I n T h e N a m e o f G O D فصلنامـه تخصـصی کاشـی و سـرامیـک Ceramic & Tile Industries Magazine سال سوم شامره 4 زمستان 1392 Vol. 03 No. 04 Winter 2014

صاحب امتیاز و مدیر مسئول: کامبیز کیامهر Owner & Managing Director (Editor): Kambiz kiaMehr جانشین مدیر مسئول: امیر روشن بخش Vice Managing Director: Amir Roshan Bakhsh سـردبیـر: نوشین پریانی Chief Editor: Nooshin Pariyani مدیـر اجـرایی: آذین بکتاش Executive Director: Azin Backtash مدیـر هامهنـگی: ساالر نیرهدی Coordination Manager: Salar Nayyerhoda مدیـر بازرگانـی: هلن مناینده امـور بازرگانـی و آگهـیها: شیدا طاهری، مریم خوش نیت، شاهین مناینده، سحر ربیعی / Commercial Manager: Helen Nemayandeh 88967914 - 88967616 مدیـر هنـری: رضـا رحیمیان Business Affairs & Advertisements: Sheiyda Taheri, Maryam KhoshNiyat, Shahin Nemayandeh, Sahar Rabiee صفحـه آرا: یاشار لطیف پور Tel: (+98) 021 88967914 - 021 88967616 طرح جلد: محمد مکاریچیان Art Director: Reza Rahimiyan امـور طراحی و گرافیـک: شاهین رفعتنژاد، آرمین مرسی، مهران قدیمی Paging & Design: Yashar Latifpour ویراستـار: منیژه شیرمحمدی Cover & Logo: Mohammad Makarichiyan حروفچینی: سمیه واعظ Design & Graphics: Shahin Rafaat Nejhad, Armin Merci,Mer Mehran Ghadimi نشانی: تهران، خیابان وصال شیرازی، خیابان ایتالیا، پالک Editor: Manijheh ShirMohammadi 27 تلفـن: Typist: Somayyeh Vaez 88989150 - 2 چـاپ: خجسته نوین Publication: Khojasteh Novin تیــراژ: 10 هزار نسخه Circulation: 10,000 copies

فهرست INDEX

Tile Patterns, bringing tile to life 04 What kind of tiles has been made? 06 Using Suspended Granilhas for Porcelain 16 Nanocomposite Ceramics, What are Nanocomposite Ceramics? 22 بـررســـی تکنولوژی روتـوکالر Technology pushes trends in Ceramic tile 28 39 پیشـکسوتان علم و صنعت رسامیک ایران The continuing evolution of quartz surfacing 30 41 دکوراسیـون دیجیتالی بر روی کاشـی A couple’s retreat built with native stone 34 43 کـوره هـای رولــــــری )Digital technology creating new possibilities for ceramic tiles 36 47 )Roller Kiln Vol. 03 No. 04 Winter 2014

eramic tile continues to reign as one Trending tiles and patterns installed in this pattern. in part to wood-look tile, one of the hottest of the most favored design staples in Many of today’s most popular tile patterns Straight Joint is one of the simplest tile pat- trends in the marketplace. What was first in- Tile Cthe floor-covering industry because are inspired by the emerging trends driving terns that showcases the beauty of every tile. troduced as a traditional take on hardwood of its performance, design versatility, color modern design. These trends take some time The straight joint pattern offers a more con- floors has evolved to include more colors and options and beauty. The range of design to get seeded, but once a trend is identified, temporary, linear look. textures to choose from than ever before. Patterns, possibilities with ceramic tile is truly endless, it tends to evolve and last for years. The most Whether tile is installed vertically or horizon- There has also been a significant rise in the which affords tile manufacturers the opportu- popular shapes right now are rectangular tally, the pattern’s clean lines make any space selection of natural stone planks due to the bringing nity to meet the varying needs of residential large formats and planks, which are often feel taller or wider. beautiful vein-cut natural stone options being and commercial audiences through extensive being used on both the floor and on the wall. Third Stagger is a variation of the Running offered today. portfolios of stylish floor and wall tile options This results in many more pattern options, Bond layout that features a stair-step pattern Chevron is an inverted V-shaped pattern. In tile to life – but there’s more to a tile installation than which designers are utilizing more frequent- with each joint offset 1/3 from the row of tiles this design, all planks are the same length and the tile itself. ly to create unique designs. For larger format below it. the pieces are installed at an angle to match How tile is laid can change the look and feel sizes, the most popular patterns are Running These larger format sizes (12”x24”, 18”x36” up perfectly with one another. of any space – and there are so many exciting Bond, Straight Joint and Third Stagger. and 24”x48”) offer a more transitional, clean This creates a perfectly straight line on both tile patterns to choose from and ways to use Running Bond is a basic yet beautiful layout, look and have less grout. Running Bond and sides of the planks. Herringbone is very simi- them to a space’s best advantage. No mat- also called a brick or offset pattern. In this Third Stagger provide a traditional spin on the lar to Chevron, but instead of having the ends ter how you want to alter the appearance or pattern, the tiles are offset by half the width modern cut tile, while the Straight Joint offers line up with one another, they overlap, creat- scale of an installation, there’s a tile pattern of the tile, offering a timeless look for almost a more modern look. ing an entirely different and unique look. designed to work for you. Using any classic any style. Mosaics are also “must-haves” right now, tile pattern can help transform a standard tile With each joint centered over the tile below, Patterns for planks especially in kitchen backsplashes, shower

By Corinthia Runge, manager, job into an extraordinary one. Considering this pattern resembles classic brickwork. For plank sizes, the most popular patterns are walls and floor accents. The texture and color Daltile Design Studio the wide variety of tile and trim tiles available, Larger formats (any side measuring over 18”) Chevron, Herringbone and Random Stagger. movement possible with these mosaics add the possibilities are limitless. require an offset of no more than 33% when The rise in popularity of these layouts is due a depth, sparkle and luminescence to any

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space. In terms of mosaic patterns, if you can imagine it, you can create it. From vivid colors and on-trend shapes to unique patterns and bold borders, one simple design can turn any space into an incredible work of art. There are hundreds of patterns and borders available that can be modified to comple- ment any design scheme. Many mosaics are available in custom (made to order) and standard patterns that can be used in any ap- plication.

On the level for proper installation The primary challenges with large-format tile patterns are foundation and installation. For large-format tiles, the foundation must be perfectly level, which at times requires exten- sive preparation work for the surface. It may also require a crack-prevention membrane. Also, during installation it may require extra setting material and extra manpower, since the large tiles may be difficult to maneuver.

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tile is a manufactured piece of is derived from the French word tuile, which is, Floor tiles Some stone tiles such as polished granite, mar- stone while limestone is an example of a more hard-wearing material such as ceram- in turn, from the Latin word tegula, meaning These are commonly made of ceramic or stone, ble, and travertine are very slippery when wet. porous stone. Different granites and marbles Stone tiles with a riven (split) surface such as have different porosities with the less porous What kind ic, stone, metal, or even glass. Tiles are a roof tile composed of fired clay. Tiles are of- although recent technological advances have A resulted in rubber or glass tiles for floors as slate or with a sawn and then sandblasted or ones being more valued and more expensive. generally used for covering roofs, floors, walls, ten used to form wall and floor coverings, and well. Ceramic tiles may be painted and glazed. honed surface will be more slip resistant. Ce- Most vendors of stone tiles emphasize that showers, or other objects such as tabletops. Al- can range from simple square tiles to complex of tiles Small mosaic tiles may be laid in various pat- ramic tiles for use in wet areas can be made there will be variation in color and pattern from ternatively, tile can sometimes refer to similar mosaics. Tiles are most often made from porce- terns. Floor tiles are typically set into mortar more slip resistant either by using very small one batch of tiles to another of the same de- has been units made from lightweight materials such lain, fired clay or ceramic with a hard glaze, but consisting of sand, cement and often a latexa- tiles so that the grout lines acts as grooves or scription and variation within the same batch. as perlite, wood, and mineral wool, typically other materials are also commonly used, such dditive for extra adhesion. The spaces between by imprinting a contour pattern onto the face Stone floor tiles tend to be heavier than ceram- of the tile. The hardness of natural stone tiles ic tiles and somewhat more prone to breakage used for wall and ceiling applications. In anoth- as glass, metal, cork, and stone. Tiling stone is the tiles are nowadays filled with sanded or unsanded floor grout, but traditionally mortar varies such that some of the softer stone (e.g. during shipment. made? er sense, a tile is a construction tile or similar typically marble, onyx, granite or slate. Thinner was used. limestone) tiles are not suitable for very heavy Rubber floor tiles have a variety of uses, both object, such as rectangular counters used in tiles can be used on walls than on floors, which Natural stone tiles can be beautiful but as a traffic floor areas. On the other hand, ceramic in residential and commercial settings. They playing games (see tile-based game). The word require thicker, more durable surfaces. natural product they are less uniform in color tiles typically have a glazed upper surface and are especially useful in situations where it is de- and pattern, and require more planning for use when that becomes scratched or pitted the sired to have high-traction floors or protection and installation. Mass-produced stone tiles are floor looks worn, whereas the same amount for an easily breakable floor. Some common uniform in width and length. Granite or marble of wear on natural stone tiles will not show, uses include flooring of garage, workshops, pa- tiles are sawn on both sides and then polished or will be less noticeable. Natural stone tiles tios, swimming pool decks, sport courts, gyms, or finished on the facing up side, so that they can be stained by spilled liquids; they must be and dance floors. have a uniform thickness. Other natural stone sealed and periodically resealed with a sealant Plastic floor tiles including interlocking floor tiles such as slate are typically “riven” (split) on in contrast to ceramic tiles which only need tiles that can be installed without adhesive or the facing up side so that the thickness of the their grout lines sealed. However, because of glue are a recent innovation and are suitable tile varies slightly from one spot on the tile to the complex, non repeating patterns in natural for areas subject to heavy traffic, wet areas and another and from one tile to another. Varia- stone, small amounts of dirt on many natural floors that are subject to movement, damp or tions in tile thickness can be handled by ad- stone floor tiles do not show. The tendency of contamination from oil, grease or other sub- justing the amount of mortar under each part floor tiles to stain depends not only on a seal- stances that may prevent adhesion to the sub- of the tile, by using wide grout lines that “ramp” ant being applied, and periodically re-applied, strate. Common uses include old factory floors, between different thicknesses, or by using a but also on their porosity or how porous the garages, gyms and sports complexes, schools cold chisel to knock off high spots. stone is. Slate is an example of a less porous and shops.

