations of the rocks composing the dumps of coal waste heaps and enrichment plants are given. A serious constraint for the industrial development of coal wastes is the requirement for a great variety of mineral constituents. The chemical and mineralogical compositions and the pre-firing ceramic properties of the waste coal heaps are studied and presented in detail. It is mentioned that fine and thin materials contain coal in an increased amount; due to this, they cannot be considered as the main raw material for the production of wall ceramics. The materials of the medium-sized grain group (2.0–5.0 mm, sifting) can contain up to 2–3% of coal and are most often represented by a mixture of mudstones, siltstones, and sandstones, with the predominance of one or another type of rock. The granulometric composition and the content of large-grained inclusions, molding moisture, plasticity, cohesiveness, desiccation properties, and air shrinkage were studied and determined. It is concluded that the middle group of waste coal heaps in particular are of the greatest interest as a basic raw material for the production of wall ceramic products.

High-Voltage Discharge Optimization of a Hybrid-Wall Hall Thruster

A segmented discharge channel is generally adopted in a hybrid-wall Hall thruster. A metallic wall is situated in the upstream portion of the channel, while a boron nitride ceramic wall is retained in the downstream portion of the channel. This hybrid-wall design avoids the disadvantages of the mechanical properties of boron nitride ceramic. Moreover, the channel can be widened by reducing the thickness of the metallic wall upstream of the channel. In this study, the width and configuration of a discharge channel based on a hybrid-wall Hall thruster are investigated, and a convergent channel configuration is adopted. The experimental results show that the configuration of the channel significantly affects the discharge process, and the ionization and acceleration efficiency of the HEP-100HW are substantially improved using the convergent hybrid channel. The specific impulse and efficiency of the HEP-100HW with the optimal convergent hybrid channel are 210 s/2.5% and 270 s/6% higher than those of the HEP-100HW with a straight hybrid channel and the HEP-100 with a straight-configuration ceramic channel at the discharge voltage of 900 V, respectively. Furthermore, from experiments and supporting simulations, it was found that the convergent hybrid-wall design resulted in an increase in the number of ions created further upstream in the channel compared to a conventional design. This led to more efficient acceleration and ejection of the ions out of the channel, resulting in the observed performance improvement. The results from this study provide valuable guidance for the design of high-power and high-voltage Hall thrusters.

Influence of Ceramic Wastes as a Recycled Coarse Aggregate with Different Maximum Sizes on the Concrete

Background Natural raw resources needed for concrete construction are continuously being depleted as a result of infrastructure development that is increasing. As a result, waste material substitutes are highly favored because they adopt a sustainable strategy. Objective In this study, the possibility of substituting natural coarse aggregates with coarse aggregate made from ceramic wall tiles with three different maximum aggregate sizes (12.5, 19, and 25 mm) in three partial replacement levels of natural coarse aggregate by (25, 50, and 75%) was investigated. Methods Concrete's hardened density, compressive and splitting tensile strengths, ultrasonic pulse velocity, water absorption, and volume of permeable pores were all tested experimentally. Results Results indicated that with the increment of the maximum aggregate size, each of the hardened densities, the compressive and splitting tensile strengths and the rate of water absorption diminished while pulse velocity enhanced, regardless of the substitution rate of ceramic aggregate. However, for all maximum aggregate sizes, the mixture containing 25% ceramic coarse aggregate showed a small improvement in mechanical properties. Compared to the reference mixture, which had compressive strengths of 29.31, 38.73, and 47.13 MPa at 7, 28, and 90 days for the 12.5 mm maximum aggregate size, the improvement ratios were 8.9%, 3.7%, and 2.7% at 7, 28, and 90 days, respectively. Moreover, because of increased heterogeneity, internal bleeding, and the development of microcracks in the larger coarse aggregate sizes, concrete with lower ceramic coarse aggregate sizes has a stronger bond than that of the latter. Results also indicated that the mechanical performance of concrete mixtures having ceramic aggregate slightly improved with 25% ceramic coarse aggregate, then lowered in the mixtures with 50% and 75%, consecutively, at all ages. Concrete using ceramic aggregate displays a poor transition zone because of the improper binding between the paste and the coarse ceramic aggregate caused by the aggregate's porcelain texture. Additionally, the water absorption of concrete mixtures containing ceramic aggregate increased with the increase in the percentage of ceramic coarse aggregate. Conclusion The employing of ceramic waste aggregate was shown to contribute to sustainable development and a cleaner environment by producing sustainable concrete from the recycling of ceramic wastes. Each of the hardened density, compressive strength, splitting tensile strength, and water absorption of concrete mixtures decreased and the pulse velocity enhanced as the maximum aggregate size increased. The mechanical properties decreased at all ages in the mixtures containing 50 and 75% of the aggregate, whereas they slightly increased in the mixture containing 25% of the aggregate.

