The change of phase composition in kaolinite- and illite-rich clay-based ceramic bodies

Abstract Raw material for ceramics consists mainly of kaolinite, illite, quartz and feldspar. Three representative clays, a high kaolinitic (HB), illitic- and quartz-rich (KW) and naturally mixed kaolinite–illite (P1) clays of Westerwald area, were chosen for this study [Kromer, H., 1980. Tertiary clays in the Westerwald area. Geol. Jb. D. Rhei D Hanover, 69–84]. The largest and oldest clay mining area of Germany is in the Westerwald area. These clays were mixed with each other and also with K, and Ca–Na feldspar. The high temperature phases of the mixed bodies were of three groups: crystalline phase, amorphous/glassy phase and porosity. The aim of this study was to determine: (1) the effect of kaolinite–illite–quartz ratios, (2) the effect of heat treatment and (3) the effect of feldspar on the fired mineralogy of the fired products. The crystalline phases are cristobalite, mullite, quartz, hematite and anatase. The bodies consist of crystalline phases such as quartz, mullite and cristobalite in a composite structure where crystals and pores are often embedded in amorphous/glassy phase. The formation of mullite and cristobalite is very distinctive in kaolinitic clay, and the structure is dominated by the spiky primary mullite. In the illite/sericite-rich mixtures, the high K content causes a large amount of melt superimposed on the mullite formation. The cristobalite formation is completely suppressed in illite/sericite-rich bodies. After dehydroxylation, metakaolinite and illite/sericite anhydride structures are formed. The persistence of illite/sericite anhydride peaks above 950 °C in KW clay indicates the presence of sericite/muscovite mineral. The disappearance temperatures and firing behaviour of K and Ca–Na feldspar observed within the XRD patterns of mixed bodies are different. K feldspar lines disappear earlier in HB bodies than in KW bodies, but Ca–Na feldspar shows a reverse behaviour. While Ca–Na feldspar peak intensity gradually decreases but persists at 1150–1250 °C, K feldspar suddenly disappears at 1150 °C.