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Decorative tilework BC), now partly reconstructed in Berlin, with Islamic tiles saic patterns. The result was a technological tri- tably the İznik pottery of Turkey under the Ot- and coloured brick sections elsewhere. Mesopotamian craftsmen Early Islamic mosaics in Persia consist main- umph as well as a dazzling display of abstract toman Empire in the 16th and 17th centuries. Decorative tilework should be distinguished were imported for the palaces of the Persian ly of geometric decorations in mosques and ornament. During the Safavid period mosaic Palaces, public buildings, mosques and türbe from mosaic, where forms are made of great Empire such asPersepolis. mausoleums, made of glazed brick. Typical ornaments vere often replaced by a haft rang mausoleums were heavily decorated with numbers of tiny irregularly positioned tesserae Tiling was widespread in the time of the Sinha- turquoise tiling becomes popular in 10th-11th (seven colors) technique. large brightly coloured patterns, typically with in a single colour, usually of glass or sometimes lese kings of ancient Sri Lanka, using smoothed century and is used mostly for Kuficinscriptions Pictures were painted on plain rectangle tiles, floral motifs, and friezes of astonishing com- ceramic. and polished stone laid on floors and in swim- on mosque walls. Seyed Mosque in Isfahan glazed and fired afterwards. Besides economic plexity, including floral motifs and calligraphy The earliest evidence of glazed brick is the dis- ming pools. Historians consider the techniques (1122 AD), Dome of Maraqeh (1147 AD) and reasons, the seven colors method gave more as well as geometric patterns. covery of glazed bricks in the Elamite Temple and tools for tiling as well advanced, evidenced the Jame Mosque of Gonabad (1212 AD) are freedom to artists and was less time-consum- The zellige tradition of Arabic North Africa uses at Chogha Zanbil, dated to the 13th century by the fine workmanship and close fit of the among the finest examples.[12] The dome of ing. It was popular until Qajar period when the small coloured tiles of various shapes to make BC. Glazed and coloured bricks were used to tiles.[citation needed] Tiling from this period Jame’ Atiq Mosque of Qazvin is also dated to palette of colors was extended by yellow and very complex geometric patterns. It is halfway make low reliefs in AncientMesopotamia, most can be seen Ruwanwelisaya and Kuttam Poku- this period. The golden age of Persian tilework orange. The Persianate tradition continued to mosaic, but as the different shapes must be famously the Ishtar Gate of Babylon (ca. 575 na in the city of Anuradhapura. began during the reign the Timurid Empire. and spread to much of the Islamic world, no- fitted precisely together, falls under tiling. Single color tiles were cut into small pieces and assembled by pouring liquid plaster between them. After hardening, these panels were as- sembled on the walls of buildings. But the mosaic was not limited to flat areas. Jame Mosque in Yazd (1324-1365 AD) and Goharshad Mosque (1418 AD) are prominent examples of brick and tile mosaics of interiors and external surfaces of domes Islamic build- ings in Bukhara (16th-17th century) also exhib- it very sophisticated floral ornaments. Mihrabs, being focus points of mosques, were usually the places where most sophisticated tilework was placed. The 14th century mihrab at Madrasa Imami in Isfahan is an outstanding example of aesthet- ic union between the Islamic calligrapher’s art and abstract ornament. The pointed arch, framing the mihrab’s niche, bears an inscrip- tion in Kufic script used in 9th-century Qur’an One of the best known architectural master- pieces of Iran is the Shah Mosque in Isfahan, from the 17th century. Its dome is a prime example of tile mosaic and its winter praying hall houses one of the finest ensembles of cuerda seca tiles in the world. Wide variety of tiles had to be manufactured in order to cover complex forms of the hall with consistent mo-

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Pebble tile Similar to mosaics or other patterned tiles, pebble tiles are tiles made up of small pebbles attached to a backing. The tile is generally de- signed in an interlocking pattern so that final installations fit of multiple tiles fit together to have a seamless appearance. A relatively new tile design, pebble tiles were originally devel- oped in Indonesia using pebbles found in vari- ous locations in the country. Today, pebble tiles feature all types of stones and pebbles from around the world, but are still generally asso- ciated with pebbles found in exotic locations.

Ceiling tiles stone and binders which is then spun to create and upon those were placed the roof tiles. They Ceiling tiles are lightweight tiles used in the the tile, or gypsum tiles which are based on the were then plastered or painted, but nowadays interior of buildings. They are placed in an alu- soft mineral and then finished with vinyl, paper are usually left bare for decorative purposes. minium grid and they provide little thermal in- or a decorative face. Ceiling tiles very often sulation but are generally designed to improve have patterns on the front face; these are there Diamond etched tiles the acoustics of a room. Mineral fibre tiles are in most circumstances to aid with the tiles abil- A new method for custom tile printing involv- fabricated from a range of products; wet felt ity to improve acoustics. ing a diamond-tipped drill controlled by a tiles can be manufactured from perlite, mineral Ceiling tiles, especially in old Mediterrane- special type of computer. Compared with the wool, and fibers from recycled paper, stone- an houses were made of terracotta and were laser engravings, diamond etching is in almost wool tiles are created by combining molten placed on top of the wooden ceiling beams every circumstance more permanent.

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Western tile work tiles, usually in blue and white, for walls rather Gothic Revival, but also the Arts and Crafts Medieval Europe made considerable use of than floors. Delftware wall tiles, typically with Movement. Patterned tiles, or tiles making up painted tiles, sometimes producing very elab- a painted design covering only one (rather patterns, were now mass-produced by ma- orate schemes, of which few have survived. small) blue and white tile, were ubiquitous in chine and reliably level for floors and cheap Religious and secular stories were depicted. Holland and widely exported over Northern to produce, especially for churches, schools The imaginary tiles with Old testament scenes Europe from the 16th century on, replacing and public buildings, but also for domestic shown on the floor in Jan van Eyck’s Annuncia- many local industries. hallways and bathrooms. For many uses the tion in Washington are an example. Several 18th century royal palaces had porce- tougher encaustic tile was used. Wall tiles in The 14th century “Tring tiles” in the British lain rooms with the walls entirely covered in various styles also revived; the rise of the bath- Museum show childhood scenes from the porcelain in tiles or panels. Surviving examples room contributing greatly to this, as well as Life of Christ, possibly for a wall rather than a include ones at Capodimonte, Naples, the Roy- greater appreciation of the benefit of hygiene floor while their 13th century “Chertsey Tiles”, al Palace of Madrid and the nearby Royal Pal- in kitchens. William De Morgan was the lead- though from an abbey, show scenes of Rich- ace of Aranjuez. There are several other types ing English designer working in tiles, strongly ard the Lionheart battling with Saladin in very of traditional tiles that remain in manufacture, influenced by Islamic designs. high-quality workMedieval letter tiles were for example the small, almost mosaic, brightly Since the Victorian period tiles have remained used to create Christian inscriptions on church coloured zellige tiles of Morocco and the sur- standard for kitchens and bathrooms, and floors. rounding countries. With exceptions, notably many types of public area. Portugal and São Transmitted via Islamic Spain, a new tradition the Porcelain Tower of Nanjing, decorated tiles Luís continue their tradition of azulejo tilework of azulejos developed in Spain and especially or glazed bricks do not feature largely in East today. Notable among American tilemakers of Portugal, which by the Baroque period pro- Asian ceramics. The Victorian period saw a the 1920s and 1930s were Ernest A. Batchelder duced extremely large painted scenes on great revival in tilework, largely as part of the and Pewabic Pottery.

Digital tile Printing techniques and digital manipulation of art and photography are used in what is known as “custom tile printing”. Dye sublima- tion printers, inkjet printers and ceramic inks and toners permit printing on a variety of tile types yielding photographic-quality reproduc- tion . Using digital image capture via scanning or digital cameras, bitmap/raster images can be prepared in Photoshop and other photo edit- ing software programs. Specialized custom-tile printing techniques permit transfer under heat and pressure or the use of high temperature kilns to fuse the picture to the tile substrate. This has become an increasingly popular method of producing custom tile murals for kitchens, showers, and commercial decoration in restaurants, hotels, and corporate lobbies.

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Abstract Introduction In Figure 1 you can see the application of sus- Using his paper details the wet application The need to develop differentiated ceramic pended granilhas by campana. of the granilhas on porcelain tiles. This products and aesthetically appealing empha- Initial estimatesindicatethe need to consume- Tmethod has the advantage of cost sized in recent years. The search for new dec- weightsper square meterbetween0.6 to 0.7kg, Suspended savings due to decreased amount (about 50 orative effects led to development in the early which islower thanrequiredamount in the ap- to 70%) of material applied without compro- 80’s, in the form of glassy atomized, granilhas plicationby dry(reductionof about 50%) Granilhas mising the technical characteristics required and “pellets”. Apart from the decreaseof the quantityto be for these products. It also allows obtaining Although it has been thought of giving the applied, the smaller grainyieldslayersthinner- great variability aesthetics (color, texture, products greater variability aesthetics (color, andmore homogeneous. for brightness, etc...) and can be marketed matt texture, etc.), this type of application gave su- Basically this method reduces the cost of or polished. This method makes a layer thin- perior properties of glass surfaces techniques. productbecause oflowerconsumptionof ma- terial and also subsequentpolishingstepscan Porcelain ner and more homogeneous, which requires The pieces with this type of finish present Figure1. Application of granilha with wet method by campana less deep polishing, and adjusts the tendency high resistance to abrasion and the granil- be made atshallower depth.This kind ofend of flooring and coating industry to produce has exactly respond to these demands. These product providestransparentmatt appear- increasingly finer. The curtain granilhas are kinds of granilhas are fritsafter they undergo a nilhas are used dry. After application of the nilhas by wet. For this purpose the granilhas ancebefore polishingand afterpolishing gives applied by the bell on the glaze. The pieces ar- grinding step and selected granulometrically glaze, those are applied onto the work piece which are used have sizes of less than those a very brighttransparenttype. efired at temperatures between 1200-1220°C. (0.15 to 2 mm). The choice of this interval is using roller or screen machines and then coat- used by the dry (<0.3 mm) suspended in an Figure 2 representthe two possibilitiesof fin- We evaluated the layer resistance tothe attack made based on the effect to be obtained in ed with a second layer glazing with adhesive organic binder. ishingproducts. of stains, to chemical attack, abrasion, and the final product. which is diluted by discs,increasing its adher- The need to use smaller granilhas comes from This advantagenot only increasesthe variabil- measured hardness (Mohs). Conclude that this The granilhas can be transparent, matt, ence to the surface of decorated tile. need to ensure that they keep up scattered in ityofaestheticpiecesproduced (matte texture- new granilhas application method produces opaque or colored. The granilhas color is In general, the application of granilhas in dry the middle hanger. The application is made and / orgloss), but also increases itsFieldof surfaces that meet the requirements of the made during the step of melting frits or by mode to polishing consumes from 1.0 to 1.5 after enameling and decoration by screen application (Zones of greater or lessertraffic Arthur R. M. Sarabandoa, Helder J. C. Oliveirab current standards while reducing costs to the adding ceramic pigments. kg per square meter granilha material. printing or ROTOCOLOR and by using of bell flow). material to be applied and the finishing steps. Currently in industries flooring / coatings, gra- This work aims to study the application of gra- (campana). Studies conductedon theflooring industryin Europe, indicatethatfloorenamelingand fin- ishing as oneof the majorcosts in construc- tion(>25%). Havingconsidered this aspect, it is interesting to adoptmethodologiesthat reducethese costs.

Experimental Procedure Characterized granilhas to be used in suspen- sion, which we will call them “microgranil- has”, have special distribution in particle size (measured by laser interference - Coulter). It was determined by the chemical composi- tion X-ray fluorescence (XRF) and evaluated the thermal behavior (dilatometer, DTA /TG).