Acid fluoride in ceramic material production

Purpose: The aim of this work is to develop fluorine anhydrite-based ceramic materials and engineering concept for their production and identify the conditions for the ceramic body formation and strength improvement.Methodology/approach: Acid fluoride without aditional processing and ash from thermal power plants are used in the experiment. Sodium silicate solution and the aluminum powder are introduced in the melt for the mullite formation. The phase composition is investigated on a Shimadzu XRD-6000 Diffractometer. Clay is dried to prepare the mixture and then it is ground in a jaw breaker and co-milled with the specific amount of acid fluoride.Research findings: Granular and piece ceramic wall materials with the required properties are obtained. Drying and firing conditions and the main performance characteristics are determined herein.Practical implications: Construction and technical characteristics of acid fluoride are detected for the ceramic material production, the proposed methods can be used for ceramics modification, allowing to reduce expenditures per unit of output for mineral raw materials.Originality: Process conditions are determined for the ceramics production, and dependencies are suggested to control the composition and properties of granular and piece ceramic wall materials.

INVESTIGATION OF THE USE OF KÜTAHYA REGION KAOLIN IN WALL TILES

The main raw materials in the ceramic wall tiles are clay, kaolin, calcite, and feldspar. The technical properties of the tiles (water absorption, total shrinkage, dry firing strength, fracture strength) and the desired physical properties (L, a, b, surface smoothness) vary depending on the raw material content in the recipe. Rheological parameters are crucial in the formulation development stages to avoid production problems and to ensure the final desired product parameters. Density, viscosity, and sieve analysis have therefore been included in the developed formulations. The use of raw materials from the region close to the production facility facilitates easy access to these materials. Thanks to this advantage, the use of domestic raw materials is becoming more widespread. In addition to the use of alternative raw materials, it contributes to the reduction of greenhouse gas emissions. The aim of this study, is to formulate a recipe for wall tiles using kaolins from the Kütahya region instead of clay from the Afyon region. Recipes containing 2%, 4%, 6%, and 8% of Kütahya region kaolin, with a corresponding reduction in clay from the Afyon region, were developed and sintered at 1130-1150°C with a 29-minute firing cycle. By analyzing the technical properties of the developed formulations, it was found that a maximum of 2% of Kütahya region kaolin could be used in the wall tile formulation. It was found that exceeding this percentage was not feasible due to the associated increase in water absorption, expansion of product size, and decrease in dry strength.

USE of Thermal Power Engineering Waste to Reduce the Average Density of Ceramic Wall Materials with a Matrix Structure

It has been presented the results of studies on reducing the average density of ceramic wall materials through the use of ash granules. The chemical, granulometric, and mineral compositions of clay raw materials and fly ash are given. It has been considered the compositions of ceramic charges with different contents of thermal power waste and sample preparation techniques. In the first case, mechanical mixing of the charge components was used, in the second case, granulation of the components and creation of a shell on the surface of the granules was used. The physical and mechanical properties of ceramic samples produced by both methods are presented. It has been established that an increase in the fly ash content in the charge leads to a decrease in the average density and compressive strength of ceramic samples. The use of the developed method for producing ceramic materials increases the strength characteristics of the samples, which makes it possible to increase the content of the ash component to 70–80 wt. % in the composition of the charge. It has been shown that the content of fly ash in the charge is more than 60 wt. % leads to an increase in water absorption of more than 20%, which practically indicates the absence of sintering processes in ash granules. Prospects and main directions for further research are formulated.

