Sintering Behavior of Bi-Material Micro-Component of 17-4PH Stainless Steel and Yttria-Stabilized Zirconia Produced by Two-Component Micro-Powder Injection Molding Process

In this research, we investigated the influence of the sintering temperature on the physical and mechanical properties of micro-sized bi-material components of 17-4PH stainless steel and 3 mol% yttria-stabilized zirconia fabricated using a two-component micro-powder injection molding (2C-μPIM) process. First, 17-4PH and zirconia powders were separately mixed with binders to obtain feedstocks, which were then injection-molded into the dumbbell shape, followed by the binder extraction process. Subsequently, the debound micro-specimens were subjected to sintering between 1250 °C and 1350 °C for 3 h. Per the observations of the microstructures using scanning electron microscopy (SEM), a strong bond between metal and ceramic in micro-sized 17-4PH/zirconia components was formed when the sintering temperature exceeded 1300 °C. The maximum relative density of 99% was achieved when the bi-material micro-part was sintered at 1350 °C. The linear shrinkage increased from 9.6% to 17.4% when the sintering temperature was increased from 1250 °C to 1350 °C. The highest hardness value of 1439.6 HV was achieved at 1350 °C along the bi-material bonding region. Moreover, a maximum tensile strength of 13.7 MPa was obtained at 1350 °C.     

Manufacturing of Open-Cell Aluminium Foams: Comparing the Sponge Replication Technique and Its Combination with the Freezing Method

The manufacturing of aluminium foams with a total porosity of 87% using the sponge replication method and a combination of the sponge replication and freezing technique is presented. Foams with different cell counts were prepared from polyurethane (PU) templates with a pore count per inch (ppi) of 10, 20 and 30; consolidation of the foams was performed in an argon atmosphere at 650 °C. The additional freezing steps resulted in lamellar pores in the foam struts. The formation of lamellar pores increased the specific surface area by a factor of 1.9 compared to foams prepared by the sponge replication method without freezing steps. The formation of additional lamellar pores improved the mechanical properties but reduced the thermal conductivity of the foams. Varying the pore cell sizes of the PU template showed that—compared to foams with dense struts—the highest increase (~7 times) in the specific surface area was observed in foams made from 10 ppi PU templates. The effect of the cell size on the mechanical and thermal properties of aluminium foams was also investigated.     

A Pathway toward a New Era of Open-Cell Polyurethane Foams—Influence of Bio-Polyols Derived from Used Cooking Oil on Foams Properties

In order to create greener polyurethane (PUR) foams, modified used cooking oils (UCO) were applied as starting resources for the synthesis of bio-polyols. The bio-polyols were produced using transesterification of UCO with diethylene glycol (UCO_DEG) and triethanolamine (UCO_TEA). Next, open-cell PUR foams were synthesized by replacing 20, 40, 60, 80 and 100% of the petrochemical polyol with the bio-polyol UCO_DEG or UCO_TEA. It was observed that an increasing bio-polyol content (up to 60%) led to an increase of the closed cell content. However, a further increase in the bio-polyol content up to 100% resulted in foam cell opening. The bio-foams obtained in the experiment had an apparent density of 13–18 kg/m³. The coefficient of thermal conductivity was determined at three different average temperatures: 10, 0 and −10 °C. The PUR bio-foams modified with bio-polyol UCO_TEA had lower values of thermal conductivity, regardless of the average temperature (35.99–39.57 mW/m·K) than the foams modified with bio-polyol UCO_DEG (36.95–43.78 mW/m·K). The compressive strength of most of the bio-foams was characterized by a higher value than the compressive strength of the reference material (without bio-polyol). Finally, it was observed that the bio-materials exhibited dimensional stability at 70 °C.     

