Abstract Adhesion and homogeneity of the coating-substrate were analyzed on the basis of the establishment of coating mineralogy. Substrate raw materials used were kaolin clay and a calcined alumina 4 µm; a series of higher density ceramic coatings were deposited using calcined aluminas 0.5 µm and 4 µm, silica fume, and talc. The dip coating technique was applied to all substrates and later sintered at 1300 ºC. Shrinkage and density of coatings mixtures and substrate were separately evaluated. X-ray diffraction was utilized to identify the crystalline phases present in the coatings, while optical and electron microscopy were employed for the structural characterization of the coatings. Coatings exhibited lower shrinkage compared to the substrate. Among the specimens that exhibited good adhesion, cracks were observed to extend parallel to the substrate surface. The presence of cristobalite on the coating indicated that the failure mechanism involved buckling. The crack dimension presented on the coating decreased after adding talc to the mixture.

Resumo Resultados das propriedades qualitativas e quantitativas de cerâmica à base de argila são apresentados neste trabalho. Foram utilizados quatro diferentes métodos de conformação e temperaturas de sinterização para entender suas influências nas propriedades finais de um material cerâmico formulado usando argila caulinítica e alumina calcinada. Este material pode ser usado como cerâmica estrutural para diferentes aplicações, e não há relação pré-estabelecida entre o método de conformação e as propriedades sinterizadas finais. Os métodos de conformação utilizados para preparar as amostras foram prensagem uniaxial (processo em batelada que permite a aplicação em amostras secas), extrusão (processo contínuo que requer umidade), colagem (processo que permite moldar produtos cerâmicos complexos) e laminação (processo em batelada que requer umidade). As temperaturas de sinterização foram na faixa de 1100 e 1400 °C. Para comparar como as propriedades se comportam à medida que o método de moldagem e a temperatura de sinterização são alterados, as propriedades de textura, retração, porosimetria, composição de fases e resistência mecânica foram avaliadas e analisadas. Microscopia eletrônica de varredura e microtomografia foram empregadas para analisar e comparar as microestruturas desenvolvidas. As diferenças nas propriedades resultantes são explicadas em termos das fases cristalinas desenvolvidas e da microestrutura.

Abstract The results of qualitative and quantitative properties of clay based ceramic are presented in this work. Four different shaping methods and sintering temperatures were used to understand their influence in the final properties of a ceramic material formulated using kaolinite clay and calcined alumina. This material can be used as a structural ceramic for different applications, and there is no pre-established relation between the forming method and the final sintered properties. Forming methods used to prepare the samples were uniaxial pressing (a batch process that allows application in dry samples), extruding (a continuous process that requires moisture), slip casting (a process that allows to shape complex ceramic ware), and lamination (a batch process that requires moisture). Sintering temperatures were in the range of 1100 and 1400 °C. In order to compare how properties behave as the shaping method and sintering temperature change, textural properties, shrinkage, porosimetry, phase composition and mechanical strength were evaluated and analyzed. Scanning electron microscopy and microtomography were employed for analyzing and comparing the developed microstructures. Differences in the resulting properties are explained in terms of the developed crystalline phases and microstructure.