Alkali-ions diffusion, mullite formation, and crystals dissolution during sintering of porcelain bodies: microstructural approach

The effect of alkali-silicate glassy matrix as replacement for feldspar in soft and hard porcelain compositions was studied. SEM and X-ray diffraction analysis were used to evidence phase evolution. For each composition, the influence of soaking time was evaluated. The difference in chemical composition (amount of alkali and alumina) between the two types of porcelain studied influenced the final microstructure: density, pore size and shape, and mullite content. Quartz dissolution was more important in soft porcelain where the mullitization was limited by the low amount of alumina compared to hard porcelain. Replacing the feldspar by alkali-silicate glassy matrices with similar chemical composition, the amount of secondary mullite and mechanical properties increased in both soft and hard compositions.