Characterization of Open-Cell Sponges via Magnetic Resonance and X-ray Tomography

The applications of polymeric sponges are varied, ranging from cleaning and filtration to medical applications. The specific properties of polymeric foams, such as pore size and connectivity, are dependent on their constituent materials and production methods. Nuclear magnetic resonance imaging (MRI) and X-ray micro-computed tomography (µCT) offer complementary information about the structure and properties of porous media. In this study, we employed MRI, in combination with µCT, to characterize the structure of polymeric open-cell foam, and to determine how it changes upon compression, µCT was used to identify the morphology of the pores within sponge plugs, extracted from polyurethane open-cell sponges. MRI T₂ relaxation maps and bulk T₂ relaxation times measurements were performed for 7° dH water contained within the same polyurethane foams used for µCT. Magnetic resonance and µCT measurements were conducted on both uncompressed and 60% compressed sponge plugs. Compression was achieved using a graduated sample holder with plunger. A relationship between the average T₂ relaxation time and maximum opening was observed, where smaller maximum openings were found to have a shorter T₂ relaxation times. It was also found that upon compression, the average maximum opening of pores decreased. Average pore size ranges of 375–632 ± 1 µm, for uncompressed plugs, and 301–473 ± 1 µm, for compressed plugs, were observed. By determining maximum opening values and T₂ relaxation times, it was observed that the pore structure varies between sponges within the same production batch, as well as even with a single sponge.     

The Influence of Sintering Temperature on the Pore Structure of an Alkali-Activated Kaolin-Based Geopolymer Ceramic

Geopolymer materials are used as construction materials due to their lower carbon dioxide (CO₂) emissions compared with conventional cementitious materials. An example of a geopolymer material is alkali-activated kaolin, which is a viable alternative for producing high-strength ceramics. Producing high-performing kaolin ceramics using the conventional method requires a high processing temperature (over 1200 °C). However, properties such as pore size and distribution are affected at high sintering temperatures. Therefore, knowledge regarding the sintering process and related pore structures on alkali-activated kaolin geopolymer ceramic is crucial for optimizing the properties of the aforementioned materials. Pore size was analyzed using neutron tomography, while pore distribution was observed using synchrotron micro-XRF. This study elucidated the pore structure of alkali-activated kaolin at various sintering temperatures. The experiments showed the presence of open pores and closed pores in alkali-activated kaolin geopolymer ceramic samples. The distributions of the main elements within the geopolymer ceramic edifice were found with Si and Al maps, allowing for the identification of the kaolin geopolymer. The results also confirmed that increasing the sintering temperature to 1100 °C resulted in the alkali-activated kaolin geopolymer ceramic samples having large pores, with an average size of ~80 µm³ and a layered porosity distribution.     

Effect of Feldspar Substitution by Basalt on Pyroplastic Behaviour of Porcelain Tile Composition

This work aims to evaluate the effects of feldspar substitution by basalt on porcelain tile composition with respect to its porosity, flexural strength, and pyroplastic deformation. Three ceramic formulations with different amounts of feldspar substituted with basalt, 50% (C1), 75% (C2), and 100% (C3), were evaluated at three different temperatures, 1200, 1220, and 1240 °C. Specifically, the effect of replacing feldspar with basalt on the pyroplastic deformation of ceramic bodies was analysed using optical fleximetry. The porosity of C1 at 1200 °C was 19.3 ± 2.9%, while that of composition C3 was 22.2 ± 0.7% at 1240 °C. The flexural strength was strongly influenced by the temperature. For C1 at 1200 and 1240 °C, flexural strengths of 11.1 ± 0.6 and 22.2 ± 1.9 MPa, respectively, were obtained. Regarding fleximetry, thermal deformation decreased with an increase in the amount of feldspar substituted with basalt. It was observed that C2 and C3 deformed less at high temperatures than the other combinations of compositions and temperature, probably owing to the lower amount of residual glass phase present during cooling. Compositions with higher substitution amounts of basalt (i.e., C2 and C3) exhibited more stable thermal behaviour than C0.     

Composite Carbon Foams as an Alternative to the Conventional Biomass-Derived Activated Carbon in Catalytic Application

The suitability of a new type of polyurethane-based composite carbon foam for several possible usages is evaluated and reported. A comparison of the properties of the as-prepared carbon foams was performed with widely available commercial biomass-derived activated carbon. Carbon foams were synthesized from polyurethane foams with different graphite contents through one-step activation using CO₂. In this work, a carbon catalyst was synthesized with a moderately active surface (S_BET = 554 m²/g), a thermal conductivity of 0.09 W/mK, and a minimum metal ion content of 0.2 wt%, which can be recommended for phosgene production. The composite carbon foams exhibited better thermal stability, as there is a very little weight loss at temperatures below 500 °C, and weight loss is slower at temperatures above 500 °C (phosgene synthesis: 550–700 °C). Owing to the good surface and thermal properties and the negligible metallic impurities, composite carbon foam produced from polyurethane foams are the best alternative to the conventional coconut-based activated carbon catalyst used in phosgene gas production.     

