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Chemistry plus physics. Maintain your recipes, test results, firing schedules, pictures, materials, projects, etc. Access your data from any connected device. Import desktop Insight data (and of other products). Group accounts for industry and education. Private accounts for potters. Get started.

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  • Hello Mr. Hansen. Your digitalfire.com site is AMAZING! I use it considerably. Thank you so much for all the information you offer! I tell all my students and friends in clay to come here to learn.
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  • I work at a small, but rapidly growing custom slip-cast studio. The first few years were a learning curve gauntlet that, in retrospect, I am surprised we exited intact. This preface is to give a sense of how in debt I am to your research and hard work. I have had to learn as I go along, and the information you provide at digitalfire.com has been indispensable, and, quite frankly, an excellent cover for my ignorance on countless occasions! It is also the only source of information about many ceramics topics that I feel I can trust, knowing that it has been backed up with careful consideration and testing. Thank you again.
  • If, like Japan, Canada had a custom of selecting certain artisans as “national treasures“ you would certainly qualify - not only for your expertise as a ceramic chemist, but for your compassion for us less expert potters!

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Blog

Petalite for Lithium Carbonate:

It takes eight times as much!

Here are the three common lithia source materials in a side-by-side calculation to compare their potencies. I have adjusted the material weights so that all are delivering the same amount of Li2O (assuming a recipe calling for 5% lithium carbonate).

By weight it takes 42 parts of petalite to deliver the same amount of Li2O as 5 parts lithium carbonate! But notice how much SiO2 and Al2O3 come along, major surgery on the host recipe is needed to compensate for this (if even possible). Spodumene is complicated too, it brings along so much Al2O3. That’s a problem because the most frequent existing Al2O3 supplier, clay, may have to be greatly reduced or even eliminated (producing a recipe that does not suspend in water). The other baggage both materials bring is lots of SiO2, especially petalite. Thus, replacing lithium carbonate with petalite or spodumene is not really a material substitution—it is a glaze reformulation.

Context: Why Petalite and Spodumene.., GLC

Wednesday 2nd September 2026

Pure Nepheline Syenite as a crackle glaze:

Its chemistry explains exactly why crackle glazes crack

Crackle glazes are often thought of simply as recipes that somehow produce a crack pattern. However, crackle is a glaze/body fit phenomenon, not simply an intrinsic visual property of the glaze. They have very high levels of Na2O and/or K2O (collectively, KNaO). These two have the highest co-efficients of thermal expansion, by far, of oxides commonly found in pottery glazes. Feldspars, and particularly nepheline syenite, can supply them in abundance.

Shown here is the 77E10A recipe, originally from Luke Lindoe. It is simply Nepheline Syenite and water (shown on three types of clay bodies). Think of it as an on-ramp to understanding more about this type of glaze. 77E10A1 and 77E10A2 are improvements on this, both provide a path to develop and adapt it for your needs.

Context: Mechanism, Crackle glaze

Tuesday 1st September 2026

Redart has a published chemical analysis:

But it doesn’t indicate what you might think

This slurry is 100% traditional Redart. This deep red color is a product of the high percentage of iron oxide in its chemical analysis. But that chemistry provides a good example of why using the classical ceramic rational-analysis method to derive a theoretical mineralogy can be misleading for an illitic clay (which this is).

The traditional calculation assumes that K2O and Na2O belong to feldspars, then assigns the remaining Al2O3 to kaolinite and the remaining SiO2 to free quartz. However, Redart is known to be an illitic sedimentary clay. And illite itself contains substantial K2O. That 4.1% K2O is a strong chemical confirmation of Redart containing a lot of illite/mica-type clay. The 1.6% MgO is another clue that some of the chemistry belongs to smectite minerals rather than discrete feldspar and MgO phases.

Context: Redart, Redart 2 1 test..

Monday 31st August 2026

Brushing glazes on large bowls:

Pour-feed the brush in one long stroke

Brushing glazes on large 10R stoneware

On the left I applied pure Ravenscrag slip, as a glaze, inside and out, using only a small brush. I did the same to the bowl on the right, using the G1947U transparent glaze. Both of H550 clay. We almost always use these as dipping glazes. But here I mix them as brushing glazes, adding 10g CMC gum powder to one liter of a water-reduced version of the slurries. Blender mixing makes it possible to mix in the powdered gum and tune water content for the best brushing experience. The gum slows down the drying speed dramatically so there is plenty of time to brush it into place (while the wheel is turning). The gum also greatly increases the cohesion, enabling pouring out of a pitcher in a long thin stream. In this firing I also glazed a leather hard 40-inch tall vase and a 35 lb bone-dry bowl using the same technique. The evenness of coverage was the best I have ever gotten (of any technique) on large sizes and shapes.

