A high-nepheline, zero-silica cone 8 silky matte glaze is cutlery marking and crazing. Why?
I will show you how found a recipe on Facebook, assessed it, substituted my own materials, tested it, adjusted it. Now it is like a cone 10 dolomite matte.
How I found a recipe on Facebook, substituted a frit for the Gerstley Borate and added the extra silica it needed to fight crazing. I got a fabulous cone 6 clear.
Using Insight-live I will demonstrate the surprising amount of silica some cone 6 base glazes that appear OK will accept and still melt well.
How to spot out-of-balance indicators in the chemistry of glazes that suggest susceptibility to scratching or cutlery marking.
Raw lithium carbonate can be replaced with a lithium-containing frit if you can do the chemistry. And you can at insight-live.com.
Use Insight-Live.com to do major surgery on a feldspar saturated cone 10R glaze recipe with multiple issues: blistering, pinholing, crazing, settling, dusting and possibly leaching!
The test bars will measure fired porosity and shrinkage over a range of temperatures, drying shrinkage, LOI and pugged water content. They follow procedures defined in Insight-live.com.
How to reference a picture from an external website like flickr.com from within a recipe in Insight-live
A short annotated video of how to create an account at insight-live.com
A short annotated video of how to sign-in to a personal account at insight-live.com
How to import the Digitalfire Insight recipe database file (INSIGHTDATA.DB) and the pictures that attach to recipes therein
Using help, your account, renewal and preferences pages, the managers and panels, recipes, materials, entering a recipe, chemistry, downloading desktop Insight.
How to find them, duplicate them and develop them within your account at insight-live.com
If your recipe is on the clipboard, this shows you how to import it into Insight-live and make adjustments after.
Learn how to add a recipe, title it, add lines and change them, set lines to added status, enter notes and pictures and print a mix ticket
An example of how to enter test results from your ceramic testing into recipes in your account at insight-live.com.
How to take a picture using an iPhone, crop and resample it, save it, then upload it to a recipe.
How to import data from desktop Insight, GlazeMaster, Matrix, GlazChem, HyperGlaze, Generic Spreadsheet CSV into your account at insight-live.com.
How to add and override material data and how to do chemistry calculations in your account at insight-live.com.
How to organize your recipes into a worksheet of recipe rows and material columns, save it as a CSV file and import into Insight-Live.com
A video tour of all the major features of the Digitalfire Insight-Live.com online recipe, material, test and picture manager.
A tour around the home page. Where to start.
I will show you some secrets of making a base engobe (or slip) apply to leather hard terracotta ware in a thick, perfectly even layer.
I will show you how to glaze a mug with a liner glaze inside and a colored one outside so that they meet in a perfect line at the rim.
To do a drop-and-hold firing you must manually program your kiln controller. It is the secret to surfaces without pinholes and blisters.
I will show you why people love/hate this material and how I substituted it for Ulexite to make a much easier-to-use glaze that fires just as good or better.
Making 10 gram balls of your glaze and firing them on 2in by 2in tiles is a great way to evaluate their flow, surface and susceptibility to defects.
I will show you why thixotropy is so important. Glazes that you have never been able to suspend or apply evenly will work beautifully.
D. Desktop Insight
Part two of a complete tour. It includes using targets, setting calculation types, entering recipe notes and details, SQLite and a review the menus.
Part one of a complete tour. The anatomy of the recipe window, how to open, edit and save recipes; the materials, oxides and supply oxide dialogs, the MDT.
Learn to how to download a recipe library from your account at Insight-live and open and explore it using desktop Insight
While comparing a real-world and theoretical feldspar learn to enter, edit, save, normalize recipes and the materials dialog. Glaze chemistry concepts.
Learn to compare a target formula with the chemistry of a feldspar. See why it does not make a good glaze by itself and what materials need to be added to make it into a balanced glaze.
Learn to do difficult formula to batch conversions. Learn mole%, finding frits by chemistry, Na2O sourcing, oxide oversupply, recipe line added status, overriding in the Supply dialog, when to compromise an exact match.
Learn to add a native volcanic ash to the INSIGHT materials database (MDT) and then create a glaze from it maximizing its percentage. Learn to impose an LOI on a material and why this method is better than line blending.
Learn to use a non-unity calculation to convert a formula into a batch recipe using theoretical and real-world materials. Retotal, round-off and make a side-by-side report.
Learn to convert a glossy glaze into a matte by comparing its chemistry with a target matte formula. Alter the chemistry in such a way that the thermal expansion does not rise and it maintains good physical application and suspension properties.