Preparation of Fly Ash-Ladle Furnace Slag Blended Geopolymer Foam via Pre-Foaming Method with Polyoxyethylene Alkyether Sulphate Incorporation

This paper uses polyoxyethylene alkyether sulphate (PAS) to form foam via pre-foaming method, which is then incorporated into geopolymer based on fly ash and ladle furnace slag. In the literature, only PAS-geopolymer foams made with single precursor were studied. Therefore, the performance of fly ash-slag blended geopolymer with and without PAS foam was investigated at 29–1000 °C. Unfoamed geopolymer (G-0) was prepared by a combination of sodium alkali, fly ash and slag. The PAS foam-to-paste ratio was set at 1.0 and 2.0 to prepare geopolymer foam (G-1 and G-2). Foamed geopolymer showed decreased compressive strength (25.1–32.0 MPa for G-1 and 21.5–36.2 MPa for G-2) compared to G-0 (36.9–43.1 MPa) at 29–1000 °C. Nevertheless, when compared to unheated samples, heated G-0 lost compressive strength by 8.7% up to 1000 °C, while the foamed geopolymer gained compressive strength by 68.5% up to 1000 °C. The thermal stability of foamed geopolymer was greatly improved due to the increased porosity, lower thermal conductivity, and incompact microstructure, which helped to reduce pressure during moisture evaporation and resulted in lessened deterioration.     

Geopolymer Ceramic Application: A Review on Mix Design,Properties and Reinforcement Enhancement

Geopolymers have been intensively explored over the past several decades and considered as green materials and may be synthesised from natural sources and wastes. Global attention has been generated by the use of kaolin and calcined kaolin in the production of ceramics, green cement, and concrete for the construction industry and composite materials. The previous findings on ceramic geopolymer mix design and factors affecting their suitability as green ceramics are reviewed. It has been found that kaolin offers significant benefit for ceramic geopolymer applications, including excellent chemical resistance, good mechanical properties, and good thermal properties that allow it to sinter at a low temperature, 200 °C. The review showed that ceramic geopolymers can be made from kaolin with a low calcination temperature that have similar properties to those made from high calcined temperature. However, the choice of alkali activator and chemical composition should be carefully investigated, especially under normal curing conditions, 27 °C. A comprehensive review of the properties of kaolin ceramic geopolymers is also presented, including compressive strength, chemical composition, morphological, and phase analysis. This review also highlights recent findings on the range of sintering temperature in the ceramic geopolymer field which should be performed between 600 °C and 1200 °C. A brief understanding of kaolin geopolymers with a few types of reinforcement towards property enhancement were covered. To improve toughness, the role of zirconia was highlighted. The addition of zirconia between 10% and 40% in geopolymer materials promises better properties and the mechanism reaction is presented. Findings from the review should be used to identify potential strategies that could develop the performance of the kaolin ceramic geopolymers industry in the electronics industry, cement, and biomedical materials.     

Open-Cellular Alumina Foams with Hierarchical Strut Porosity by Ice Templating: A Thickening Agent Study