Figure2. Possibilities of final product (picture on the left: before polish) (picture on the right: after polish) Character of the glaze on which the granilha

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will be appliedis matt glaze and consists of putupthepiecesof evidencein contactwith dry method (conventional A, B and C). supposesapplyingof the suspensionon It also appears that it is a matt glaze opaque of quartz present the composition (to 573 ° C). 40% frit-rich BaO / ZnO and BaO /CaO, the thetest substancesfor 24 hours(citric aci- It was pointed in a scanning electron micro- aglaze,whose behaviormustbe compatible. by the presence of alumina and zirconia which From 750 ° C registers a sudden retraction re- remaining 60% include raw materials (silica, dand lactic acid)and96 hours (Hydrochloric scope (SEM) of granilhas in suspension, which Therefore,the glaze which is selectedand are respectively matt and opacifyingagents. flecting material softening and loss of dimen- feldspar,kaolin, zirconia, alumina, etc). The acid and potassium hydroxide) according confirms the size of particle, as seen in its ir- characterizedconsidered appropriate. It’s The dilatometric behavior of glaze is very sionality. The coefficient of thermal expansion glaze was applied by bell, with a density be- to standard ISO10545-136. Abrasion resist- regular shape. chemical compositionshown in Table2. important and must have compatibility with (COE), rated between 50 and 400 ° C, is 61.6 tween 1840 and 1860 gL-1 and with a viscos- ance(PEI)was measured accordingto stand- In Figure 4, once again it can be seen that the It can beseenthatit is amattglazeopaque .it microgranilhas which will be applied on it to × 10-7 ° C-1, so in the near of microgranilhas. ity of 40/45 seconds (Ford cup 4 mm diame- ardISO10545-76and hardness wasmeasured particles sizes are very small, below 300 mi- containssignificant amounts ofopacifying avoid the emergence of tensions and risks of The Softening also occurs in a region near, ter). accordingresistance MOHS7 riskasscale. crons. agents like (zirconia, alumina, calcium oxide- cracks. guaranteeing good compatibility between Table 1 shows the chemical analysis of granil- and zinc oxide). Figure 9 shows the dilatometry curve of the the two components. Themicrogranilhaswere added toan organic Results ha for application wet obtained by X-ray fluo- Figure 8 showstheX-ray diffractionperformed glaze. Figure 10 shows the thermal analysis, differ- binderin a ratioby weight of70:30%respec- The results are explained in three sections rescence (XRF). on theglaze. Up to about 750 ° C there is a tendency expan- ential and Thermo gravimetric of the glaze. tively.The suspensionwas applied also with that we will describe them below .These sec- The X-ray diffraction (see Figure 5) confirmed It is possible to observe the existence of crys- sive that is not too much significant(between The mass loss recorded at about 100 ° C (ap- campana. tions are characterization of materials like the amorphous nature the material was not talline phases. Theseare the raw elements 0.5 and 0.6%), whose linearity is disturbed es- proximately 6%), accompanied by an endo- The specimenswere firedbetweenthe maxi- glaze and granilha used , application of gra- detecting any crystalline compound. forming part of the composition of the glaze. pecially the transition between α and β forms thermic reaction, results from decomposition mum temperature1200-1220° C in acyclelast- nilha and finally the characterization of final The granilha that we are speaking about does ing 60minutes. product. not contain opacifying agents, which gener- The samples wereexaminedvisuallyand 3.1. Characterization of Materials ally correspond to the crystalline phases (e.g., evaluatedfor resistancelayerto attackstains, Figure 3 shows the particle size distributions zirconia). usingiodine, olive oil, red pasteFe,Crgreen of the granilhas different compositions, It is the absence of these phases which gives a pasteand alsoblue markerE3200accordingto milled in different conditions, for applying dry result after polishing without variation in hue standardISO10545-146. or in suspension. in the final product. The resistance tochemical etchingwas ob- The average particle size, for application of Figure 6 shows the dilatometric behavior of servedwipingsurface of thetest piecewith granilhas suspension is 87 microM and 90% granilha obtained on heating. a solvent(acetone) and drying complete- (by volume) of the particles have size less The absence of changes to linearity up to ly beforestarting the test. Test substance- than 150 microns. The maximum size is 300 700 ° C confirms the stability of the material sused werehydrochloric acid 18%(V /V), microns. It observed that the size distribution expected to have suffered prior melt during citric acid100gL-1 lactic acid5% (V / V) and for granilhas application in suspension is nar- sintering. It also confirms the absence of raw potassium hydroxide30and 100g.L-1.They rower than the particle size for application of components. The softening of the material occurs from this temperature (700 ° C), with a sharp decline. The coefficient of thermal expansion (COE), measured between 50 and 400 ° C is 63.2 × 10-7 ° C-1. Figure 7 shows thermal analysis, differential and gravimetric (DTA / TG, respectively). So according toprevious observations, the thermal behavior of granilhais quite stable, notregisteringdecompositions. Figure3. Granulometery distribution of granilha wet Figure4. Micrograph of wet applied granilha and dry Theapplying techniqueofwetgranilhaspre-

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quired is0.46 kgof thiscomponentper square sandlessroughcomparedwithdry application. Oxide Percentage Sio2 55.7 meter. Thissuitthecurrent industries produce parts Al2o3 18.1 The pieceswere fired at a cycleof 60 minutes. thickness further reduced. Cao 10.3 Figure12represents the variation oftempera- It also allowsstoring thefinal product as am- K2o 1.1 ture againstlengthof the kiln. attand onlypolish it when necessaryaccord- Na2o 4.3 Theapplication withcampanaachievesperfect ing to thecommercialapplication. Without Fe2o3 0.2 surfacesandwithsmoothsurface appearance. beingpolishedthe piecesexhibitvalues of Sro 3.2 3.3.ProductCharacterization PEIIVwhich allowsits use intraffic areaseasily. Zno 6.5 Figures 13and 14,testsillustrate theresistance The application ofwet granilhaspresentsitself Table1. Chemical composition of granilha in wet method (XRF) tostain andresistance to attack as aviable alternative toapplicationby dry pro- chemicalpolished andnon-polished tilesre- cessing offers the possibilitytwodifferent fin- Oxide Percentage spectively. ishes (polished and unpolished) and increases Sio2 47 The resultsof resistanceto attack byaggressive variabilityareasof applicability. Al2o3 23.8 agents are shown in Table 3. These surfaceshave highresistance to chemi- Bao 2.6 Aboutstain, the stain removalis achieved- cal attackbeing classified asclass product GLA Cao 6.3 placing the tileinhot water (55 ° C)streamfor and GHA ISO10545-136. For these reasonsit is K2o 2.2 5 minutes,for all elementsusedin the testex- concludedthat the surfacesmattand shiny, by Mgo 1.2 ceptthe marker. TheRemoval of themarkeris this methodmeet the requirementsrequired Na2o 3.5 made withalcohol.This result givesthe classi- byregulations. Fe2o3 0.1 fication5of the productin all cases. Zno 2.6 References Table 4 showsthe results ofresistance to Zro2 3.4 1. Amoros, J.GlazedCeramic TilesandFloor- Table2. Chemical composition of glaze (XRF) chemical attack. The surfaceof the sample- ing: shad a highresistance to attack of all chemi- Evolutionand Prospects. Castellón: Institute ofCeramicTechnology- of adsorbed water and confirms presence of calagents used. ITC, UniversitatJaumeI,2001.part. 2nd. components in the composition of raw glaze. The classification GLA-GHA isthat indicates- 2. LABRINCHA, J. A., LUCAS, D.B.Notes Because of using kaolin or clay as a suspend- greater resistance to chemical attackby fromDiscipline Glazes.Aveiro: University ofAveiro, 2001. ing agent of the glaze so around 800 ° C is ISO10545-136, which requiresnodetection- 3. OLIVEIRA, H.J.C.Technical Data. IFH-Ce- recorded again endothermic peak accompa- any degradation, visible on the sample sur- ramicStudio, Ltd., nied by loss mass resulting from the decom- faceafter interactionwithaggressive agents. 2009-2010. 4. SACMI. Applied CeramicTechnology. position of carbonates (dolomite Theabrasion resistancetest(PEI) according to Castellónde laPlana: Faenza micronized) also present in the formulation ISO10545-76wasnotdonein apolishedplate. EditriceIbérica,2004.Vol.One. of glaze. Thehardness testMOHSwas conductedin apo- 5. AGRAFIOTIS, C.; TSOUTOS, T.Energy Sav- 3.2.Application of granilha lishedplatealready (see both results Table5). ingTechnologiesin the EuropeanCeramicSector: ASystematicRe- Figure 11 illustratesthe appearance of thesus- view.AppliedThermal pension andmicrogranilhasinthe compound. Conclusions Engineering, vol. 21, p. 1231-1249, 2001. Theslurry densitywas optimizedfor applica- Withthis new development, there is need- http://dx.doi.org/10.1016/ S1359-4311 (01) 00006-0 applyinghigh amount of granilha to obtain tiononbell. The densityused was1520gL-1 and 6.EUROPEANNETWORKOFNATIONALCERAMI- the viscositywas adjusted to22/24seconds in- a good result by dry method (we need 1.0 CLABORATORIES. Ford cup4 mmin diameter. to 1.5kg.m2 in dry method) ,while now the Ceramic TilestheISOInternational Standards forCeramic Chinese Porcelain Optimizedthe amountof suspensionto be valuedrops toabout 0.46kg.m2, equivalent Tiles. IntEdCERLabs, 1993. Underglaze Blue appliedper square meter product, and has to areduction of 55to 70%.This decreasecan 7. EUROPEANCOMMITTEEFORStandardiza- and Copper Red achievedthe value of0.66 kgsuspension. make cost reductionswith these materials. tion. CeramicTiles -Definitions, Classification, Characteris- Decorated Meiping Whereas70% suspensioncomprisesbygranil- The resulting productrequiresless deeppol- ticsandMarking.European Vase,18th century has, it is estimated that the amount which re- ishing,becausethelayer ismore homogeneou- Standard,2006.

20 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 21 Vol. 03 No. 04 Winter 2014

ver the past half century ceramics interface atoms. important for such future applications. tions. improvement in both strength and fracture have received significant attention The surface/interface energies essentially Advanced bulk ceramic composite materials One such material system in this class of toughness, better retention of strength at Nano Oas candidate materials for use as control the properties of a solid. Interfaces that can withstand high temperatures (>1500 composites, Silicon Carbide/Silicon Nitride high temperatures, and better creep proper- structural materials under conditions of high provide a means to introduce non-homoge- °C) without degradation or oxidation can (SiC/Si3N4) composites, have been shown to ties were observed. composite loading rates, high temperature, wear, and neity in the material. This non-homogene- also be used for applications such as struc- perform very well under high temperature An advanced nanocomposite microstructure chemical attack that are too severe for metals. ity acts as a significant modification of both tural parts of motor engines, catalytic heat oxidizing conditions. Interest in such nano- such as that of polycrystalline Silicon Carbide Ceramics, However, inherent brittleness of the ceramics thermal and mechanical properties of the exchangers, nuclear power plants, and com- composites started with experiments of Nii- (SiC)-Silicon Nitride (Si3N4) nanocomposites, has prevented their wide use in different ap- composites. Selective mixing of materials in bustion systems, besides their use in fossil hara2 who reported large improvements in Figure 1, contains multiple length scales with plications. a highly tailored morphology with high per- energy conversion power plants. These hard, both the fracture toughness and the strength grain boundary (GB) thickness of the order of What are Significant scientific effort has been directed centage of interface area, leads to materials high-temperature stable, oxidation-resistant of materials by embedding nanometer range 50 nm, SiC particle sizes of the order of 200- towards making ceramics more flaw-tolerant with enhanced properties. ceramic composites and coatings are also in (20-300 nm) particles within a matrix of larger 300 nm and Si3N4 grain sizes of the order of Nano through design of their microstructures by in- The properties of nano-composite materials demand for aircraft and spacecraft applica- grains and at the grain boundaries. A 200% 0.8 to 1.5 µm1. Designing the microstructure corporation of fibers or whiskers which bridge depend not only on the properties of their in- the crack faces just behind the crack tip; by dividual parents but also on their morphology composite designing microstructures with elongated and interfacial characteristics. The nanocom- grains which act as bridges between crack posites find their use in various applications Ceramics? faces just behind the crack tip; by incorpo- because of the improvements in the proper- rating second phase particles which deflect ties over the simpler structures. Few of such the crack making it travel a more tortuous advantages can be summarized as: path; and by incorporating secondary phases • Improved Mechanical properties e.g. strength, which undergo stress induced volume expan- modulus and dimensional stability sion that forces the crack faces together. How- • Decreased permeability to gases, water and ever, one of the most recent development has hydrocarbons been the distribution of multiple phases in a • Higher Thermal stability and heat distortion ceramic composite at the nanoscopic length temperature scale. Owing to prevalence of nanoscopic • Higher Flame retardancy and reduced smoke features, such composites are referred to as emissions ceramic nanocomposites. • Higher Chemical resistance The definition of nanocomposite material • Smoother Surface appearance has broadened significantly to encompass a • Higher Electrical conductivity large variety of systems such as one-dimen- For components used in a gas turbine en- sional, two-dimensional, three-dimensional gine, a lifetime upto 10000 h and a retained and amorphous materials, made of distinctly strength of ~300 MPa at a temperature of dissimilar components and mixed at the na- 1400 °C have been postulated, together with nometer scale. The general class of nanocom- negligible creep rate. Furthermore, at elevat- posite organic/inorganic materials is a fast ed temperatures, the material must exhibit growing area of research. Reducing the sizes high resistance to thermal shock, oxidation, Professor Vikas Tomar, [email protected] of structural features in materials leads to a and subcritical crack growth. Ceramic nano- significant increase in the portion of surface/ composites have been shown to be extremely

