Influence of firing temperature on the ceramic properties of illite-chlorite-calcitic clays

The influence of firing temperature on the ceramic properties of illite-chlorite-calcitic clays has been investigated. Three samples of the same clay deposit have been selected. Weight loss, dimensional changes, water absorption, bulk density, open porosity, flexural and compressive strengths, initial capillary water absorption rate and thermal conductivity have been determined as a function of firing temperature in the range 900-1200 °C with 1 h of soaking time. The microstructures of the fired samples have been examined by SEM and the phase evolution studied by XRD. The water absorption capacity decreased from ∼ 22% at 900 °C/1 h to a maximum of 12% at 1200 °C/1 h with a maximum linear shrinkage of ∼ 2.7%. The open porosities decreased from ∼ 36% at 900 °C/1 h up to ∼ 20% at 1200 °C/1 h as an effect of progressive sintering with higher densification degree of the ceramic bodies. The flexural strength reached a maximum value of ∼ 34 MPa at 1200 °C/1 h. In contrast, the compressive strengths increased by firing up to a maximum of ∼ 114 MPa at 1200 °C/1 h. The thermal conductivity increased slightly as increasing firing temperature with a maximum value of 0.582 W/m·K in samples fired at 1200 °C/1 h. The Ryshkevitch-Duckworth equation was applied and the results indicated that compressive strength is related linearly with open porosity. A linear correlation was found between thermal conductivity and open porosity. The microstructural evolution by SEM indicated that there is a change of the fired samples at 1100 °C as compared to SEM observations at 900 and 1000 °C. There is an increase of contacts between particles and layered structures associated to dehydroxylated clay minerals (illite and chlorite), quartz particles and pores developed by firing. At 1200 °C/1 h, the microstructures have changed associated to the higher degree of vitrification in the fired sample, with consolidation of the material, interparticle and neck contacts with formation of vitrified bridges. The formation of closed and large open pores of several sizes has been achieved by firing. Small particles were observed as a fine precipitation of crystals in the vitrified structures associated to anorthite, hematite and quartz relicts. This change in microstructure allowed deduce that the compressive strength increased upon firing, with maximum values of this ceramic property at 1200 °C. The ceramic bodies were more sintered by firing and the open porosity decreased progressively. Brickmaking is the main application of these fired illite-chlorite calcitic clays. These clays fired at 900–1100 °C, with 1 h of soaking time, could be applied in the fabrication of clay roofing tiles, tiles and even porous ceramic supports with small variations on shrinkage and porosity, good flexural strengths and high compressive strengths. Samples fired at higher temperatures, 1100 °C/1 h, could be applied as ceramic bricks showing a medium porosity (∼ 20%). They show almost the same bulk density when they are fired at lower temperatures (900 °C). Samples fired at higher temperatures (1150–1200 °C/1 h) could be applied as dark ceramic products. This investigation was interesting because a better knowledge of illite-chlorite-calcitic clays applied as ceramic raw materials has been achieved.