Investigation of the formation kinetics of the black core problem observed in thick section floor tiles by simulating on thin section floor tiles

The high abrasion resistance possessed by ceramic coating materials, resistance to chemicals, long-term lifespan, high strength, as well as the properties of the base, as well as its decorative and structural properties are driving the demand for these materials. Increasing capacities, along with trying to produce products more quickly and ever-increasing energy costs, have revealed the need to reduce firing times. Due to the shortening of the firing times and the high temperatures applied to make porcelain tiles sinterable more quickly, the problem of black core on porcelain floor tiles appears and remains up-to-date. Porcelain tile manufacturing processes make the black core problem more complicated. Dimensional differences of porcelain tiles produced for different decorative purposes were also seen as a parameter for this problem to occur. In the thesis study, the black core problem that occurs on thick sectional floor tiles is simulated in thin cross-section floor tiles, examining the production parameters that affect the likelihood of black core forming. The study explored the impact of thickness and organic matter in particular, without changes in firing times and temperatures known to be effective in the occurrence of black core problem. The work was carried out at the Veli Akgün Seramik San. Tic. A.Ş Tile Factory. Tablets at different thicknesses (6,1, 10,4, 12,6 mm) for the study of the effect of porcelain tile thicknesses, different proportions of carbon additions by weight (0,01 – 0,06g) for the study of the organic raw material quantity effect fired on standard regime. Differences appeared in the microstructure and chemical phases of regions that formed black core. In porcelain tiles consisting of black core, the amount and size of pore increased, and the amount of organic from thickness and raw material increased the appearance of black core in sintered samples.