A ceramic glass that has been premixed from raw powdered minerals and then melted, cooled by quenching in water, and ground into a fine powder (search youtube for interesting videos). Huge quantities and varieties of frits are manufactured for the ceramic industry every year (especially for tile) by dozens of different companies.
Frits work much better in glaze chemistry
The same glaze with MgO sourced from a frit (left) and from talc (right). The glaze is 1215U. Notice how much more the fritted one melts, even though they have the same chemistry. Frits are predictable when using glaze chemistry, it is more absolute and less relative. Mineral sources of oxides impose their own melting patterns and when one is substituted for another to supply an oxide in a glaze a different system with its own relative chemistry is entered. But when changing form one frit to another to supply an oxide or set of oxides, the melting properties stay within the same system and are predictable.
Frits melt so much better than raw materials
Feldspar and talc are both flux sources (glaze melters). But the fluxes (Na2O and MgO) within these materials need the right mix of other oxides with which to interact to vitrify or melt a mix. The feldspar does source other oxides for the Na2O to interact with, but lacks other fluxes and the proportions are not right, it is only beginning to soften at cone 6. The soda frit is already very active at cone 06! As high as cone 6, talc (the best source of MgO) shows no signs of melting activity at all. But a high MgO frit is melting beautifully at cone 06. While the frits are melting primarily because of the boron content, the Na2O and MgO have become active participants in the melting of a low temperature glass. In addition, the oxides exist in a glass matrix that is much easier to melt than the crystal matrix of the raw materials.
Can you actually throw a Gerstley Borate glaze? Yes!
Worthington Clear is a popular low fire transparent glaze recipe. It has 55% Gerstley Borate plus 30% kaolin (Gerstley Borate melts at a very low temperature because it sources lots of boron). GB is also very plastic, like a clay. I have thrown a pot from this recipe! This explains why high Gerstley Borate glazes often dry so slowly and shrink and crack during drying. When recipes also contain a plastic clay the shirinkage is even worse. GB is also slightly soluble, over time it gels glaze slurries. Countless potters struggle with Gerstley Borate recipes. How could we fix this one? First, substitute all or part of the raw kaolin for calcined kaolin (using 10% less because it has zero LOI). Second: It is possible to calculate a recipe having the same chemistry but sourcing the magic melting oxide, boron, from a frit instead.
At 1550F Gerstley Borate suddenly shrinks!
These balls were fired at 1550F and were the same size to start. The Gerstley Borate has suddenly shrunk dramatically in the last 40 degrees (and will melt down flat within the next 50). The talc is still refractory, the Ferro Frit 3124 slowly softens across a wide temperature range. The frit and Gerstley Borate are always fluxes, the talc is a flux under certain circumstances.
Frits do not dissolve in water, right? Wrong.
This is an example of two types of crystals that have formed on the surface of a fritted glaze after a long period of storage (Ferro Frit 3249 in this case). Frits are formulated to give chemistries that natural materials cannot supply. To do that they have to push the boundaries of stability (solubility). Any frit that has an inordinately high amount (compared to natural sources) of a specific oxide (in this case MgO) or lacks Al2O3 (like Frit 3134) are suspect.
Glaze chemistry works best when changing material amounts, not material types
Two glazes, same chemistry, different materials. The glaze on the left is sourcing CaO from wollastonite, the one on the right from calcium carbonate. Thus the oxide chemistry of the two is the same but the recipe of materials sourcing that chemistry is different. The difference in the melt flow you see here is an expression of how choosing different mineral sources to source an oxide can produce melting patterns that go outside what the chemistry suggests. The difference here is not extreme, but it can be much more. Glaze chemistry is relative, not absolute. It works best when you are changing material amounts, not material types. When you do introduce a very different mineral then you have a different system which has its own relative chemistry.
G2931F Ulexite-based transparent bubbles, G2931K frit-based version does not
I melted these two 9 gram balls on tiles to compare their melting (the chemistry of these is identical, the recipes are different). The Ulexite in the G2931F (left) drives the LOI to more than 14%. That means the while the ulexite is decomposing during melting it is creating gases that are creating bubbles in the glass. Notice the size of the F is greater (because it is full of bubbles). While this seems like a serious problem, in practice the F fires crystal-clear on most ware.
Do you know the purpose of these common Ferro frits?