22 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 23 Vol. 03 No. 04 Winter 2014

of such a composite (and similar others such ramic Nanocomposites for Extreme En- a collaborative multiscale modeling-material an uncharacteristic correlation between the as TiN-Si3N4, SiC-Al2O3, SiC-SiC, Graphene/ vironments Including Nuclear Applica- design-experimental processing approach. A grain boundary (GB) thickness and tempera- CNT+SiC, and Carbon Fiber+SiC nanocom- tions6-12: This research work focuses on snapshot of the overall collaborative research ture. posites) for a targeted set of material proper- understanding mechanisms of room tem- approach on modeling, design, and fabrica- The strength showed decrease with increase ties is, therefore, a daunting task. Since the mi- perature and high temperature operations tion highlights is provided below in temperature for structures having thick GBs crostructure involves multiple length scales, of advanced nanocomposite ceramic mate- • Multiscale Modeling of Ceramic Nano- having diffusion of C, N, or Si atoms. How- multiscale analyses based material design is rials that can enable power plant operation composites: An Example of Work in SiC-Si3N4 ever, for structures with no appreciable GB an appropriate approach for such a task. at temperatures in excess of 1750 K leading Ceramic Nanocomposites Our multiscale anal- thickness (no diffusion of C, N, or Si atoms),

The ceramic nanocomposite work in Multi- to efficiencies of almost 70% and significant yses (at nanometer and micrometer length due to the particle clustering and increase Figure 4. Schematic Petascale Material Design Framework physics Lab at Purdue focuses on (1) Under- reduction in the plant emissions. As an off- and time scales) based on a combination in SiC-Si3N4interfacial strength with temper- standing Performance of Carbide and Nitride shoot, this project also focuses on thermal of CFEM and MD based techniques have re- ature, the strength improved with increase Based High Temperature Ceramic Nanocom- properties of these materials for possible use vealed that high strength and relatively small in temperature. Figure 2 shows snapshots of posites for Extreme Environments found in as high temperature multifunctional materi- sized SiC particles act as stress concentration fracture propagation analyses in such nano- Figure 1. Actual microstructure of a SiC-Si3N4 nano- composite1 power generation cycles Including Nuclear als, high temperature structural materials in sites in Si3N4 matrix leading to inter-granular composites obtained using the CFEM. Applications, (2) Multiscale Modeling and nuclear applications or heat sensors in nucle- Si3N4 matrix cracking as a dominant failure Characterization in Oxide Ceramic Materials ar applications. mode. CFEM analyses have also revealed that Figure 3 displays snapshots obtained using and (3) Understanding thermal conduction • Multiscale Modeling and Characteriza- due to a significant number of nano-sized MD. Current research work focuses on ob- and thermal issues in materials for thermo- tion in Oxide Ceramic Materials13-18: SiC particles being present in micro-sized taining experimental images of the ceramic Figure 5. High and low fidelity models for the CFCC electric power generation. A description of Focus during this work has been on under- Si3N4matrix, the SiC particles invariantly fall nanocomposites developed by collaborators, nanocomposites major areas of interest and contributions is as standing multiscale thermomechanical be- in wake regions of micro-cracks leading to developing nanoscale CFEM meshes on such Figure 2. Snapshots of mesoscale crack propagation follows: havior of advanced composite materials such significant mechanical strength. This finding images, and performing failure analyses using and damage propagation in the Si3N4 nanocom- posites •Understanding thermal conduction and as multifunctional Al+Fe2O3 nanocrystalline was confirmed in the MD analyses that re- the combination of MD and CFEM techniques. thermal issues to develop materials with composites and high-strength Al2O3/TiB2 vealed that particle clustering along the GBs low thermal conductivity3-5: This work ceramic armor composites. This research on significantly increases the strength of these Petascale Computing Based Figure 6. (left) Strength and creep strain rate at 1500oC as a function of the design variable width- focuses on understanding atomistic mech- atomistic deformation analyses of Al+Fe2O3 nanocomposites. While some nanocomposite Material Design height (d) for the 2-D low fidelity model. (right) anisms of operation of nanocomposites for multifunctional nanocomposites using MD is morphologies have sharply defined SiC-Si3N4 Atomistic analyses at the nanoscale can im- Strength and creep strain rate at 1500°C as a func- tion of the design variables width-height (d) and thermoelectric power generation such that one of the first in the area of atomistic defor- interfaces19, other nanocomposite morphol- part important information about the effect length of fibers (l) for the 3-D high fidelity model. materials with low thermal conductivity mation analyses of advanced ceramic com- ogies have diffusion of C, N, or Si atoms at the of critical features such as a GB, an interface, could be developed. Explicit molecular sim- posite nanomaterials. In this work large scale interfaces20. or a triple junction, etc. on mechanical defor-

ulations using molecular dynamics (MD) are MD simulations of nanocrystalline Al+Fe2O3 In the case of SiC-Si3N4 nanocomposites, MD mation behavior of a small nanoscale (~ few performed to understand how morphology multifunctional composites, of single crystal- analyses have also revealed that the second nm) sample. In multiscale modeling such

alterations can be used to reduce thermal line Al, of single crystalline Fe2O3, and of var- phase particles act as significant stress raisers information is used to formulate macroscale conductivity in nanocomposites. We have ious interfacial configurations of single crys- in the case of single crystalline Si3N4 phase (>few µm) material models for understanding

found certain biomimetic arrangements that talline Al and Fe2O3 are performed. In the case matrix affecting the strength significantly. microstructure dependent deformation be- could achieve significant reduction in thermal of Al2O3/TiB2 ceramic armor composites, we However, the particle’s presence does not havior of a material sample such as the one conduction. We are in the process of making have developed and used a new cohesive fi- have a significant effect on the mechanical shown in Fig. 1. Figure 3. Snapshots of atomistic damage and fail- and testing such materials. nite element method (CFEM) for quantitative strength of bicrystalline or nanocrystalline Appropriate mathematical models of micro- ure propagation in two different SiC (particle) and Si3N4(matrix) nanocomposites at two different tem- • Understanding Performance of Carbide characterization of dynamic fracture. Si3N4 phase matrices. The strength of the structure property relations allow to relate Figure 7. Schematic of Phase Relations in the Si-O-C peratures. and Nitride Based High Temperature Ce- The above contribution is strongly based on SiC-Si3N4 nanocomposite structures showed performances like fracture toughness, ulti- System

24 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 25 Vol. 03 No. 04 Winter 2014

mate strength, fatigue lifetime etc., to key ma- SGI for CFEM and MPI for MD and the uncer- CFCC strength and a corresponding decrease Some of their unique properties are associ- terial microstructure parameters like volume tainty modeling. Both MD and the uncertain- in the creep strain rate as the design variable ated with in-situ formation of nanodomains fraction, particle size, and phase composition. ty quantification (via quasi-Monte Carlo inte- d increases. Similarly for the high fidelity mod- and lack of grain boundaries in their mi- Since a typical nanoscale test sample is much gration) can use 1000 processors, and CFEM el, Fig. 6 (right) shows an increase in the CFCC crostructures. Due to the polymeric nature smaller and is subjected to varied surround- 10, so 1000 uncertainty quantification groups strength and a corresponding decrease in the (thermoset) of the precursors, this family of ings in a typical microstructure (e.g. Fig. 1), of 10 CFEM groups of 1000 HMC processors is creep strain rate as the design variables d and materials is easily processable as fibers, ma- the incorporation of nanoscale information in 107 processors, nearing exascale. l increase. trices for composites, porous structures and macroscale models is subjected to statistical Preliminary material design analyses of the coatings30,31. Most studied PDCs can be uncertainty. model system have been performed to un- Fabrication categorized into three main groups: (i) silicon If a complex microstructure is to be designed derstand the morphology related param- Focus during this activity is on forming a carbide (SiC) (ii) silicon oxycarbides (SiOC) for a targeted set of properties, it is important eters that must be controlled for optimal collaborative modeling-deign-processing and (iii) silicon carbonitrides (SiCN). SiOCs that such uncertainties be correctly quanti- targeted set of properties. The application framework where complex ceramic nano- and SiCNs are distinctive due to their hybrid fied and incorporated within a robust mate- of design tool is focusing on the continuous composites for targeted set of mechanical molecular composition between SiO2and SiC rial design framework. We have pioneered fiber ceramic composite (CFCCs) models of and non-mechanical properties could be and between SiC and Si3N4, respectively with the development of a variable fidelity model SiC-Si3N4 nanocomposites, Fig. 5. The second produced without wasting significant tri- additional level of “free” carbon as schemati- management framework that can incorpo- phase (circles and cylinders) are the SiC fibers al-and-error time and money. We are collab- cally illustrated in Fig 7 for Si-O-C system. rate material behavior analyses at multiple that have higher elastic modulus and higher orating with Prof. Rajendra K Bordia’s group A unique nanostructural feature of these ma- length scales in a design optimization frame- creep resistance (E) but lower yield stress and at the University of Washington-Seattle. Poly- terials is that the controlled excess carbon is work21-24, (Collaboration with Prof. John fracture toughness, than that of the primary mer derived ceramics (PDCs) are an attractive dispersed as graphene layers with domain Renaud’s group at the University of Notre Si3N4 phase. The problem is to design the approach to make material design predicted size of a few nms. Control of, and understand- Dame). most suitable CFCC, with maximum strength morphology of ceramic nanocomposites. First ing of development of such nanostructural Figure 4 details the process flow of a petas- and creep resistance for a set of external tem- Niihara and his coworkers and then others features, using an integrated experimental cale multi-physics model management tool peratures T, where the number of design var- used this approach to make high performance and atomistic simulation approach, is the fo- for multiscale material design. Deployed on a iables will depend on whether the simulation nanoscale reinforced composites25-27. cus of our collaborative research. petascale machine, the design tool developed tests are run on the 2-dimensional (2-D) or Continued research in this area has led to the in this research, that integrates atomistic and 3-dimensional (3-D) model. The design var- development of a range of nanostructures. mesoscale analyses using a variable fidelity iables to be considered in the nanocompos- One particularly interesting class of materi- model management framework, will facilitate ite design optimization problem, for the 2-D als have predominantly amorphous Si-O-C a significant reduction in nanomaterials’ de- model, are the fibers diameter (d) and the ex- nanodomains containing nanoscale SiC and velopment cost and time with a simultaneous ternal temperature (T). And for the 3-D model C reinforcements. These materials have the increase in the possible different combina- the design variables to be considered are the desired characteristics for a broad range of tions of individual composite material phases fibers diameter (d), the length of fibers (l) and high-temperature applications while offering to achieve desired material performance. the external temperature (T). The problem greater control over processing, composi- The model management framework21,22, definition in standard form is given below: tions and nanostructure. PDCs are produced besides managing the models and scales, is Figure 6 illustrates normalized (0-100) func- by pyrolyzing preceramic polymers and are also well suited to control hierarchical par- tion values for the strength and creep strain typically amorphous up to very high temper- allelism. The natural hierarchy is MD within rate as a function of design variables for the ature but provide very intriguing ceramic-like CFEM within design under uncertainty, using high fidelity model (3-D) and low fidelity mod- properties, such as good creep and oxidation a mixed programming model SHMEMTM by el (2-D). Figure 6 (left) shows an increase in the resistance28,29.