Alumina replica foams were manufactured by the Schwartzwalder sponge replication technique and were provided with an additional strut porosity by a freeze-drying/ice-templating step prior to thermal processing. A variety of thickeners in combination with different alumina solid loads in the dispersion used for polyurethane foam template coating were studied. An additional strut porosity as generated by freeze-drying was found to be in the order of ~20%, and the spacings between the strut pores generated by ice-templating were in the range between 20 µm and 32 µm. In spite of the lamellar strut pore structure and a total porosity exceeding 90%, the compressive strength was found to be up to 1.3 MPa. Combining the replica process with freeze-drying proves to be a suitable method to enhance foams with respect to their surface area accessible for active coatings while preserving the advantageous flow properties of the cellular structure. A two-to-threefold object surface-to-object volume ratio of 55 to 77 mm⁻¹ was achieved for samples with 30 vol% solid load compared to 26 mm⁻¹ for non-freeze-dried samples. The freeze-drying technique allows the control of the proportion and properties of the introduced pores in an uncomplicated and predictable way by adjusting the process parameters. Nevertheless, the present article demonstrates that a suitable thickener in the dispersion used for the Schwartzwalder process is inevitable to obtain ceramic foams with sufficient mechanical strength due to the necessarily increased water content of the ceramic dispersion used for foam manufacturing.     

Development of 3D Slurry Printing Technology with Submersion-Light Apparatus in Dental Application

This study proposes an innovative three-dimensional printing technology with submersion-light apparatus. A zirconia powder with an average particle size of 0.5 µm is mixed with 1,6-Hexanediol diacrylate (HDDA) and photo-initiator to form a slurry. The weight percentage of zirconia powder to HDDA is 70:30 wt.%. A light engine box is submerged in a slurry and emits a layered pattern to induce photopolymerization and transform a slurry into a printed green body. Green body sintering parameters for the first and second stages are 380 °C with a holding time of 1.5 h and 1550 °C with a holding time of 2 h. The sintered parts’ length, width, and height shrinkage ratios are 29.9%, 29.7%, and 30.6%. The ball milling decreases the powder particle size to 158 ± 16 nm and the mean grain size of the sintered part is 423 ± 25 nm. The sintered part has an average hardness of 1224 (HV), a density of 5.45 g/cm³, and a flexural strength of 641.04 MPa. A three-unit zirconia dental bridge also has been fabricated with a clinically acceptable marginal gap.     

Polyols from Microwave Liquefied Bagasse and Its Application to Rigid Polyurethane Foam

Bagasse flour (BF) was liquefied using bi-component polyhydric alcohol (PA) as a solvent and phosphoric acid as a catalyst in a microwave reactor. The effect of BF to solvent ratio and reaction temperatures on the liquefaction extent and characteristics of liquefied products were evaluated. The results revealed that almost 75% of the raw bagasse was converted into liquid products within 9 min at 150 °C with a BF to solvent ratio of 1/4. The hydroxyl and acid values of the liquefied bagasse (LB) varied with the liquefied conditions. High reaction temperature combining with low BF to solvent ratio resulted in a low hydroxyl number for the LB. The molecular weight and polydispersity of the LB from reactions of 150 °C was lower compared to that from 125 °C. Rigid polyurethane (PU) foams were prepared from LB and methylene diphenyl diisocyanate (MDI), and the structural, mechanical and thermal properties of the PU foam were evaluated. The PU foams prepared using the LB from high reaction temperature showed better physical and mechanical performance in comparison to those from low reaction temperature. The amount of PA in the LB has the ability of increasing thermal stability of LB-PU foams. The results in this study may provide fundamental information on integrated utilizations of sugarcane bagasse via microwave liquefaction process.     

Does Preheating Resin Cements Affect Fracture Resistance of Lithium Disilicate and Zirconia Restorations?

This paper assesses the impact of preheating of adhesive cement on the fracture resistance of lithium disilicate and zirconia restorations. Methods: A total of 80 human maxillary premolar teeth were assigned into 8 groups (n = 10) according to material type (either lithium disilicate or zirconia) and type of resin cement (either LinkForce or Panavia SA) with preheating temperature at 54 °C or at room temperature (25 °C). Teeth were prepared and restored with either lithium disilicate or zirconia restorations. After cementation, specimens were thermal cycled (10,000 cycles, 5 °C/55 °C), then load cycled for 240,000 cycles (50 N). Each specimen was statically loaded until fracture and the load (N) at fracture was recorded, then the failure mode was detected. Statistical analysis of data was performed (p ≤ 0.05). Results: There was no significant difference (p = 0.978) in fracture mean values between LinkForce and Panavia SA. Statistically significant difference (p = 0.001) was revealed between fracture resistance of lithium disilicate restorations cemented with LinkForce at 25 °C and at 54 °C; however there was no significant difference (p = 0.92) between the fracture resistance of lithium disilicate restorations cemented with Panavia SA used at 25 °C and at 54 °C. Regarding the interaction between ceramic material, cement type, and cement preheating, there was no significant effect (p > 0.05) in fracture resistance. The cement type does not influence the fracture resistance of ceramic restorations. Preheating of resin cement has negatively influenced the fracture resistance of all tested groups, except for lithium disilicate cemented using LinkForce cement.     