It might surprise you that handmade tile is often glazed using brushing. A glaze can be squirted onto a tile and spread with a large brush in seconds. This can be done on a passing conveyor or in batches on a table.

Context: Add CMC gum to.., Glaze large bowls inside-and-out.., DIY brushing glazes by-the-jar.., Youtube Video Brush Glazing.., Brushing Glaze

Sunday 30th August 2026

Bubbles in a fritted cone 6 glaze:

What are the options?

This is a cone 6 transparent fritted glaze (converted from a Gerstley Borate one). Its B2O3 content is high, sourced by Ferro Frit 3134. Bubbles in transparent glazes often plague potters; many just keep trying new glazes until one works, or give up on never finding one. Why not try to fix this problem?

Is thickness the issue? A bubble has farther to travel through a thick glaze, and the volume of bubble-generating material is greater. A glaze that clears beautifully at 0.3–0.4 mm can become a bubble bath at 0.8–1.0 mm. Often when potters find a glaze that works, they have just found one that goes on thinner and more evenly.
Is it the frit? This frit begins softening and participating in glass formation as early as 1350°F, while decomposition gases may still be arriving from clays, carbonates, the body, organics, etc. In an industrial fast-fire kiln, they need late-melters, not bubble-trappers like this. They employ fast-fire frits that melt later. That being said, potters do have flexible firing, so this could still be made to work by slowing down the firing leading up to 1350. It also could be held at top temp, then either slow-cooled or a drop-and-hold.
Is it the recipe? Notice the big bubbles; they started as little ones that merged. Given enough time, big ones break at the surface, but only under the right conditions: Low enough melt viscosity and surface tension. Strangely, some old recipes sourcing high boron from Gerstley Borate had surprisingly few problems with bubbles! Why? While GB has substantial LOI itself, it appears that it can be its own fining agent with the right viscosity-versus-temperature curve. Its boron enters the melt later, and the melt develops unevenly, and may create localized channels and variable viscosity zones for easier bubble escape. The larger bubbles may better move laterally by combinations of lower surface tension, layer thickness and temperature gradients, and downward movement that creates shear.
Is it the melt surface tension?

Let's assume this glaze melt has high surface tension. It pulls liquid inward around each bubble, stabilizing them round and making rupture more difficult. But if surface tension drops, even slightly, bubbles deform more easily and adjacent ones merge. What could help? Industrial technicians have found that surprisingly small recipe changes can really help with bubble release.

  • Sourcing the CaO from wollastonite can help bubbles coalescence and reduce melt surface tension.
  • Zinc oxide often changes surface behavior more than expected. As little as 2% can alter the viscosity curve, surface tension and melt interface properties (possibly weakening bubble walls and improving near-surface rupture). Zinc is also a key to later-melting glazes.
  • Although MgO stiffens the melt somewhat, it can also change bubble wall elasticity; it is worth testing to determine if small additions can help bubbles merge better.

Context: Gerstley Borate vs Frit.., Four boron frits with.., Glaze Bubbles

Saturday 29th August 2026

A high-expansion glaze can actually bow a plate

The calculated thermal expansion of this glaze is 8.8, very high because of its high KNaO and low SiO2. These plates are unglazed on the underside. The upper one has a well-fitting glaze and its base remains flat. On the lower one, the high-expansion glaze on the inside contracts much more on cooling and, because it is bonded to the body, ends up in tension. The resulting stress is enough to pull the plate out of shape, bowing the base upward. This issue is common with ceramic tile, where an otherwise flat tile bows as the two layers contract differently on cooling.

A glaze this far into tension will also be highly prone to crazing. And its combination of high alkali and low silica raises another red flag: chemical durability. The solution is to reformulate, reduce KNaO in favour of lower-expansion fluxes (among which MgO is most effective), and increase SiO2 as much as the desired melting behaviour and surface will permit.