26 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 27 Vol. 03 No. 04 Winter 2014

hat could be new about some- uct made of pyrolized red or white clay, it’s the vice president of Emil America. of Wales. As far as color, mid-tones, neutrals, siding. The color and texture say wood, but it Technology thing that has been around more grout, sealants, adhesives and manufacturing Chis Abatte, who has tracked the Italian tile beige and far more than 50 shades of gray resists the elements with ease. Wthan 4,000 years? When it comes and installation processes that are constantly industry for more than 20 years, said large-for- were being offered in all tile categories. Red So why choose a porcelain or ceramic tile over to tile, a lot. During coverings 2014, the larg- being evaluated in terms of the environment. mat tiles are growing in popularity along with and green remain popular accent colors, but real wood, stone or concrete? Because tile is all pushes est tile-and-stone trade expo in the country, The biggest style trend now is the look of playing with grout lines and texture. “The as Fasan explained: “Our product is designed about easy maintenance, high performance the buzz was about baking technology, sci- wood, with reclaimed wood being a favorite industry is not satisfied with making a great to make other elements look good.” and durability. Tile’s design possibilities have ence and great design into modern ceramic for wall and floor tiles. Like pre-washed jeans, flat tile. They have been twisting, bending and Interceramic introduced Moods, a concept attracted architect-designer Philippe Starck, trends in tile. it’s not enough to imitate natural materials warping tiles to create amazing architectural that uses specific palettes incorporating glass, who has teamed with Sant’Agostino, and “Technology has been one of the tile indus- such as cement, stone and wood. They must surfaces,” she said. ceramic and other tile combinations. singer/songwriter Lenny Kravitz, who is work- try’s inspirations,” said Ryan Fasan, tile-and- also have a time-worn patina. Porcelanosa has created textural tiles that Exterior tile on buildings is more popular in ing with Lea Ceramiche, to add their creative Ceramic tile stone consultant for Tiles of Spain. Florida Tiles showed Magnolia, a printed look and feel like fabric, waves or fallen leaves. Europe than the United States, but that could vision to wall tiles. “Tile is very personal. It is Innovations over the past several years have wood look that comes in a variety of colors. They are so skilled at imitation that Porcelano- be changing with products such as Coopera- forever with an almost infinite lifespan,” Fasan included super-thin, extremely light tile that Fioranese’s Old Wood series is nearly indistin- sa USA holds a Royal Warrant from the Prince tive of D’Imola Ceramica’s woodlike ceramic said. can be applied to cabinets or counters, very guishable from the real thing; even wood’s thick and anti-slip tile that can be used on un- texture is replicated. Aparici, which does great even outdoor surfaces and tile that can resist inkjet designs, showed several of its Sonar col- wide temperature fluctuations. Antibacterial lection of ceramic wood-flooring options to- tile is a smart option for bathrooms, hospitals, gether for an impressive display. Viva Made’s schools or any public place. Some tile even Street collection of ceramic planks was an cleans the air and itself. urban-inspired design. For a very dramatic ef- American-based Crossville teamed up with fect, Over by Cerdomus combines black and Japanese company Toto to create ceramic white wood-style tile planking. The Maderia tile that purifies the air and destroys stains. A Collection by Keraben was another example special coating that is baked onto the surface of tile imitating wood that would be perfect of the tile is activated by light. Crossville uses for mudrooms and kitchens. recycled content in its products. Del Conca and Cisa Ceramiche are just two Italian company Casagrande Padana is turn- companies that have re-created the look of ing out its own self-cleaning ceramic that petrified wood on tile. Del Conca, an Italian works like trees, removing nitrogen oxide pro- manufacturer, is building a plant in Tennes- duced by car exhaust from the atmosphere. see to produce porcelain stoneware tile. Del This is tile and technology at its best. Conca Fast is a high-tech tile installed without Digital inkjet printing revolutionized the man- joints, adhesives or grout. It’s basically a float- ufacturing of ceramic and porcelain tile. ing ceramic floor. “One of the great things about this process is Fiandre’s large-format, manmade Precious we can reproduce the look of stones that are Stone collection uses the best of inkjet print- extinct or which are not environmentally re- ing to create porcelain wall panels that are sponsible to harvest,” Fasan explained. as artistic as they are architectural. And Emil Tile makers in Spain, Italy, Mexico and beyond Ceramica introduced Stone Box. Each box has are embracing environmentally friendly prac- 36 tiles representing different stones such as tices and adopting the Tile Council of North marble, granite, onyx, etc., but the color pal- America’s Green Squared certification for por- ette is the same. William Rostoker; Elizabeth Gebhard celain tile as the industry’s watermark for sus- “We are seeing large tiles trending in both tainable practices. Since tile is a natural prod- matte and polished finishes,” said David Lang,

28 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 29 Vol. 03 No. 04 Winter 2014

The continuing evolution of quartz surfacing

ver the past decade, the use of cause of its inherent technical character- standing technical characteristics, ease of munity, grays and whites are popular, while be attributed to the strong marketing efforts quartz surfacing — especially istics — mainly durability — and ease of maintenance and, when it comes to design- beige and browns are popular with consum- of the leading quartz manufacturers. “With Ofor countertops — has been on maintenance,” said Michele Caneva of the ers, the possibility to have custom colors.” ers. “Quartz has definitely grown in popularity, consumers, we focus on advertising both on- the rise. For those seeking a durable and Italian-based company Santa Margherita. And while custom colors are appealing, Cane- but mainly on the coasts,” Amir went on to ex- line and in print, and we try to educate them consistent look, quartz surfacing products “The residential market has not signifi- va finds that several basics remain favorites. plain. “Middle America is still learning about about the benefits of quartz,” said Amir. “With offer an alternative to natural stone or other cantly changed, and the quartz surfacing is “Some colors simply never go out of fashion the product. In the last five years, quartz has architects and designers, Caesarstone takes a surfacing materials. And due to its evolving still promoted and sold mainly for kitchen — white and gray in different shades and become more readily available at point of direct approach. Our reps are out in the field popularity, quartz surfacing manufacturers countertop applications. We have seen an black,” he said. “We see a trend for beige in sales, and the consumer has learned of the meeting with the A&D community and build- are expanding their selections — providing increased interest coming from designers ‘cold’ hues and taupe colors.” great benefits of the product, including dura- ing strong partnerships with them.” solutions for both consumers and the de- working on commercial projects — main- Maggie Amir, Brand Manager for Caesarstone bility and color consistency.” Santa Margherita also takes a solid approach sign community. ly for flooring and bathroom area appli- of Van Nuys, CA, confirms the color trends. to marketing its products and educating its “Quartz surfacing continues to be very cations. Again, I think the interest toward “White is definitely a hot color when it comes Marketing approaches consumers. “All technical data, including in- Michel Kornmann and CTTB popular for countertop applications be- quartz surfacing is mainly due to its out- to quartz surfaces,” she said. “In the A&D com- The increased interest in quartz surfacing can struction for maintenance and certifications,

30 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 31 Vol. 03 No. 04 Winter 2014

are available on our Web site and in all our that, quartz surfacing shows a long life cycle. ufacturing of quartz surfacing uses materials Rupesh Shah, co-president of MS Internation- published literature,” explained Caneva. “For Today, many quartz surfaces can be manufac- that could otherwise be wasted and just go al (MSI), an Orange, CA-based stone and tile the A&D community, we have developed an tured using recycled raw materials, such as directly into landfills. The quartz engineered distributor with locations throughout the U.S., iPhone/iPad application, a CEU online course glass, mirrors, feldspar, granite and porcelain. stone manufacturing process results in a very agrees that a polished finish is still in high de- for AIA members (hosted by www.aecdaily. Santa Margherita has developed a special line durable material, which is highly resistant to mand. “Occasionally, we are asked for a honed com) and a ‘lunch & learn’ presentation valid called Second Life, manufactured with 89% damages from scratching and warping, thus finish, but I would say that 95% of the time for both AIA and ASID members.” certified recycled content.” you can truly rely on having this ‘green’ coun- consumers are looking for polished,” he said. Chris Carlson, Vice President of Sales and Mar- tertop last for a very long time.” “I think people like shiny quartz.” Environmental benefits keting at QuintessenzaTM Stoneworks, states Shah explained that MSI got into the quartz In addition to strong marketing campaigns, that his company’s line of quartz surfacing Surface finishes business about four to five years ago. “In the environmental benefits of quartz surfac- also is made with the environment in mind. While quartz products present a wide selec- the last 18 months, we are seeing a definite ing are alluring in this day and age of green “Quintessenza Stonework’s quartz materials tion of color options, various finishes are also [surge],” he said. “One reason is because pure building and sustainability. “Caesarstone sur- are environmentally friendly, and fit right into available. However, a polished surface re- white is in. That’s one large part of it. The sec- faces are non-porous and prevent the growth our commitment to provide safe products for mains popular in the U.S. market. ond thing that is driving its popularity is that of surface mold and bacteria due to the use of our customers and for the planet,” he said, “In Europe, honed, brushed and textured fin- the price points are becoming more compa- quartz as a key ingredient,” said Amir. “In ad- adding that the company’s factory in China, ishes have been popular for at least the past rable to natural stone. China is becoming a dition, our product is in compliance with ISO CXUN, has 14 active production lines, with five years,” explained Caneva. “The North huge player.” Additionally, Shah believes that 14001: 2004 to intensify environmental pro- two more being added. “All of our products American market has always preferred a pol- quartz products are much better marketed tection activities both in the manufacturing are continually tested beyond the industry ished finish — mainly because of its ease of than competing products such as marble and facilities and the outside world.” standards for bisphenol A (BPA), phthalates maintenance. We are seeing a slight change granite. Caneva agrees that quartz surfacing offers en- and lead content to ensure our stone is com- to the market with an increased interest in “I think many quartz manufacturers are keep- vironmental benefits. “Most quartz surfaces to pletely safe for direct food contact.” textured finish — especially when a design- ing on top of the technology and evolving,” be found on the U.S. market, and Santa Mar- When speaking more on the environmental er is involved. We offer a textured finish line said Shah. “Our customers are purchasing it. gherita is among them, are Greenguard certi- benefits of quartz, Carlson cites that it is ra- called Wave that recalls the look of slate, and This year, I think we will sell 20% quartz. It fied,” he explained. “This means that the level don and radiation free, and it has no harmful Concreto that is reminiscent of a polished will be interesting to see what happens once of VOC emission is very low. In addition to effects on indoor air quality. “[Also], the man- concrete look.” white isn’t popular anymore.”

32 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 33 Vol. 03 No. 04 Winter 2014

“They wanted to achieve a comfortable feel — a balance of wood and stone with the use A couple’s of warm colors.” Among the design objectives for the new res- idence was the importance that the building retreat materials required little maintenance. “Llano sandstone from the nearby Highland Lakes built with area, aluminum clad windows and a clay tile roof were chosen as the exterior building materials,” said Lott. “Wood plantation shut- native ters were installed for privacy along the golf course.” The home’s entire exterior facade is construct- stone ed with Llano sandstone. The golden and rust-colored hues of the stone give the resi- dence a warm and welcoming effect. More- over, the rough-cut solid look of the stone provides a sense of permanence and nicely complements the natural surroundings. Because the Llano sandstone has a lot of nat- ural color variation to it, mock-ups were done prior to installation for the owners and archi- Texas limestone and sandstone bring rustic charm to a private tect to approve. residence designed for homeowners who love to travel In addition to exterior walls, the local sand- and entertain stone forms a series of archways on the veran- da, where the homeowners and their guests can sit, relax and dine. “The veranda sand- stone arches are repeated in the dining room areful consideration to all of her cli- — creating an intimate dining experience,” ent’s requests had to be taken when explained Lott. “Flagstone-shaped Lueders Carchitect Katheryn Lott, AIA, RID, LEED limestone flooring flows from the interior out AP BD+C, set out to design a private residence to the veranda and down the stairs — elimi- on a small golf course in Austin, TX. Lott, who nating the boundaries between indoors and owns her own Austin-based firm, Katheryn outdoors.” Lott Architects, had to incorporate the home- The interior also features a fireplace wall owners’ love for entertaining, along with a built of Llano sandstone, which is paired with desire for rustic charm and low-maintenance wooden beams and the flagstone flooring. building materials, into the design of their The combination of materials — along with new home. the open floor plan — creates an inviting at- The answer was to build the structure with re- mosphere with country elegance that is ideal gional sandstone and limestone. for entertaining. “[My client was] an executive from an interna- “The client’s reaction was fabulous after the tional firm and his wife who dreamed of living house was completed,” said Lott, adding that on a small golf course lot in Austin,” the archi- construction time took between 14 to 16 tect explained. months.