I used a binder to form 10 gram balls and fired them at cone 08 (1700F). Frits melt really well, they do not gas and they have chemistries we cannot get from raw materials (similar ones to these are sold by other manufacturers). These contain boron (B2O3), it is magic, a low expansion super-melter. Frit 3124 (glossy) and 3195 (silky matte) are balanced-chemistry bases (just add 10-15% kaolin for a cone 04 glaze, or more silica+kaolin to go higher). Consider Frit 3110 a man-made low-Al2O3 super feldspar. Its high-sodium makes it high thermal expansion. It works in bodies and is great to incorporate into glazes that shiver. The high-MgO Frit 3249 has a very-low expansion, it is great for crazing glazes. Frit 3134 is similar to 3124 but without Al2O3. Use it where the glaze does not need more Al2O3 (e.g. it already has enough clay). It is no accident that these are used by potters in North America, they complement each other well. The Gerstley Borate is a natural source of boron (with issues frits do not have).
Frits melt so much more evenly and trouble free
These two specimens are the same terra cotta clay fired at the same temperature (cone 03) in the same kiln. The chemistry of the glazes is similar but the materials that supply that chemistry are different. The one on the left mixes 30% frit with five other materials, the one on the right mixes 90%+ frit with one other material. Ulexite is the main source of boron (the melter) in #1, it decomposes during firing expelling 30% of its weight as gases (mostly CO2). These create the bubbles. Each of its six materials has its own melting characteristics. While they interact during melting they do not mix to create a homogeneous glass, it contains phases (discontinuities) that mar the fired surface. In the fritted glaze all the particles soften and melt in unison and produce no gas. Notice that it has also interacted with the body, fluxing and darkening it and forming a better interface. And it has passed (and healed) most of the bubbles from the body.
Glaze melt fluidity comparison between G2931F and fritted G2931K show the effect of LOI
These two glazes have the same chemistry but different recipes. The F gets its boron from Ulexite, and Ulexite has a high LOI (it generates gases during firing, notice that these gases have affected the downward flow during melting). The frit-based version on the right flows cleanly and contains almost no bubbles. At high and medium temperatures potters seldom have bubble issues with glazes. This is not because they do not occur, it is because the appearance of typical glaze types are not affected by bubbles (and infact are often enhanced by them). But at low temperatures potters usually want to achieve good clarity in transparents and brilliance in a colors, so they find themselves in the same territory as the ceramic industry. An important way to do this is by using more frits (and the right firing schedules).
Glazes of the same chemistry: The fritted one melts better
It seems logical (and convenient) to just say that the kiln does not care what materials source the oxides in a glaze melt. Li2O, CaO, Al2O3, SiO2 are oxides (there are about ten common ones). The kiln just melts everything and constructs the glaze from the ones available. Right? Wrong! Things get more complicated when frits are introduced. Frits are man-made glasses, they melt much more readily than raw materials like feldspar. Raw materials are often crystalline. Crystals put up a fuss when asked to melt, often holding on as long as they can and then suddenly melting. Frits soften over a range and they start melting early. To illustrate: These two glazes have the same chemistry. But the one on the left sources sodium and alumina (Na2O3, Al2O3) from the 48% feldspar present. The other sources these from a frit (only 30% is needed for the same amount of Na2O3). The remainder of the recipe has been juggled to match the other oxides. The frit version is crystallizing on cooling (further testament to how fluid the melt is). What has happened here is great. Why? First, the chemistry has not changed (fewer firing differences). The frit has no Al2O3, it is being sourced from kaolin instead, now the slurry does not settle like a rock. Even better, silica can be added until the melt flow matches (might be up to 20%). That will drop the thermal expansion and reduce crazing. The added SiO2 will add resistance leaching and add durability. Frits are great! But you need to know how to incorporate them into a recipe using a little glaze chemistry.
A settling, running glaze recipe gets a makeover
The original cone 6 recipe, WCB, fires to a beautiful brilliant deep blue green (shown in column 2 of this Insight-live screen-shot). But it is crazing and settling badly in the bucket. The crazing is because of high KNaO (potassium and sodium from the high feldspar). The settling is because there is almost no clay. Adjustment 1 (column 3) eliminates the feldspar and sources Al2O3 from kaolin and KNaO from Frit 3110. The chemistry of the new chemistry is very close. To make that happen the amounts of other materials had to be juggled (you can click on any material to see what oxides it contributes). But the fired test reveals that this one, although very similar, is melting more (because the frit releases its oxide more readily than feldspar). Adjustment 2 (column 4) proposes a 10-part silica addition (to supply more SiO2). SiO2 is the glass former, the more a glaze will accept, the better. Silica is refractory so the glaze will run less. It will also fire more durable and be more resistant to leaching.
Out Bound Links
In Bound Links