The Natural History of Clay

by Alfred B. Searle

In practice, a suggestion made many years ago by Seger ([7]) is used; the clay to be tested is made into a small tetrahedron ([fig. 6]), heated slowly until it bends over and the point of the test-piece is almost on a level with the base. The temperature at which this occurs is termed the 'fusing point' though it really only indicates the heat-treatment which is sufficient to soften the material sufficiently to cause it to bend in the manner described. In spite of the apparent crudeness of the test this 'softening point' appears to be fairly constant for most refractory clays.

The bending of a test-piece in this manner is the result of the action of all fluxes[6] in the clay, and as this depends on the size of grain and the duration of the heating above incipient fusion and does not give a direct measure of temperature, nor is the softening effect under one rate of rise in temperature the same as that at another rate. Nevertheless a study of the behaviour of various clays heated simultaneously is valuable and the method forms a convenient means of comparing different materials.

[6] For fluxing materials see [p. 8].

The temperature may be measured by means of a pyrometer, but for the reason just stated it is more convenient and in some respects more accurate to use standard mixtures known as Seger Cones ([fig. 6]), and to state the softening point in terms of the 'cone' which behaves like the clay being tested. A medium fireclay will not soften below Seger Cone 26 (1650° C.) and a really good one will have a softening point of cone 34 or 35 (1750° to 1800° C.).

Fig. 6. Seger Cones indicating a temperature of 1250° C.

The refractoriness of a clay, or its resistance to high temperatures, is an important requirement in bricks required for furnace linings, in crucibles, gas retorts and other articles used in the metallurgical and other industries. The term is much abused and is frequently understood to mean resistance to the cutting action of flue gases and flame, the corrosive action of slags, and the strains set up by the repeated changes in temperature. This is unfortunate, for the term refractoriness has a perfectly definite meaning and should be employed exclusively to denote that a given clay is capable of retaining its shape at a given temperature or under given conditions when heated alone and without being subjected to any pressure. In Great Britain there is no officially recognized standard of minimum refractoriness[7], but where one is required the suggested minimum of Seger Cone 26 (1650° C.) made by E. Cramer ([8]) is usually employed. This is the recognized minimum in Germany for fireclays, and though objections may be urged against the use of Seger Cones as a standard, equally forcible ones may be brought against making a temperature-scale the basis of measurement. Under present circumstances, however, it is necessary to adopt one or other of these.

[7] See Refractory Clays, [Chapter V].

Various attempts have been made to ascertain the relationship (if any) between the refractoriness of clays and their chemical composition. If attention is confined strictly to the more refractory clays, some kind of relationship does appear to exist. Thus Richter found that the refractoriness of clay is influenced by certain oxides in the following order: magnesia, lime, ferrous oxide, soda and potash, but this only applies to clays containing less than 3 per cent. of all these oxides. Cramer, in 1895, found that free silica also interfered with the action of these oxides and more recently Ludwig ([9]) has devised a chart ([fig. 7]), on the upright sides of which are plotted the equivalents of the lime, magnesia and alkalies, whilst the silica equivalents are plotted on the horizontal base. In each case the 'molecular formula' of the clay is calculated from its percentage composition, and this 'formula' is reduced so as to have one 'molecule' of alumina, thereby fixing the alumina as a constant and reducing the number of variables to two—the metallic oxides and the silica. Unfortunately Ludwig's chart is only applicable to the more refractory clays and cannot be relied upon even for these, though it is extremely useful for comparing clays from identical or similar geological formations.