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e all know that digital tech- from across a room, and a look that can ones that evoke a long ago time and place. Digital nology has transformed change in the course of a day, depending Grespania, a Spanish tile manufacturer, makes Wphotography and the music on how sunlight hits it. a red-clay-colored Palace Alicante tile that is a technology business. The sizes of these distinctly differ- dead ringer for Rojo Alicante, a very common It has also transformed the ceramic tile ent-looking tiles have also changed; tile Spanish marble that will look familiar to many industry, creating new and intriguing manufacturers can now produce tiles Americans. If you want to wow your visitors as creating possibilities for home interiors. that are very large and very thin — 3-by- they step over the threshold into your foyer, Digital technology’s most obvious im- 10-feet in area and 3 millimeters (about this would be a good flooring choice. new pact has been the change in the appear- 1/8-inch) thick. Knoxville-based Crossville’s brand-new Vir- ance of the tiles. Adapting inkjet printing What does all this mean for homeown- tue looks like white marble, but not a specif- techniques, ceramic tile manufacturers ers? You can make dramatic changes to ic stone, because it’s a combination of three possibilities can now make tiles that so closely re- your entire interior with a material that classics — Carrara, Calacatta and Statuario. semble natural materials like marble you probably thought best suited to With subtle veining and a soft satin finish that for and wood, even the tile professionals bathrooms and kitchens. imbues it with a calming ambience, Virtue can’t tell the difference. “Once the tile Whether you’re going for a more deco- would be perfect flooring for a sitting area ceramic is installed, unless I touch it and I’m six rative, turn-of-the-last-century look, a where you want to unwind after a long day. inches away, I can be fooled,” said Van- spare, midcentury modern look or a more Marble is not the only stone that tile mak- couver-based tile designer Ryan Fasan, in eclectic contemporary “I’ll create my own ers are mimicking. Lamosa, a Mexican firm, tiles a recent interview. aesthetic” look, there’s a tile out there for makes Piedra Terraza. It looks like real river Another plus with the new technology: It every household and every room. stones — stones with a rounded surface after is almost impossible to discern a repeat- The choices number in the thousands; eons of contact with running water in rivers ed pattern because the tile makers now these are a few of the standouts that I or streams. Moreover, each individual stone create “pattern areas” that are 30-by-30- saw in April at Coverings, the annual in- on each tile is raised, a detail that becomes feet square. In the old days, you could ternational trade show in Atlanta for the obvious when you walk on it barefoot. easily spot identical tiles within about ceramics and stone industry. Reflecting The porcelain ceramic wood look-alikes are two or three feet of where you were the fact that nearly 70 percent of the ce- made to resemble individual floor planks or standing. Not anymore, Fasan pointed ramic tiles used in the United States are parquet flooring with multiple wood pieces out. imported, four of these five standouts are on each tile. Of even greater interest to tile designers, produced by foreign companies. Lamosa’s Firenze collection includes Ameri- the new technology allows them to de- The most dramatic possibilities for a new can standards like Cherry and tropical hard- sign tiles with unusual three-dimension- look with tile are the look-alikes. If you’ve woods like Ipe and Zebra wood. al qualities, Fasan said. always hankered for marble but resisted Aparici’s Sonar displays a distressed or worn, In the past, a raised pattern could not it for practical reasons — real marble is a weathered look that does not resemble real project more than 1/16th of an inch from soft stone that cracks and scratches easi- flooring; it’s actually more interesting. The the tile surface. The effect was subtle ly — here’s your chance. wood “wannabes” can be used in any room and only visible at close range. Today, You can install ceramic porcelain tiles but are especially well suited to wet areas

Joseph W. Shaw, a tile pattern can project as much as a that look exactly like the real deal, com- such as kitchens and bathrooms or outside as John C. Overbeck, half-inch, creating effects that are visible bine the look of several real stones, or a pool deck.

36 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 37 Vol. 03 No. 04 Winter 2014

یكــی از مشــكالت موجــود در صنعت كاشــیهای دیــواری و كف 4- تنظیم دقیق پروپیلــن اســت. فریــت بهعــالوه رنگدانــه پایــه اصلــی كــه تنــوع در تنالیتــه و شــید رنگــی اســت. معمــوالً ایــن مشــكل بــر 5- در ســیلندرهای فــوق نــرم جدیــد امــکان چــاپ جتــی در حــدود 50 تــا 70 درصــد تركیــب خمیــر چــاپ را تشــكیل بـررســـی اثــر وجــود تنــوع در تركیبــات رنگــی لعــاب بهوجــود منیآیــد، در برجســتگی هــا وجــود دارد و در نتیجــه مشــکالت قبلــی میدهنــد، ســاییده شــده تــا بــه دانهبنــدی مناســب بلكــه اغلــب بــر اثــر فرآیندهــای بعــدی تولیــد، مثــل عملیــات نظیــر چــاپ نخــوردن کاشــی هــا در گوشــه هــا و یــا ســایر بــرای روتوكالــر برســند. همچنیــن میبایســت فریــت و دكوراســیون اســت. قســمتهای طــرح رفــع شــده اســت و ایــن ســیلندرها هــم رنگدانــه بــه طــور مناســبی در روغــن چــاپ پخــش شــود. تکنولوژی امــروزه در صنعــت تولیــد كاشــی، اســتفاده از روش دكوراســیون چنیــن قابلیــت اجــرای طــرح را در کاشــی هــای اســراکچر میــزان پخــش شــدن، روش اســتفاده بــرای مخلــوط كــردن رولــری، بــه ویــژه روتوكالــر كــه متعلــق بــه رشكــت »سیســتم و یــا برجســته را دارنــد کــه در نتیجــه مشــکالت پیشــین و ســایش متفــاوت میباشــد. بــرای كنــرل میــزان پخــش )System( «اســت بســیار رایــج شــده اســت. در ایــن روش تاحــدودی رفــع شــده اســت. شــدن میتــوان از روش آنالیــز عكــس اســتفاده منــود. روتـوکالر چــاپ، خمیــر چــاپ کــه محتــوی رنگدانــه رسامیکــی اســت بــه در این بخش موارد زیر مورد بررسی قرار میگیرد: در روش چــاپ تخــت، روغــن چــاپ برپایــه پلــی اتیلــن وســیله غلتکــی کــه طــرح مــورد نظــر بــر روی آن و بــا اســتفاده • رشایط اجزای خمیر چاپ گلیكــول بــا وزن مولكولــی كــم اســت كــه مزیــت آن از سیســتم لیــزر حکاکــی شــده اســت بر ســطح کاشــی نشــانده • روغن چاپ و رشایط آن پالســتی ســایزر و روانســاز بــودن آن اســت و اشــكال آن میشــود. بســته بــه عمــق و نــوع حکاکــی غلتــک یــا ســیلندر، • فرآیند دكوراسیون و متغیرهای آن قــدرت اتصــال كــم آن اســت کــه بــا اضافــه كــردن باینــدر به شــدت رنــگ ایجــاد شــده بــر روی کاشــی میتوانــد متفــاوت • مشخصات بدنه دكور شده و تغییرات آن تصحیــح مشــكل ذكــر شــده میپردازنــد. فیكســاتیو مــورد باشــد. بســته بــه تعــدد رنگهــای مــورد اســتفاده در یــک طرح • تغییرات تجهیزات دكور )ماشین و رولر( اســتفاده برپایــه پلی وینیلاســتات و یــا پلی وینیلالــكل تعــداد ســیلندرها نیــز متغیــر اســت. تنــوع در رنــگ عــالوه بــر مشــكالتی كــه در هنــگام اســتفاده از سیســتم روتوكالــر اســت كــه اشــكال آن چســبندگی براســاس رسعــت خشــك رشایــط و فرآینــد تولیــد میتوانــد ناشــی از تركیــب لعــاب و ممكــن اســت ایجــاد شــود عبارتنــد از: شــدن آن اســت. در عملیــات دكوراســیون، رفتــار خمیــر خمیــر چــاپ باشــد كــه میبایســت از نظــر تنــوع رنگــی مــد • شید رنگی چــاپ براســاس رفتــار رئولــوژی آن تعریــف میگــردد كــه به نظــر قــرار گیــرد. بنابرایــن بررســی تأثیــر مــواد بــر روی خمیــر • چاپ بد در اطراف كاشی صــورت ایــدهآل عبــارت اســت از اینکــه، ویســكوزیته بــاال چــاپ، مشــخصات رئولوژیــك روغــن چــاپ و همچنیــن • چاپ بد در لبه های كاشی بــه هنــگام ســكون داشــته كــه از جداشــدن آن جلوگیــری مشــخصات بدنــه و لعــاب هامننــد روش چــاپ میتوانــد در • تفاوت در شدت رنگ كاشی میكنــد و بــه هنــگام جنبــش و حركــت ویســكوزیته كــم مــورد شــید رنگــی مؤثــر باشــد. • قسمتهایی كه بد چاپ خورده باشد بــوده كــه موجــب بهــر شــدن خاصیــت عبــور میشــود. در • سخت بودن كار با رنگهای تیره روش دكوراســیون روتوكالــر انتخــاب روغــن چــاپ بســتگی ارتفاع سیلندر و مشخصات تیغه بــه نــوع تولیــد اعــم از تكپخــت یــا دوپخــت بــودن یكــی از فاكتورهــای مهــم بــر شــید رنگــی بــا كاهــش فاصلــه و خمیر چاپ در سیستم چاپ روتاری محصــول دارد. در نتیجــه افزایش فشــار شــاهد افزایــش dE هســتیم. هرچقدر سیســتم روتوكالــر براســاس اعــامل رنــگ در قســمتهای مشــخصه هــای مــورد نیــاز بــرای خمیر چــاپ عبارت اســت فشــار بیشــر باشــد )ارتفــاع كمت باشــد( بــه دلیل تخلیه بیشــر مشــخص بــه وســیله سیســتم چرخشــی – رولــری و بــا از: خمیــر توســط حفرههــای ســیلندر شــاهد تیرهتــر شــدن كاشــی اســتفاده از تیغــه و ســیلندر جهــت دكــور كاشــی و انتقــال • قدرت تعلیق خواهیــم بــود. فشــار بیشــر موجــب كاهــش كیفیــت ســطح طــرح بــه كاشــی عمــل میمنایــد. طــرح براســاس نحــوه • قدرت تركنندگی میگــردد. هــم چنیــن بــا افزایــش فشــار، شــاهد کاهــش عمــر توزیــع شــكافها )حفرههــای حكاكــی شــده روی ســیلندر( • رئولوژی ســیلندر و ایجــاد اثــر کاشــی بــر روی ســیلندر در درازمــدت در ســطح غلتــك اســت. براثــر هــم پوشــانی و بــهكار بــردن • پایداری در تولید خواهیــم بــود. در صورتــی کــه ناگزیــر بــه کاهــش ارتفــاع چاپهــای پــی در پــی در نهایــت شــاهد ایجــاد طــرح مــورد • كشش سطحی كم برای قدرتتركنندگی باال ســیلندر باشــیم، معمــوالً افزایــش فشــار بــه دالیــل زیــر صــورت نظــر خواهیــم بــود. • قدرت باالی تصحیح میگیــرد: خمیــر چــاپ مــورد اســتفاده در سیســتم روتوكالــر از دو نكات و متغیرهایی كه میبایست مد نظر قرار گیرد: 1- شــدت رنــگ مــورد نیــاز بیشــر )مخصوصــاً ایــن مــورد بــا بخــش اصلــی تشــكیل شــده اســت: پارامتهایــی كــه قبــل از روتوكالــر میبایســت كنــرل اســتفاده از ســیلندرهای نــرم امــکان پذیــر اســت. 1- بخــش پایــه و یــا Base كــه شــامل فــاز جامــد یعنــی شــوند عبارتنــد از: مشــخصات بدنــه، پــرس، دمــای كاشــی، 2- نزدیــك بــودن طــرح بــه لبههــای ســیلندر )مخصوصــاً در فریــت )پــودر چــاپ(، اكســیدهای رنگــی و مــواد رســی اســپری آب اعاملــی، انگــوب و لعــاب و خــط لعــابكاری. ســیلندرهای نــرم بــه کمــک ایــن کار میتــوان مشــکالت را رفــع اســت. پارامتهایــی كــه در حیــن اســتفاده از روتوكالــر تأثیرگــذار گردآوری: امیر حسین موسوی منــود. 2- بخــش مایــع یعنــی روغــن چــاپ یــا Medium كــه هســتند عبارتنــد از: خمیــر، پــودر چــاپ و مشــخصات 3- تفاوت كم در چاپ نقاط كوچك شــامل تركیبــی از اتیلــن، دی و پلی اتیلن گلیكولهــا و مكانیكــی روتوكالــر