Learn what crazing is, how it is related to glaze chemistry, how INSIGHT calculates thermal expansion and how to substitute high expansion oxides (e.g. Na2O, K2O) with lower expansion ones (e.g. MgO, Li2O, B2O3).
Shows four different ways to add materials to the desktop Insight materials database (MDT)
Do this completely outside of Insight, it knows how to read it at each startup.
There are five ways to do it. Generate your MDT at digitalfire.com, copy and paste XML, type in the formula, enter an analysis as a recipe, handle the MDT as a CSV file in Excel.
Wollastonite is 50:50 CaO:SiO2. So why not just substitute 40 wollastonite for 20 calcium carbonate and 20 silica?
Learn to substitute Nepheline Syenite for Soda Feldspar (and vice versa) using the KNaO checkbox to. You will see the benefit of in-recipe substitution calculation rather than making substitution rules.
Learn the chemistry differences between cone 10 and 6 glazes and how to make a glaze melt at a lower temperature without introducing other problems like crazing.
Learn to reformulate a glaze that is settling in the bucket. Al2O3 and KNaO are sourced by the feldspar, we will source them from kaolin and frits instead.
How to use desktop Insight to substitute wollastonite for calcium carbonate (and vice versa) while maintaining the same SiO2 level. Create substitution rules.
Use Desktop Insight to explore ways of calculating substitutes for Gerstley Borate in the popular Floating Blue cone 6 glaze recipe while maintaining or improving the other raw and fired properties of the glaze.
How to fine-tune the thixotropy of a ceramic engobe for pottery
Tony Hansen takes you through all the steps from opening the box and wedging the clay to taking the fired mug from the kiln.
*Youtube Video, +MP4 Video, #ScreenCast, ^URL
Lesson 1C - Substituting Wollastonite for Whiting in Glazes
Compare calcium carbonate (whiting) with other sources of CaO (dolomite, wollastonite, frit), learn to understand the chemistry differences between materials and then substitute wollastonite for whiting in a specific recipe.
D. Desktop Insight
Click here to watch this at youtube.com or click here to go to our Youtube channel
This video discusses substituting for and comparing calcium carbonate (whiting) with other sources of CaO (dolomite, wollastonite, frit): It teaches you how to go about using glaze chemistry to understand the differences between materials and then remove whiting and replace it with the preferred material, wollastonite, in a recipe. The reason for doing this, in this case, is that wollastonite is a better quality and more consistent material and it is not a carbonate, so it does not produce gases as it decomposes during melting (these gases can cause issues with glaze bubbles, pinholes, blisters, etc.).
An important point to remember about materials substitution, wollastonite for whiting in this case, is that you cannot just replace one with the other gram-for-gram. Whiting supplies only CaO oxide to the glaze melt whereas wollasonite supplies both CaO and SiO2. In addition, 1 gram of wollastonite does not supply the same amount of CaO as 1 gram of whiting. Thus, to substitute, you need to calculate how much wollastonite is needed to supply the same amount of calcia, but also how much the silica in the recipe needs to be reduced so the overall SiO2 content in the glaze stays the same (becase the incoming wollastonite is bringing its own SiO2). This process is quite fascinating and opens up the doors to being about to substitute many other materials; ultimately you will be able to work a frit into a recipe (frits are premelted and generate no gases during melting, they are the ultimate material to substitute many oxides that are delivered by troublesome raw materials (eg. MgO in talc or dolomite, Li2O in lithium carbonate), even substitute more than one at the same time (e.g. removing both Gerstley Borate and whiting from a recipe and supplying the CaO and B2O3 from a frit).
Transcript of video 1C - Comparing Calcia Sourcing Materials
LOI and study calcia contributing materials specifically, what makes frits such great sources of oxides, the concept of alternate sourcing an oxide, non-participant recipe materials and the digitalfire material information strategy
Two Sources of Calcia
Welcome. In this lesson we will talk about LOI and study calcia contributing materials specifically. We will discuss what makes frits such great sources of oxides, the concept of alternate sourcing an oxide, non-participant recipe materials and the digitalfire material information strategy.
Examining calcium carbonate
We are going to take a closer look at the makeup of calcium carbonate (also called whiting). To more fully understand this material it needs it to be alone in a recipe.
I will select the custer feldspar line in recipe 1 (from lesson 1B) and click the Delete button to remove the amount for the feldspar.
This leaves only the whiting in recipe 1.
Before continuing I should point out that the calculated molecular weight of calcium carbonate is 100, by a rather amazing coincidence. Hopefully that will reduce a little confusion in this lesson.
Why is the formula weight different?
Notice the formula weight INSIGHT calculates for whiting in the Calculated Items list: '56.1'.
