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Drying and firing a 31-inch porcelain plate without cracks. How?

It takes extreme care. Three months of it! Porcelains are fine-grained and, for heavy pieces, they will not tolerate uneven drying at any stage. These cone 10 plates are made by Peter Flanagan at Okanagan Pottery in Nelson, B.C. Firing is also a real challenge. Pottery porcelains are high in quartz, getting a piece like this down through quartz inversion (~1200-900F) without dunting is only possible if done very slowly. The fact that ancient Chinese potters made very large porcelain pieces means they knew about slow cooling also (and it was a natural consequence of the heavy kilns they used). But our modern kilns cool quickly so the drop must be slowed. Peter adds an extra level of "super humanness" by actually lustre-firing these pieces, which means 2 more trips through the hazardous quartz inversion territory! If you do this be prepared to fire super slow (e.g. 25 degrees per hour) through this range.

31-inch porcelain plate successfully fired

Related Pictures

22 inch slabs successfully fired after a change. What?


22 inch tiles successfully being fired

Giant thin meter-square tiles are fired flat and crack-free by tile companies. How? Kilns that heat evenly from above and below (the tiles are on rollers). But these round tiles are being fired in an electric kiln, a device incapable of heating a large slab evenly. They are so large they reach almost to the outer walls. That means the outer edges receive direct radiant heat from the elements, this sets up a temperature gradient running from the edges toward the center. Passing such a piece up and down through quartz inversion thus creates a wave of sudden expansion and contraction moving through the piece. The artist was losing every one of these to dunting. It is not really advisable to even try this - but he was determined to do it anyway. One change in the process brought this one through: Slowing down to 50F/hr up and down through the quartz inversion (950-1150F).

Links

Articles Drying Ceramics Without Cracks
Anything ceramic ware can be dried if it is done slowly and evenly enough. To dry faster optimize the body recipe, ware cross section, drying process and develop a good test to rate drying performance.
Glossary Quartz Inversion
In ceramics, this refers to the sudden volume change in crystalline quartz particles experience as they pass up and down a temperature window centering on 573C.
URLs https://www.okanaganpottery.com/
Okanagan Pottery - Peter Flanagan makes giant impossible porcelain plates.

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