摘要
低温快烧工艺是目前陶瓷行业节约能源、降低燃耗、提高生产效率的有效途径。
陶瓷生产线上大量瑕疵品的出现,从很大程度上影响了厂家的收入效益,如果将陶瓷表面上的斑点除掉,用釉料重新覆盖烧成,将会大幅度提高陶瓷产品的成品率,这种起表面修复作用的陶瓷釉料最好采取超低温烧成,以免破坏原有釉面和胚体,并能大幅度降低能耗和产品成本。
本论文设计了釉料配方和添加剂,成功制备出烧成温度低于800℃的优质釉面；用DSC-TG、XRD、SEM、拉曼光谱对样品的结构、微观形貌、形成过程等进行了表征,测试了釉面的物理性能,研究了超低温釉的低温烧成机理和最佳烧成制度,讨论了ZnO、Na2B4O7对釉料烧成温度的影响以及烧成制度对釉面质量的影响。
实验结果表明,釉料配方中,B2O3：SiO2为1.367：1(质量比),ZnO含量为11.74%,釉料烧成温度在780℃左右,烧成后釉面平整光滑,光泽度高,透明性好,有较强的耐热性,胚釉断面有结合层生成。与原配方相比,始熔温度降低了500℃左右；熔融过程温宽增加了200℃；脱出CO2等气体的温度降低了80℃。510℃-600℃,Na2B4O7开始软化,同时ZnO、钾长石、滑石、方解石、碳酸钡等矿物开始和软化的Na2B4O7反应逐渐熔化,形成了以硼酸钠为主的硼酸盐低共熔体；600℃-715℃,难熔石英开始熔化,剩余矿物先后完全熔化；到780℃时,釉料完全处于熔融状态。焙烧过程中,600℃-780℃,升温速率为6℃/min,烧成后的釉面平整光滑,光泽性高；800℃-500℃,降温速率为20-25℃/min,釉面析晶最少；500℃-25℃,降温速率为2-5℃/min,釉面无裂纹。
Nowdays, low-temperature quick firing technology is an effective way to save energy, reduce fuel consumption and improve the production efficiency in the ceramic industries.
The defectives in the ceramic production line have greatly reduced the profits of many manufactures. Some industries choose to remove the spots and covered with glaze on the ceramic surface, and then calcined to be a perfect one. This method will greatly improve the yield of ceramic products. Since avoide to destroy the original glazes and embryos, the glazes must be calcined at an ultra-low temperature. This method can greatly reduce the energy consumption and the production cost.
In this paper, a glaze with a melting temperature below 800℃was obtained on the basis of lots of experimental designs. By DSC-TG, XRD, SEM and Raman analysis, the structure, microstructure and forming process of glazes were discussed, and the physical properties of the glazes were also tested. Finally the calcined mechanism and the calcined system of these glazes were discussed.
The conclusions showed that, when the mass proportion of B2O3: SiO2 is 1.367:1, and the content of ZnO is 11.74%, the new glazes are melted at about 780℃with great glossy, the best transparency and high thermal stabilities, and the embryo glaze layer was generated. Compeared with the glazes melted at 1180℃, the initial melting temperature of new glazes is reduced by 500℃, the temperature width of melting process is increased by 20℃, and the weight loss coursed by the emission of CO2 is reduced by 80℃.510℃-600℃, Na2B4O7 and NaBO2 firstly begin to melt, and at the same temperature ZnO, feldspar, talc, calcite, BaCO3 and other minerals also begin to melt, and at about 710℃these minerals melt down; Melting of quartz and a small amount of silicate begin at 600℃-715℃, and at 780℃all of the glaze have been gone into the melt. In the calcined process,600℃-780℃, when the heating rate is 6℃/min, glazes with great glossy can be made; 800℃-500℃, when the cooling rate is 20-25℃/min, glazes with little recrystallization and good transparency can be obtained; below the initial melting temperature, when the cooling rate is 2-5℃/min, the glazes are heated equably and with little crack.
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