If I double-click the whiting recipe line the materials dialog shows a weight of '100'. Why? Whiting powder is not pure calcium oxide, it contains carbon dioxide. Of 100 grams of calcium carbonate powder that you put in the kiln, only 56.1 will be present in the fired glaze (the rest is lost as CO2 vapors).
Here you can see that INSIGHT calls the 43.9% loss LOI (literally loss-on-ignition or weight lost on firing). Here is the other 56.1 that is left.
Of course if I double-click CaO to see it in the oxides dialog: Its weight is 56.1.
How INSIGHT handles LOI
When INSIGHT calculates it is portraying only what is left after firing and gives us the weight of that. There is no CO2 in the formula list, it is gone.
So the materials dialog is representing raw materials with LOIs, the recipe window is showing us only the calculated products.
However notice that INSIGHT actually displays two different LOI figures in the recipe window, the Calculated LOI and the Imposed LOI. I will demonstrate.
Before going on note that I have the lessons materials database selected as with other lessons.
Imposing an LOI
I have closed the Materials and Oxides dialogs and will choose Override Calculated LOI in the Calc menu.
Notice this window already knows that my raw recipe has a total LOI of 43.9, so I will set it to that.
INSIGHT now calculates the correct weight for the RAW material and the override I just set is displayed as the Imposed LOI. Being able to impose an LOI is important to adding new materials to the materials database.
As you will learn, when materials lose this much weight during firing they generate a lot of gases, this can have an impact on the glaze, especially if the gases are coming out as bubbles after melting starts.
Finding CaO sources: Wollastonite
There sources of CaO without such a high LOI? I will show you in the materials dialog. Notice on the lower left there is a pop-up list where you can select an oxide. I have selected CaO. As you can see it is obviously sourced by many materials. I'll scroll down the list and show you Wollastonite.
Notice it contains equal CaO and SiO2 (of course this is a theoretical material, real world wollastonites have traces of other things and the SiO2 and CaO are not exactly equal). Like a feldspar, getting SiO2 for a glaze this way is better than from raw quartz powder. Notice also this it has no LOI. Want to learn more? Level 2 INSIGHT users can click this button.
Here is dolomite. This is actually worse than calcium carbonate. It loses 47.6% on firing, leaving 53.4.
This formula weight, 96.4, is thus 53.4 percent of the formula weight of the raw material.
When we talk about LOI we also need to think about when the gases are liberated during kiln heat-up. If it happens after the glaze starts melting, that is obviously not good. The Digitalfire Reference Library has a special area called Temperatures, it is attempting to map the decomposition events from many materials during kiln firing.
Analyzing a frit
Here is a boron frit, notice that it has 20% CaO. If your glaze also needs sodium, boron and silica, and the vast majority of glazes do, a frit like this is a good source of CaO. INSIGHT is a great way to figure out how to juggle things to incorporate frits into glaze recipes while maintaining the chemistry.
The really great thing about this material that no feldspar on earth can offer is this: No alumina. That makes more room in recipes for clays, they are sources of alumina and suspend the slurry and harden the dried layer. In addition, frits generate no gases on firing.
A recipe can contain materials not known by INSIGHT, we call these phantom or non-participant materials.
To demonstrate I have entered a line with 50 parts of “SPIDERS LEGS”. The asterisk before it means INSIGHT cannot find chemistry for it. Organic gums are like this, they are added to glazes to impart working properties but contribute no oxides to the fired product, they just burn away.
When doing glaze chemistry we most often like to see a clean formula not cluttered up with colorants or opacifiers. Thus, you will actually want to leave materials like zircon, tin oxide and raw coloring oxides or stains out of your MDT and enter them into glazes the way I have done with spiders legs here.
Which materials included in MDT?
I want to talk for a moment about how we decide what materials to include in the standard list.
Of course, the lessons materials database, the one we are using here is small. But the standard one distributed with INSIGHT normally has about 250 generic and name brand (mostly North American) materials. The MDT section of the Digitalfire Reference Library website explains the logic behind how we determine which materials to include in the starter tables that are available for various parts of the world and specific ceramic industries. There is a page where logged in INSIGHT level 2 users can add to one of the starter databases and customize materials names and even translate them.
Digitalfire materials strategy
This page at the Digitalfire Reference Library is where we focus our material information efforts. These links and this search are the home page for thousands of materials. This link goes to the area we were just looking at and all of these others are interrelated in a material centric reference database. We will be using this resource much more in subsequent lessons.
Video 7A - Formulating Substitution Rules with Whiting and Wollastonite
Rationalization of the relative merits of materials, using the Supply Oxide dialog both ways on side-by-side no-unity recipes, and learning to spot obvious supply problems and theoretical vs. actual materials
Out Bound Links
In Bound Links