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Introduction of Glassy Spheres in an Acrylic Matrix: A New Solution for Low-Pressure Sanitaryware Moulds

A. Fortuna, D. M. Fortuna, E. Martini, V. Tagliaferri, G. Rubino

Journal of Ceramic Science and Technology, Vol. 6, No. 3 (2015), pp. 249-254

DOI: 10.4416/JCST2015-00019

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Abstract

In this work we have conducted a study to improve the mechanical strength and abrasive wear of the moulds used for traditional casting in the sanitaryware industry. We replaced the beta gypsum commonly employed in low-pressure moulds with a mix of alpha plaster and acrylic resin (Poolkemie Ecoresin). This product greatly improves the mechanical properties of the mould, but does not enable adequate thickness formation owing to the low porosity of the compound. For this reason we introduced increasing amounts of Poraver glassy spheres (10 %, 20 %, 30 %, 40 %) with the goal of ensuring the same thickness formation as in the case of the beta plaster, but with higher values for flexural strength and abrasion resistance. We conducted a series of abrasion tests and obtained good values with all samples containing spheres. In the mechanical flexural test, the best result was obtained by the resin formulation, but we also obtained very good results for 10-% and 20-% samples. On the other hand, in the casting test the best thickness is obtained with the formulation using 20 % spheres. This mix is therefore the best compared to the beta plaster and can definitely be applied in low-pressure casting.

Keywords

Keywords: Sanitaryware casting, thickness formation, beta plaster moulds, acrylic resin and glassy spheres, flexural strength and abrasion resistance.

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