Characterization and properties of Chinese red clay for use as ceramic and construction materials

Abstract

This study involves the characterization and analysis of a Chinese red clay obtained from Hunan province to determine its suitability for manufacturing ceramic products. X-ray fluorescence analysis showed the clay has high silica (63.25 weight percent) and alumina (21.38 weight percent) content along with iron oxide, alkalis, and calcium acting as fluxes. X-ray diffraction (XRD) confirmed the presence of quartz, kaolinite, illite, and hematite as the major mineralogical phases. Scanning electron microscopy revealed loosely stacked, plate-shaped kaolinite particles exhibiting pseudohexagonal morphology. Particle size distribution shows a d50 of 12.7 μm and specific surface area is 21.3 m2/g. Differential thermal analysis-thermogravimetric analysis showed mass losses between 450–600°C and 950–1050°C corresponding to dehydroxylation and formation of a liquid phase, respectively. Dilatometry traced the onset of viscous flow sintering around 1000°C. Test bars produced from the clay were fired at 800°C, 900°C, 950°C, 1000°C, and 1050°C. The firing shrinkage increased from 2.5% at 800°C to 12.8% at 1050°C. Strength improved from 11.2 megapascals at 800°C to 42.3 megapascals at 1050°C due to densification and mullite formation. Hematite content caused the color to change from orange-red at 950°C to dark red at 1050°C. XRD analysis of fired specimens confirmed the presence of hematite and newly formed mullite and cristobalite phases. The results indicate the suitability of the clay for manufacturing bricks, roof tiles, and wall tiles using appropriate firing temperatures and cycles.