Additive and intensive grinding effects on the synthesis of cordierite

Cordierite was mechanochemically synthesized by mixing proper amounts of kaolin, talc and Al(OH)3. Full factorial experiments were planned, conducted, and the results were analyzed by the use of statistical techniques in order to understand the effects of process variables on the amount of synthesized product. The powder products were analyzed by XRD, DTA, and SEM-EDS. As a result of the statistical analysis, temperature was found to be the most important factor. Based on XRD peak intensity measurements, the cordierite mixture was completely amorphized by grinding at 300 rpm for 60 min. Cordierite was successfully produced at temperatures as low as 1150 °C by using the mixture after intensive grinding. The combined effect of magnesium borate additive and grinding on cordierite synthesis was also studied. These factors successfully decreased the synthesis temperature down to 1000 °C.