38 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 39 Vol. 03 No. 04 Winter 2014

پیشـکسوتان علم و صنعت رسامیک ایران

دکرت فتح الله مضطرزاده عباسعلی قصاعی او چهارمین نسل از خانواده خود است که یک کسب و کار صنعتی خانوادگی را مدیریت می کند، کسب و کاری که وی اســتاد متــام دانشــگاه صنعتــی امیرکبیــر اســت کــه تاکنــون کتــاب هــا و مقــاالت بســیاری در 130 سال پیش در کارگاه کوچکی در نطنز آغاز شد. قصاعی مدیرعامل رشکت چینی زرین ایران است که تحصیالت زمینــه تخصصــی خــود بــه چــاپ رســانده اســت و آثــار او از پــر اســتنادترین آثــار اســاتید کشــور بــه مرتبط با کار خود را- مهندسی رسامیک- در دانشگاه نورنربگ آملان در سال 1973 میالدی به پایان رسانده است. وی از شــ رام می آیــد. او در ســابقه خــود عــاوه بــر ثبــت چندیــن دســتاورد بین املللــی، پــرورش دانشــجویان شناخته شده ترین صنعتگران ایرانی است که از فناوری های نوین رسامیک در تولیدات خود بهره می گیرد و با خط بســیاری را بــر عهــده داشــته اســت کــه آنهــا نیــز هــم اکنــون بــه جمــع اســاتید دانشــگاه هــای کشــور تولید مدرن خود صادرات پیوسته به 20 کشور دنیا از جمله آملان، اسپانیا، ایتالیا، فرانسه، انگلستان، سوئد و کانادا دارد. و متخصصــان صنعــت پیوســته انــد.

دکرت فرهاد گلستانی فرد وی اســتاد متــام دانشــگاه علــم و صنعــت ایــران اســت کــه دکــرتی مهندســی مــواد و متالــورژی خــود را در ســال 1356 از دانشــگاه برنــل انگلســتان دریافــت کــرده اســت. دکرت عباس یوسفی او کــه در زمینــه رسامیــک از چهــره هــای رسشــناس دنیاســت، ســابقه ثبــت بیــن املللــی چندیــن دکرت عبـاس یوسـفی هم اکنون مدیرعامل مرکــز تحقیـقاتی پـر طــاووس وابـستـــه بــه شــرکت لعــاب ایـــران در دســتاورد در حــوزه رسامیــک را دارد و در زمینــه مــواد نســوز، رسامیــک و شناســایی و آنالیــز مــواد مشهـــد است. دکرت یوسـفی، مدرک دکرتی رشته مواد شیشه و رسامیک خود را از دانشگاه لوئی پاستور اسرتاسبورگ پژوهشــهای بســیاری انجــام داده اســت. دکــرت گلســتانی فــرد کــه در کنگــره نهــم رسامیــک کــه طــی دریافت کرده است و تدریس دروس شیشه و رسامیک را در دانشگاه های علم و صنعت و فردوسی مشهد در دو روز گذشــته برگــزار شــد بــه عنــوان ســخرنان کلیــدی حضــور داشــت، دروس روش هــای آنالیــز و گردآوری: نوشین پریانی کارنامه خود دارد. وی از سال 1360 فعالیت های تحقیقاتی اش را در صنایع رسامیک و چینی ایران آغاز کرده و از شــناخت مــواد رسامیکــی، آزمایشــگاه روش هــای شــناخت و بررســی مــواد رسامیکــی، مــواد دیرگــداز، آن سال تاکنون چهره شناخته شده ای در عرصه ارتباط بین فناوران و صنعتگران است. روش هــای پیرشفتــه شــناخت و آنالیــز مــواد و رسامیــک هــای غیراســیدی را تدریــس میکنــد.

40 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 41 Vol. 03 No. 04 Winter 2014

تکنولــوژی پرینــت دیجیتالــی در صنعــت رسامیــک کــه هماکنــون جهانــی شــده اســت، اگــر موجــب انقــاب در صنعــت کاشــی نشــده باشــد حداقــل بــه میــزان بســیار زیــادی موجــب بهبــود دکوراســیون شــد و راههــای دکوراســیون را تغییــر داد و تکنولــوژی Inkjetباعــث بــاال بــردن کارایــی پروژههــای رسامیکــی شــد. بــه گفتــه آقــای Penna رییــس تولیــد رشکــت Imola،کــه هفــت ماشــین دیجیتالــی را راهانــدازی منــوده اســت، اهمیــت نــوآوری دکوراســیون دیجیتالــی در صنعــت کاشــی بــه انــدازه تغییــر کورههــای تونلــی بــه کورههــای رولــری اســت. بــه گفتــه وی فرآینــد چــاپ دیجیتالــی مشــکلت موجــود از تنــوع در رنــگ گرفتــه تــا محصــوالت نامنطبــق در صنعــت چــاپ را رفــع میکنــد و قطعــات یدکــی انبــار را کاهــش میدهــد. ایــن تکنولــوژی همچنیــن قــادر اســت کــه ارزش افــزوده کاشــیها را نیــز افزایــش دهــد. همچنیــن بــا ایــن روش زمــان دکوراسیـون تولیــد طرحهــا و قــرار گرفــن ان در خــط تولیــد نیــز کــم میشــود. دیجیتالی بر روی کاشـی

طراحی گرافیکی دیجیتال فرآینــد تولیــد هامهنگــی ایجــاد منــود کــه ایــن کار نیازمنــد Antonio De Carlo از رشکــت Ferro گفــت: در ایــن وجــود نرمافزارهــای کامپیوتــری مناســب اســت. بخــش ســعی و تــاش زیــادی بــرای اجــرای تصاویــر گرافیکــی بــر روی کاشــی انجــام شــده اســت و بــرای ایــن کار بایــد یکپارچگی بین تکنولوژیهای موجود تصاویــر تهیــه شــده توســط دوربیــن دیجیتالــی با اســتفاده از امــروزه میتــوان گفــت در جهــان بــه یــک نــوع یکپارچگــی نــرم افــزار بــه طــرح گرافیکــی تبدیــل شــود و ســپس عملیات فکــری درخصــوص تکنولوژیهــای موجــود در زمینــه پرینــت انجــام شــود و بایــد در نظــر داشــت کــه طراحــی دکوراســیون رسامیــک بــا اســتفاده از تکنولــوژی Inkjet گرافیکــی دیجیتالــی هامننــد فتوکپــی نیســت و انجــام آن رســیدهاند و همــگان بــاور دارنــد کــه میبایســت ایــن خیلــی ســاده نیســت. Paolo Zannini رییــس انجمــن تکنولــوژی تقویــت شــود.Paolo Monari از رشکت سیســتم رسامیــک ایتالیــا اضافــه کــرد که بــرای رســیدن به دکوراســیون اعــام منــود بــه عنــوان مثــال امــروزه مشــکلی کــه در ایــن دیجیتالــی بایــد روشهــا را تغییــر داد. تخصیــص مجــدد تکنولــوژی وجــود دارد ایــن اســت کــه بــرای اعــامل مــواد اصــل طــرح بــه وســیله رشکتهــای رسامیکــی بهطــور دکوراســیون بــا ضخامــت زیــاد بــا مشــکل مواجــه آشــکار وابســته بــه تولیدکننــدگان لعــاب و رنگ و موسســات هســتیم و هماکنــون اعــامل لعــاب بــه صــورت طراحــی گرافیکــی اســت De Carlo گفــت مــا همــواره بایــد دیجیتالــی هنــوز غیــر قابــل تصــور اســت. بــه دنبــال پیرشفــت باشــیم و ایــن درســت شــبیه پیرشفــت اســتفاده از ایــن روش بــرای دکوراســیون از تایــپ دســتی بــه تایــپ کامپیوتــری اســت و مــا بایــد هــم در زمینــه فاصلــه بیــن رنگهــا هنــوز در زمینــه رنــگ و ماشــینآالت پیرشفــت کنیــم کــه البتــه بــا مشــکل مواجــه اســت و در خیلــی مــوارد هنــوز بــه طــور کامــل شــناخته نشــده اســت نتیجــه کیفیــت محصــوالت و بایــد از پتانســیلهای تکنولــوژی Inkjet اســتفاده منــود تولیــد شــده در این روش Paolo Zannini ادامــه داد کــه تکنولوژیهــای جدیــد کیفیـــت منـاســـبی نیــاز بــه نرمافزارهــای دیجیتــال مدیریــت رنــگ دارد و در در مقـایســـه بــا گردآوری: زینب حسنی تکنولــوژی Inkjet بــرای رســیدن بــه نتایــج رضایتبخــش روشهـــای میبایســت چگونــه میبایســت بیــن پارامرتهــای متغیــر را یــــج

42 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 43 Vol. 03 No. 04 Winter 2014

