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Making your own hexagonal shelves using calcined alumina
This homemade kiln shelf (left) for our test kiln was fired at cone 10. This is a third the weight (and thickness) of the cordierite one on the right. However it does not have the thermal shock resistance of cordierite, uneven heatup can crack it. It is made from a body I slurry up consisting of 96.25% calcined alumina and 3.75% Veegum. It rolls out nicely and dries flat between pieces of plasterboard, taking about three days (if you try this and the body is not plastic then your alumina is not fine enough or you did not blender mix the slurry well enough). Alumina produces a lighter shelf than Zircopax and shrinks much less than refractory bodies we have tried (e.g. L4543), I cut the slab only 1/4" larger and it has fired to the same size.
Related Pictures
Drying a flat slab of clay between sheets of Gyproc
This picture has its own page with more detail, click here to see it.
I am making my own low-temperature kiln shelves by rolling 3/16-inch thick slabs from plastic clay (from a 50:50 mix of Pyrax and Kaolin with 20% grog added). How can I dry them flat? Between two sheets of plasterboard. You might think that the weight of the board above would impede the shrinkage of the slab and crack it, but that does not happen. Even if the clay is quite soft or less plastic these still slabs still dry within two days without splitting or cracking.
My first zircopax kiln shelf
This picture has its own page with more detail, click here to see it.
It is 5 mm thick (compared to the 17mm of the cordierite one). It weighs 650 grams (vs. 1700 grams). It will perform at any temperature that my test kiln can do, and far in excess of that. It is made from a body I slurry up (80% Zircopax Plus, 16.5% 60-80 Molochite grog, 3.5% Veegum T). The body is plastic and easy to roll and had 4.2% drying shrinkage at 15.3% water. The shelf warped slightly during drying (I should have dried it between sheets of plasterboard). Firing at cone 4 yielded a shrinkage of 1%. Notice that cone on the shelf: It has not stuck even though no kiln wash was used! Zircopax is super refractory! This is sinter bonded, so the higher the temperature you can fire the stronger it will be. Although it would be very hard to make full 18 or 22-inch shelves for larger kilns, smaller ones designed to "network" would enable a tighter load of ware with a much lower shelf-to-ware weight ratio (especially using my own lightweight posts). Like alumina, this does not have the thermal shock resistance of cordierite, uneven heating can crack these.
A small test kiln: More control, faster learning
This picture has its own page with more detail, click here to see it.
A question about a glaze or body should be a reason to run a test. Having your own small programmable kiln means you can do that without waiting for a production load or tolerating someone else’s firing schedule.
This is a Cone Art 119D: an 11-inch-diameter, 9-inch-deep, 0.57-cubic-foot cone 10 test kiln. It runs on 208 V and has a Bartlett Genesis touchscreen controller. Being able to create, edit and repeat firing schedules easily is central to how it's used and what can be tested. It holds four or five mugs, or a dozen clay and glaze test specimens. Small loads make frequent testing practical: compare a recipe adjustment, investigate a defect or check a new material shipment. Controlling the cooling schedule is among the most fascinating of tests (and a way to emulate a slow-cooling production kiln). With most firings below cone 7, a set of elements can last a thousand firings. Start with a kiln like this and you will discover how much you can accomplish before needing a larger one. Even then, the little kiln keeps its job.
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| Materials |
Calcined Alumina
A high-purity Al2O3 used in technical ceramics, refractories, glazes, and bodies for its extreme hardness, high-temperature strength, and chemical stability. |
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