Preparation of Ceramic Press Powder Based on Aluminosilicate Clay Raw Materials and Ash and Slag Waste from Thermal Power Plants Synthesized by Vitreous Microspheres

The possibility of using 3-component charges in the production of wall ceramics by semi-dry pressing from aluminosilicate loams in a composition with ash and slag waste from CHP plants, cullet and silica gel obtained by the sol-gel method is considered. The physicochemical processes and phase formations occurring in the production of ceramic materials using WCO at the firing stage have been studied. It was found that the introduction of fluxes in the form of cullet and silica gel reduces the temperature of heat treatment and are intensifiers of mineral neoplasms that increase mechanical strength compared with samples made from 2-component compositions «loam + ASW».

Use of Industrial Waste to Improve the Performance Properties of Ceramic

Industrial waste, with an in-depth study of its resource capacity, physico-chemical and technological properties, is a valuable raw material for construction ceramics. The possibility of replacing high-quality clays in technologies for producing clarified ceramic bricks and effective wall ceramics using high-calcium waste generated during water purification by liming in thermal power engineering, chemical and other enterprises has been established. The obtained physicochemical patterns of formation on their basis of the structure and properties of a ceramic composite provide a scientific basis for the use of typical waste, in these studies, dust from electric precipitators of cement production. The role of aluminum-containing waste generated during the electrolysis of molten aluminum in regulating the technological properties of the masses and firing properties of clinker bricks has been revealed, which allows the use of low-grade clays for its production. Scientific research and recommendations on the use of various industrial wastes not only for the purpose of recycling, but also for the use of their valuable properties associated with the chemical composition, behavior in heat treatment, reactivity, the possibility of strengthening due to the formation of a controlled structure of the material, help slow down the process of decline reserves of high-quality clay raw materials.

Assessment of the effect of moisture on the strength of concrete and ceramic masonry wall products

Introduction. The material of the article considers the strength characteristics of ceramic and concrete masonry products, the operation of which is carried out in difficult conditions. The analysis of domestic and foreign publications and sources carried out in this work, including the results of previously performed experiments and field studies, showed that the values of the tensile strength of concrete and ceramic masonry products largely depend on moisture saturation.
 
 Aim. When analyzing previously performed works, it was found that moisture saturation and operating conditions significantly affect the strength properties of concrete and ceramic masonry products in the form of bricks and small blocks. It is noted that in some cases, the effect of degradation of the physical and mechanical properties of the products was observed. When performing surveys of buildings and structures, it becomes necessary to determine the bearing capacity of the masonry of foundations and basement walls located below the mark of the adjacent ground surface. These structures are located in an environment of excessive humidity, therefore, the masonry products themselves are in a state of increased moisture saturation, for example, due to the absence or damage of waterproofing, violation of the heat and humidity regime of the indoor microclimate.
 
 Materials and methods. During the work, masonry ceramic products in the form of bricks were used – new ones made according to State Standard 530-2012; historical bricks selected during the inspection of buildings and structures of historical buildings, as well as concrete wall products made according to State Standard 6133-2019. The test procedure complies with the established standard State Standard R 58527-2019.
 
 Results. Conducting of the research and developing of methods to assess the effect of humidification of ceramic and concrete masonry products on the strength of masonry is important for assessing the reliability of buildings and structures.
 
 Conclusions. The current problem requires comprehensive studies of the strength characteristics of ceramic and concrete masonry wall products, taking into account the influence of humidity.

Micromilling of high-aspect-ratio ceramic thin walls with customized micro PCD end mills

With the increasing application of ceramic structural parts, how to realize the ductile cutting of ceramics and high-quality machining of ceramic structural parts have become an important research direction. In this paper, the micromilling of fully sintered zirconia ceramics is studied using customized PCD end mills with three different rake angles. The critical thickness for microcutting of ceramics during the micromilling process is theoretically analyzed and experimentally identified. Then, the ductile cutting of ceramic materials is to be realized by controlling the key cutting parameter (feed per tooth fz) considering the critical cutting thickness. Under the condition of ductile cutting, the high-aspect-ratio vortex curved thin walls of fully sintered zirconia ceramics are successfully fabricated. Furthermore, the tool wear of the customized PCD end mill is analyzed. The tool geometric parameters that are beneficial to ensure both ductile cutting and high tool life are identified.