Preparation,Reinforcement And Properties Of Ultrathin Architectural Ceramic Plate With High Strength

Large size ceramic sheet is a new innovative product which is developed for“the Belt and Road”initiative.Compared with the traditional ceramics tiles,large size ceramic sheet preparation technology can effectively reduce the raw material and energy consumption,and the exhaust of SO₂,NO_x and environmental-harmful fog.It is the green manufacturing development direction of the traditional building and sanitary ceramics.Therefore,how to reduce the manufacturing cost such as using the dump slag as raw materials and how to promote the product strength and reduce the thickness of the ceramics sheet are the most important problems and the difficulties.The preparation technology,structures and properties of the porous light-weight ceramic sheet?QQ sheet?were investigated in this thesis by using the polished slag as main raw materials.Base on it,magnesia ceramic sheet with high whiteness and strength was developed.Also the mullites crystallites,yttrium silicates whisker,ZrO₂ fiber,TiO₂ fiber and Al₂O₃ fibers were used to enhance the magnesia ceramic sheet.The relationship between the composition,structure and properties was also researched.The optimized several kinds of ceramics sheets were pilot investigated on industrialization.The main research results were concluded as follows.1.The porous light-weight ceramic sheets were prepared by using polished slag.The recipe and chemical composition of the QQ sheet were optimized.Results showed that sintering process has great influence on the ceramics porous structure and the corresponding properties.The sheet will foaming when the temperature is over 1000?.With the increase of firing temperature,the increase in porosity and closed porosity was found,while the decrease in ceramics strength was also detected.The increase in firing temperature and high temperature maintain time is helpful for the achieving of mullites crystallites.2.Large size ceramic sheet?PP sheet?which meet national and international product standards is successfully developed by using MgO-Al₂O₃-SiO₂ system and kaolin,potash feldspar,soda feldspar and talc as raw materials under the triangle experimental design.The phase is composed by enstatite,mullites and little quartz.Under the sintering temperature of 1200-1260?,the bending strength,porosity and whiteness are 51MPa,0.23%and 85orespectively.3.The mullites crystallite were synthesized at low temperature by using fly ash and fly ash floating beads as raw materials and introduction of high Al₂O₃content mineral materials.The as-prepared mullites crystallite meet the national standards.Also the ultra-fine mullites powders were also prepared by sol-gel process at 800-1000?.Results showed that the Al₂O₃-riched mullites powder can be acquired at low temperature and pure mullites powder can be prepared at high temperature?1000??.The preparation activation energy of mullites powders was calculated to be 62.8 kJ/mol by using Kissinger methods.4.Crystallites reinforced large size ceramic sheets were prepared by using fly ash,fly ash floating beads resulted and sol-gel mullites as reinforcement.Results showed that the three kinds of mullites could effectively reinforce the ceramics sheet.With the increase of mullites content,the bending strength of the sheets was increased.The Bending strength reached the maximum value when mullites content arrived to 6%.The optimized sintering temperature is 1200?and the fly ash floating beads resulted mullites reinforced ceramics sheet exhibited the maximum bending strength of 83MPa,which is higher than the required value of the national standard.5.The yttrium silicates whisker with the diameter of 1-5?m and length of30-60?m was prepared by a solvothermal process.Results showed that the thermal conductivity of the as-prepared whisker is 1.15-1.25 W/?m?K?at the temperature range of 25-1000?.And the thermal expansion coefficient of the as-prepared whisker is 6-7×10^-6/K at the temperature range of 500-1000?.By using the as-prepared whisker to enhance the ceramics sheet,Spodumene is more suitable to act as fluxing agent than potash feldspar and soda feldspar.When yttrium silicates whisker content reached 6%,the maximum strength of the ceramics sheet was achieved as 92MPa.Compared with the raw one,the strength of the reinforced sheet was improved by 80.4%.6.The large size ceramic sheets were reinforced by ZrO₂,TiO₂ and Al₂O₃short fibers without changing the traditional preparation technology of the ceramics sheets.Results showed that the mechanical properties of the sheets were improved to some extent by using both fibers.The bending strength of the sheet firstly increased and then decreased with the increase of fiber content.The ZrO₂ short fibers exhibited the best reinforcement and the bending strength of the sheet reached the maximum value of 85MPa when ZrO₂ fiber content was 7%,which displaying 66.7%improvement in bending strength.7.WO₃?H₂O crystallites were prepared by a solution process.It was found that the microstructure and the phase structure had great influence on the catalysis reactivity.Thin flaky WO₃?H₂O crystallites possessed good photocatalytic degradation performance due to the exposure of active crystal surface and high specific surface area characteristics.Used it as the photocatalytic degradation active ingredient in glaze,tungsten based fast crystallization glaze was prepared on the surface of ceramic sheet.Results showed that the main phase composition of the glaze was WOP₂O₇ with large size and obvious crystallizing orientation,displaying good decoration and degradation of pollutants by UV-visible light.This provides a new direction for improving the functional application of crystalline glaze.8.Pilot studies were carried out for the QQ sheet,PP sheet,mullites PP sheet?MPP sheet?,ZrO₂ PP sheet?ZPP sheet?and WO₃ PP sheet?WPP sheet?products.Results showed that the size,modulus of rupture,water absorption,wear resistance,soluble lead content,soluble cadmium content and static friction coefficient of the all PP sheet products meet the requirement value of the national standard.The density,thermal conductivity,average modulus of rupture and water absorption of the QQ sheet products meet the requirement value of occupation standard.