Context: Thermal Expansion in Ceramic.., Calculated Thermal Expansion

Wednesday 26th August 2026

Custer Feldspar update

The chemistry for Custer Feldspar has been updated in the materials at Digitalfire and Insight-live. Until now, the Pacer-published values have been used, but at Ron Roy's request, this has been changed (see the link to his article below). The average of assays done from 2000 to 2012 has been used for the chemistry. The material name has been changed to "Custer Feldspar (post-2000)". However, Insight-live will still find it in recipes when needing its chemistry, since "Custer Feldspar" has been included as an alternate name. The old material's name has been changed to "Custer Feldspar (pre-2000)".

In this image, you can see the material chemistries on the right and each of them being used in a one-material recipe on the left. To verify they are calculating correctly, the calculation of each has been set to formula plus analysis.

If you have defined your own material for this (typically done to set a cost), everything should still work correctly (using your chemistry if you provided it).

Context: Ron Roy article about..

Tuesday 25th August 2026

Rutile in functional glazes:

Push the limit and you might get this

Rutile saturated glazes

The 80:20 GA6-A Alberta Slip base becomes oatmeal-like when oversaturated with rutile and/or titanium (left: 6% rutile + 3% titanium dioxide; right: 4% rutile + 2% titanium dioxide). The rough surface results from excessive crystallization of titanium-bearing phases from the melt during cooling. It is unpleasant to touch, readily shows cutlery marking and is less desirable for functional surfaces. In glazes of this type, rutile additions above about 4% can become increasingly difficult to keep smooth and consistent. Crystallization, rather than phase separation, increasingly dominates the variegation mechanism.

One way of avoiding problems is staying below the tipping point, keeping the percentage as low as possible while still getting the desired variegation (of course, that will vary depending on the melt fluidity of the glaze and kiln cooling). Surprisingly, making the glaze more fluid does not necessarily solve the problem. Greater melt fluidity increases ion mobility and can actually promote crystal growth during cooling, producing an even rougher surface.

Context: Ceramic Rutile, GA6-F, High-rutile titanium glazes Great.., Leaching, Crystallization, Food Safe, Rutile Blue Glazes

Tuesday 25th August 2026

This talc artware body looked white...

Until I put it beside a cone 04 porcelain!

Porcelain clear glaze at cone 04

On the right is L213, a body made using Texas talc and Kentucky ball clay. On the left is L3778H, a translucent cone 6 porcelain made using Grolleg kaolin, Nepheline syenite and silica. These test tiles were in the same cone 04 firing. Since both of these bodies have similar porosities and fired strengths at cone 04, does that mean one could use the porcelain? It appears the answer is yes. Why is that again? Because low-temperature artware clay doesn’t need vitrification; all the bodies are porous.

What could make this work? This crystal clear glaze, G1916QL1, fits the L213 but crazes after a few days on the porcelain. Increasing the firing temperature to cone 03 extends that time to 3 weeks. Cone 02 would likely extend it further. Adjustments to the glaze recipe (e.g. 400 mesh silica and increasing its percentage) would lower the thermal expansion and improve fit even more. This whole scenario is doable for DIY potters who mix their own bodies and glazes, especially for casting. The materials to make the porcelain are kaolin, silica and feldspar, even inexpensive kaolins would produce a body almost as white as this one at low fire.

Context: Artware

Monday 24th August 2026

Why is spodumene so expensive?

Industrial spodumene is found in massive quantities across major mining regions like Australia, Africa, and North America. Yet if this 1.5kg rock was pure spodumene, it could be ground and sold for $45 (prices at ceramic suppliers in UK, US and Australia are about $31-35/kg in June 2026). The actual mining commodity price is US$2,100/tonne, pricing this rock at $3. That means finely ground ceramic spodumene is currently selling for 10+ times the mine/concentrate price. The battery industry is responsible; it has effectively repriced a ceramic feldspathic mineral as "lithium ore"!

What about lithium carbonate? Albemarle reported an average industrial price of US$19.53/kg in Q2 2026. So potters currently pay only up to 8 times that! Yet, the processing is formidable: The ore must be crushed and beneficiated, then subjected to a high-temperature calcination that converts alpha spodumene to the more reactive beta form, followed by acid roasting, leaching, neutralization, impurity removal and further conversion.

Fortunately, our kilns don’t care where the Li2O comes from: both spodumene and lithium carbonate have advantages, so understanding how to substitute between them is becoming increasingly important. As evidence that lithium is still important, one potter just purchased a 50 pound bag of spodumene for $1200 so she wouldn’t have to worry about it for the rest of her career!

Context: Why is tin oxide.., Why Petalite and Spodumene.., How to make Spodumene..

Monday 24th August 2026



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