فعلــی وجــود نــدارد و بــا اســتفاده از روش حکاکــی ســیلندر نیــز بــرای رســیدن بــه محدودههــای رنگــی کافــی اســت. کیفیــت مناســبتری در مقایســه بــا تکنولــوژی دیجیتــال MarcoFerrari افــزود نســخه جدیــد نرمافــزار فتوشــاپ موجــود میتــوان حاصــل منــود Marco Ferrari از رشکــت خصوصیــات مربــوط بــه رنگهــا را در خــود جــای داده Colorobbia اضافــه منــود بایــد در نظــر داشــت کــه اســت و برنامههــای دیگــر جهــت اســتفاده پیچیــده هســتند میبایســت در ادامــه روشهــای فعلــی ســعی در بهبــود آن و بــه تازگــی نســخههای برنامههــای مربــوط بــه صنعــت بــا اســتفاده از روشهــای جدیــد داشــت. رسامیــک ارائــه شــده اســت. امــروزه تولیدکننــدگان رنــگ بهطــور ویــژه بــه روی اســتفاده از ســه رنــگ ]اصلــی[ پتانسیلهای زیبایی شناختی بهعــالوه رنــگ مشــکی مترکــز کردهانــد. بــرای فایــق آمــدن Zannini افــزود مزیــت اســتفاده از روشهــای جدیــد ایــن بــر مشــکل عــدم حضــور رنــگ واقعــی Magneta، ســختی اســت کــه لبههــای کاشــی ســطح مــورد نظــر و هــم چنیــن کار در ایجــاد رنــگ زرد مناســب، قهــوهای و ســبز مربــوط نقــوش برجســته موجــود در ســطح نیــز میتوانــد بــا اســتفاده ترکیبــات ایجادکننــده رنــگ ســیاه اســت کــه تحقیقــات بــرای از ایــن روش دکــور شــود. در حالیکــه بــه عنــوان مثــال در ایجــاد ترکیبــات ارگانومتالیــک )Organometallic( جدیــد و روش دکوراســیون روتوکالــر کــه از ســیلندرهای حکاکــی بــرای همچنیــن محدودههــای وســیعی از رنگ دانههــای بســیار اعــامل رنــگ اســتفاده میکنــد ایــن امــکان وجــود نــدارد ریــز )SuperFine( در حــال انجــام اســت. امــروزه تقریبــاً AlbertoGhisellini از رشکــت Kerajet افــزود بــا اســتفاده متــام تولیدکننــدگان پایــدار بــوده و شــدت رنــگ خــود را طــی از روش دکوراســیون Inkjet میتــوان بــه افکتهــای مشــابه فرآینــد تولیــد از دســت منیدهنــد. پــرس دوبــل و یــا کاشــیهای رگهرگــه دســت یافــت. ایــن روش میتوانــد بــر روی بدنــه پــرس شــده بــه صــورت هزینهها مســتقیم بــکار رود و یــا اینکــه در کاشــیهای دوپخــت از در مــورد هزینههــای تولیــدی در دکوراســیون بــه روش ایــن تکنولــوژی اســتفاده منــود. دیجیتــال اشــاره شــد کــه هنــوز بــرای ارایــه هزینــه هــر واحــد از کاال زود اســت. Ghisellini اشــاره کــرد کــه هزینه ســفارش، جوهر و رنگ ماشــینآالت دیجیتــال بــاال اســت و ایــن قیمــت بــاال بهدلیــل Warren Green از رشکــت Jettable گفــت بــا وجــود اینکــه تجهیــزات الکتونیــک مربــوط بــه دســتگاه اســت. در ســالهای اخیــر تــالش زیــادی بــرای ســاخت رنــگ مناســب Claudio Ricci از رشکــت ســاکمی اشــاره کــرد کــه بــرای انجــام شــده اســت، ولیکــن هنــوز نیــاز بــه تــالش بیشــر در ارزیابــی هزینههــا میبایســت متــام مراحــل را از هزینههــای زمینــه رنــگ وجــود دارد. تولیــد متامی رنگهــا بــا اســتفاده مربــوط بــه پرســنل طــراح گرفیــک تــا اپراتورهــای ماشــینآالت از ســه، چهــار و یــا شــش رنــگ اصلــی هنــوز بــه صــورت را محاســبه منــود زیــرا ماشــینآالت فعلــی پیچیدهتــر عمــل کامــل قابــل دستســی نیســت و اســتفاده از روشهــای مــورد میمناینــد. اســتفاده در صنایــع دیگــر در صنعــت رسامیــک بــه صــورت Chisellini افــزود البتــه ایــن نکتــه را نبایــد فرامــوش کنیــم کامــالً مشــابه در صنعــت رسامیــک قابــل اجــرا نیســت زیــرا کــه در تکنولــوژی Inkjet تنــوع رنگــی ایجــاد شــده و شــید در صنعــت تکنولــوژی دیجیتــال عوامــل دیگــر فرآینــد تولیــد کمــر اســت و همچنیــن میــزان مــ فرص و مــواد مرصفشــده نظیــر پخــت، واکنــش بــا یکدیگــر از جملــه واکنــش بیــن و کالیرباســیونهای مکانیکــی کــه در روشهــای فعلــی رنــگ، لعــاب و بدنــه نیــز تاثیرگذارنــد. وجــود دارد در اینجــا حــذف میگــردد و همچنیــن فضــای Alessandro Giudice از رشکــت Colorstore عنــوان اشــغال شــده در ایــن روش کمــر اســت. Norbert von منــودار آزمایشــات انجــام شــده بــا اســتفاده از چهــار رنــگ Aufschnaiter از رشکــت Durst گفــت: بــرای تولیــدات در رسامیکــی میتــوان 80 تــا90 درصــد تولیــدات را از نظــر محــدوده وســیع روشهــای رایــج بــه نســبت دکوراســیون رنگبنــدی تولیــد منــود و در برخــی مــوارد حتــی ســه رنــگ دیجیتــال هزینــه بیشــری ایجــاد میکنــد.

44 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 45 Vol. 03 No. 04 Winter 2014

کورههــای مــداوم رولــری جدیدتریــن و اقتصادیتریــن کــوره، جهــت پخــت رسیــع محصوالت رسامیکــی هســتند. مطالعات و تجربیــات حــارض نشــان میدهــد کــه هزینــه تولیــد محصوالت کـوره هـای رسامیکــی) کاشــی، ظــروف، چینــی، بهداشــتی( در ایــن کورههــا کمــر از کورههــای دیگــر اســت. البتــه ایــن بــدان معنــا نیســت کــه ســایر کورههــای متنــاوب و یــا مــداوم مــورد اســتفاده قــرار رولــــــری منیگیرنــد، البتــه هــم اکنــون بــرای پخــت ســایر قطعــات کــه دارای محتویــات مــواد فــرار بــاال، یــا شــکل پیچیــده و بــزرگ و یــا دمــای پخــت باالیــی باشــند، کورههــای غیــر رولــری )Roller Kiln( مناســب هســتند. از آنجــا کــه کورههــای رولــری دارای ابعــاد مشــخص و همچنیــن زمــان پخــت کمی هســتند، امــکان پخت قطعــات بــزرگ )از نظــر ارتفــاع( و همچنیــن پخــت قطعاتــی بــا فرمول هــای متنــوع )بدنــه و لعــاب( درآنهــا وجــود نــدارد. ایــن کــوره هــا در دو نــوع تــک پخــت و دو پخــت بــکار مــی رونــد. نــوع تکپخــت اغلــب بــرای تولیــد کاشــی کــف و نــوع دو پخــت آن بــرای کاشــی دیــواری و چینــی مظــروف و چینــی بهداشــتی مــورد اســتفاده قــرار میگیرنــد. ســاختامن کورههــای رولــری بصــورت یــک تونــل )محفظــه( طویــل بــوده کــه بصــورت پیــش ســاخته بر اســاس نیاز مشــری بــا اســتفاده از نســوزهای ســبک بــه ابعــاد )1000×1000 تــا 75×75( میلیمــر و ارتفــاع 700 میلیمــر )بــرای کــوره هــای دو طبقــه( ســاخته میشــوند. کورههــای رولــری یــک طبقــه بــر اســاس نیــاز موجــود و پیرشفــت فنــاوری، بــه کورههــای رولــری دو طبقــه تبدیل شــده کــه در بعضــی جهــات در مقایســه بــا کورههــای یــک طبقــه دارای مــزا عبارتنــد از : الــف- کاهــش مــرف انــرژی ، بخاطــر کاهــش اتــاف حرارتــی ســاختامن کوره. ب- کاهــش مســاحت تاسیســات بــه نصــف، بــا ظرفیــت تولید مشــابه، وجــود سیســتمهایی کــه اجــازه کنــرتل و کار مجــزای هــر دو کانــال کــوره را هامننــد دو کــوره مجــزا میدهنــد. ایــن کورههــا بــا واحدهــای پیــش ســاخته دیرگــداز و عایــق، بــا منطقههایــی مشــابه کــوره یــک کانالــه تقســیم بنــدی شــدهاند. دارا بــودن دو کانــال اجــازه تولیــد دو نــوع محصــول مختلــف بــا ســیکلهای مختلــف پخــت در یــک زمــان مشــابه را فراهــم مــیآورد. عــالوه بــر داشــن کنــرل کامــالً مجــزا، تفاوتهــای گردآوری: امیر حسین موسوی عملکــرد دو کانــال نیــز میتوانــد بیشــر از 150 درجــه ســانتیگراد باشــد. در ایــن حــال کــوره رولــری تــک کانالــه

46 Ceramic & Tile Industries Magazine Ceramic & Tile Industries Magazine 47 Vol. 03 No. 04 Winter 2014

مطمنئتریــن کــوره بــرای پخــت رسیــع محصــوالت اســت. ایــن کورههــا بــه سیســتم کنــرل خــودکاری بــرای تنظیــم درجــه د – نیاز به حجم و فضای کم در ایــن کورههــا قطعــات توســط دوران رولرهای نســوز ، از یک ،حــرارت تنظیــم رسعــت ، دوران رولرهــا، میــزان هــوای احــراق، ذ - حذف استفاده و مرصف ساگار ســمت وارده کــوره شــده و در طــول مســیر از مراحــل مختلــف تنظیــم فشــار و ... مجهــز شــده اند. مزایــای ومعایــب کوره های ر – کاهش احتامل ورود ناخالصی های حاصل از ساختامن کوره کــوره میگذرنــد. باالتریــن درجــه حــرارت در وســط کــوره رولــری نســبت بــه کــوره هــای دیگــر در ذیــل ذکر شــده اســت. ز- سبک بودن تجهیزات کوره بــوده و عمــل پخــت نهایــی در آن منطقــه انجــام میشــود. ژ- افزایش رسعت و حجم تولید درســت در خــالف جهــت حرکــت رولرهــا )قطعــات( هــوای مزایای و معایب کوره های رولری س- تشخیص و برطرف کردن رسیع عیوب فرموالیسون محصول خنــک دمیــده میشــود و ســبب رسد شــدن قطعــات پــس از الف- رصفه جویی در مرصف سوخت و کاهش هزینه پخت بــه عــالوه مکانیــزم دســتگاه هــا بــه گونــه ای اســت کــه احتامل ،پخــت در رشایــط کنــرل شــده میشــود. بنابرایــن قطعــات ب – کاهش اتالف حرارتی در نتیجه عایق بندی مناسب ایجــاد خطــر و تنــش بــرای رولــر بســیار کــم اســت و در رشایــط خروجــی، بــا دمــای محیــط تفــاوت اندکــی دارنــد کــه مانــع از پ – یکنواختــی پخــت در طــول کــوره ، بــه دلیــل اســتفاده از ســنگین )ســخت( کاری عملکــرد خوبــی را از خــود نشــان ایجــاد شــوک در قطعــات میشــود. ایــن کورههــا معمــوالً بــا مشــعل هــای ویــژه بــا اختــالط مناســب هــوا و گاز داده انــد. بــا ایــن وجــود کــوره هــای رولیــری دارای معیــاب و اغلــب ســوختها ، نظیــرگاز طبیعــی، گاز شــهری و ســوخت ت – دارا بــودن حداکــر بــازده پــس گازهــای احــراق ، بــع علت محدودیــت هایــی نیــز بــه رشح زیــر هســتند: مایــع ســبک )نفــت ســفید( کار میکننــد. کــوره هــای ))رولــری داشــن ظرفیت حرارتــی مختلف الکتیکــی (( نیــز از انــواع کورههــای رولــری هســتند امــا بــه ث – مقــدار ثابــت فشــار نســبت بــه زمــان در رشایــط مختلــف محدودیت ها و معایب کورههای رولری دلیــل بــاال بــودن هزینــه بــرق و مشــکالت تهیــه املنتهــای بارگــذاری )مقادیــر مختلــف مــواد پخت شــونده( الف- توقف ناگهانی کوره در صورت عدم چرخش رولرها در حین کار حرارتــی کــه قــادر بــه تحمــل تغییــرات مــداوم درجــه حــرارت ج – سهولت کنتل و تنظیم سیستم در طول کوره ب - وابســتگی کار کــوره و رشایــط پخــت بــه انــواع رولــری بیــش از 1200 درجــه ســانتیگراد نیســتند، فقــط بــرای پخــت چ – پایین بودن هزینه تعمیر و نگهداری مــورد اســتفاده تزیینی)دکــور( اســتفاده میشــوند. ح - استفاده از گرمای اتالفی جهت پیش گرم کردن هوای ثانویه پ – چسبیدن احتاملی قطعات به رولرها بــه علــت اهمیــت زیــاد کورههــای رولــری و مراحــل پخــت آن خ – عدم نیاز به پی ریزی و فوندانسیون قوی ت – هزینه بر بودن تعویض رولرها

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