The effect of trimming waste on the porcelain tiles
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Date
2016-06
Authors
Nur Aishah Mokhtar
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Abstract
Trimming waste (TW) is the scrap from trimming process during production of porcelain tile. The objective of this study are to evaluate the suitability of using TW as porcelain tile composition and to investigate the effect of different firing temperature on the properties of porcelain tile. The composition of porcelain tile in this study were TW, basic (B) and sodium feldspar (SF). This study covered three parts, part 1 was the characterisation of raw materials using particle size analysis, X-Ray Flourescene (XRF), X-Ray Diffraction (XRD) and Field Emission Scanning Electron Microscope (FESEM). XRF, XRD and FESEM were used to examine the chemical composition, phases and morphology of raw materials. Part 2 was the sample preparation of porcelain tile body [porcelain tile composition, wt% TW:B:SF, 0:60:40 (PT1), 12:60:28 (PT2), 16:60:24 (PT3), 20:60:20 (PT4), 24:60:16 (PT5), 28:60:12 (PT6) and 40:60:0 (PT7) with 49wt% of water]. The mixing and milling time was fixed for 15 minutes. The slip was dried in the oven (100°C, 24 hours) and crushed into powder from. The powder pressed into two shape; button shape (Pressure: 90 bar, weight: 24grams, diameter: 50mm) and rectangular test piece (Pressure: 320 bar, weight: 320grams, width: 10mm, length: 20mm). The green ceramic tile produced was dried in electric oven in order to remove excess moisture (100°C, 24 hours). The green body of sample then fired at different firing temperature (1090°C, 1110°C, 1130°C and 1150°C) with 4.5 hours soaking time. In part 3, the fired porcelain tile body was undergone testing and characterisation such as fired colour, shrinkage, water absorption and bulk density. Modulus of Rupture (MOR) for mechanical strength. XRD, FESEM and Energy Dispersive X-Ray (EDX) were used to analyse phase, microstructure and elemental of fired porcelain tile body. Composition PT5 (24:60:16) has lower water absorption (0.08%) and highest MOR (85.42N/mm2) at firing temperature, 1130°C. This is because the formation of mullite phase. As a conclusion, 24 wt% of TW was the optimum composition that can be added in the porcelain tile body at firing temperature, 1130°C.