Effect of size of fly ash particle on enhancement of mullite content and glass formation

Quartz is widely replaced by fly ash in traditional porcelain composite. Increased strength and stability of the fly ash-mixed composite depends on the quantity and crystallinity of the mullite phase in the fly ash. Our aim in this investigation is to increase the formation of mullite in nanocrystalline form and study the effect of temperature. Quantitative estimation of mullite and residual quartz content were done by X-ray diffraction (XRD) and nanostructure and crystallization were studied using differential thermal analysis (DTA), field effect scanning electron microscopy (FESEM), XRD and Fourier transform infrared (FTIR) spectroscopy. The results show that fly ash sieved through 250 holes/cm2 mesh contain more mullite initially and growth of mullite as well as glass formation was faster in this sample compared to coarse fly ash. The maximum mullite in these samples was formed at 1600°C. Transformation of quartz and cristobalite phases into glassy phase was also faster for smaller particle sizes of fly ash.