In a previous blog, we described our 4-stage project methodology where the results of one phase lead to the next - or they don’t.
We see it as a go - no go process, and we strive to present our clients with the data and professional interpretation that lets them make sound business decisions.
Within the 4 stages – or project phases, as we like to call them – there are several routes to that go - no go decision. Key to determining the best path is the material itself.
This is why we break Phase 1 into two parts:
Phase 1A - Analytical Sample Testing
IntoCeramics’ analytical team determines the composition of your sample and our experts assess the potential for commercial use across different markets.
Phase 1B - Lab Scale Processing
If Phase 1A indicates “go”, we evaluate using your sample to manufacture lab quantities of potential products. We assess the material’s suitability in terms of handling, processing, and finished properties. This brings us to a major decision point where IntoCeramics will make recommendations for Phase 2 – Product Development.
We split Phase 1 this way for the simple reason that sometimes a material just isn’t suitable for further development.
Proceeding with lab scale processing when it’s not justified would lead to wasted time, money, and effort.
A quick, definitive “no” is much better than a tortured “maybe, but we need more time".
Testing Regimen
We follow a standard analytical testing sequence during Phase 1A that is designed to confirm the viability of most materials:
- Chemistry determined by X-Ray Fluorescence (XRF) - Provides accurate and reliable quantitative results expressed in oxides.
- Mineralogy determined by X-Ray Diffraction (XRD) - A semi-quantitative test that gives a comprehensive assessment of sample constituents in combination with XRF results.
- Loss on Ignition (LOI) - Used together with XRF and XRD results, LOI determines total weight loss during sintering due to outgassing of carbonates, hydroxyls, chlorides, sulfates, and other chemically bound substances during the firing cycle.
These tests are run first and will guide what further analytical testing is required, based on the specific types of minerals and oxides we find.
Physical testing of the sample will include:
- Bulk Density
- Specific Gravity
- Composite Sieve Analysis
These tests help us to evaluate what additional processing might be required for the material to be usable in a ceramic product.
Although the complexity of sample composition will dictate the overall extent of analytical testing, none of these tests are particularly expensive.
Our partnership with Clemson’s Bishop Materials Research Center ensures that we can offer our clients the lowest possible costs for any tests not performed by our own laboratories.
What If It’s Already Been Tested?
Many clients tell us they have all the analytical data that we could possibly want, and that there’s no point running a new testing regimen.
Our experience leads us to doubt those assertions.
In one example, the client’s XRD results seemed “off” and weren’t supported by the corresponding XRF data we received. One mineral detected by XRD was rich in magnesium, whereas no magnesium was detected by XRF.
Sure enough, our eventual XRD re-test revealed an entirely different mineralogy than initially reported by the client.
We will never know if the erroneous XRD report was due to incorrect interpretation of the XRD spectrum or if the machine itself was having problems.
For this reason, we are happy to review client data, but we insist on completing our minimum testing regimen during Phase 1A to protect both the client and IntoCeramics from making decisions based on faulty information.
Will your material qualify for Phase 1B? We don’t know until we test but Phase 1A will turn those unknowns into knowns.
Contact us to find out how we can help.
