Development and study of the properties of a ceramic-matrix composite material for the production of ultra-thin large-format ceramic granite slabs

Abstract

The article analyzes the advantages and disadvantages of large-format ultra-thin ceramic granite slabs, shows the need and identifies ways to increase their strength. The composition of the ceramic matrix has been developed, provides the maximum level of sintering (W ≤ 0.5 %) in accordance with the requirements for ceramic plates of class ВІа, and the choice of the reinforcing filler has also been substantiated. It has been experimentally established that mullite-silica fibers have a positive effect on the physical and mechanical properties of the slabs, which makes it possible to reduce their thickness by three times, and therefore significantly reduce the weight of products. The fractional composition of the grinding products of mullitesilica fibers was determined depending on the grinding conditions, and the influence of the quantitative and qualitative characteristics of the reinforcing filler on the main properties that determine the quality of ceramic granite slabs was investigated. The conditions for the formation of densely sintered composite materials with a complex of high-performance properties have been determined. It was shown the possibility of increasing the samples bending strength up to 57 MPa by introducing 4 wt. % of finely dispersed mullitesilica fibers, most of which (~ 60 %) have a length up to 45 microns, which is achieved by 3 min grinding in a planetary mill at a speed of 300 rpm. The structural-phase features of the samples obtained under the high-speed firing conditions, which consist in the increased amount of the mullite phase formation in the presence of mullite-silica fibers, have been established. The latter not only reinforce the ceramic matrix, but also act as a precursor of new mullite formations, the crystals of which, in the presence of a melt, acquire an isometric shape and contribute to an increase in the products strength. The research results indicate the promising obtain large-format ultra-thin ceramic granite slabs using composite materials technology. The combination of excellent technical qualities, large dimensions, and reduced slabs thickness opens up the new possibilities for using composite ceramic granite in design of furniture and large rooms due to the possibility of creating a continuous seamless coating and a significant reduction in the products weight.