Effect of Complex Strengthening on the Continuous Cooling Transformation Behavior of High-Strength Rebar

The effects of niobium and composite strengthening on the phase transformation characteristics and precipitation behavior of continuous cooling transformation of high-strength rebar during thermal deformation and subsequent cooling were investigated. The results show that when the cooling rate was within 0.3–5 °C/s, ferrite transformation and pearlite transformation occurred in the experimental steels. The Nb content increased to 0.062 wt.%, and the starting temperature of the ferrite transformation decreased. Meanwhile, the ferrite phase transformation zone gradually expanded, and the pearlite phase transformation zone gradually narrowed with the increase in the cooling rate. When the cooling rate was 1 °C/s, bainite transformation began to occur, and the amount of transformation increased with the increase in the cooling rate. It was found that the main precipitates in the experimental steels were (Nb, Ti, V)C, with an average particle size of about 10–50 nm. When the Nb content was increased to 0.062 wt.% and the cooling rate was increased to 5 °C/s, the ferrite grain size was reduced from 19.5 to 7.5 μm, and the particle size of the precipitate (Nb, Ti, V)C could be effectively reduced. The strength of the steel was significantly improved, but the elongation of the steel was reduced. However, the comprehensive mechanical properties of 0.062 wt.% Nb experimental steel was significantly improved at a cooling rate of 5 °C/s.     

Investigation on the Evolution of Nano-Scale Defects of CL-20 Crystals under Thermal Treatment by Wide/Small-Angle X-ray Scattering

Nano-scale crystal defects extremely affect the security and reliability of the explosive charges of weapons. In order to understand the evolution of nano-scale defects of 2,4,6,8,10,12-hexanitro-2,4,6,8,10,12-hexaaza-isowurtzitane (CL-20) explosive crystals under thermal treatments, the specific surface, volume fraction and size distribution of the nano-scale defects were studied by using Wide Angle X-ray Scattering (WAXS) and Small Angle X-ray Scattering (SAXS) during the temperature range from 30 °C to 200 °C. The results showed that the number and size of the pores in CL-20 powder did not change significantly during the heating process before phase transformation (30–160 °C). At 170 °C, CL-20 began to convert from ε- to γ- phase, and the specific surface and volume fraction of the nano-scale defects increased significantly. Further investigation of the pore size distribution showed that the number of pores with a small size (radius 9–21 nm) changed particularly significantly, resulting from the cracking of the CL-20 crystal powder during phase transition. At 200 °C, the phase transition was completed and γ-CL-20 was created, and the small-sized pores gradually grew into medium-sized (radius 21–52 nm) pores over time when the temperature was fixed at 200 °C.     

Composites of Open-Cell Viscoelastic Foams with Blackcurrant Pomace

Taking into account the circular economy guidelines and results of life cycle analyses of various materials, it was proposed to use a blackcurrant pomace filler in the production process of viscoelastic polyurethane (PUR) foams intended for application as mattresses, pillows, or elements for orthopedics. Open-cell viscoelastic PUR foams containing 10–60 per hundred polyols (php) blackcurrant pomace were prepared. It was found that after introducing the filler to the PUR foam formulation, the speed of the first stage of the foaming process significantly decreases, the maximum temperature achieved during the synthesis drops (by 30 °C for the foam containing 40 php of filler compared to unfilled foam), and the maximum pressure achieved during the synthesis of foam containing 20 php is reduced by approximately 57% compared to the foam without filler. The growth time of the foams increases with increasing the amount of introduced filler; for the foam containing 60 php, the time is extended even by about 24%. The effect of the filler on the physical, morphological, mechanical, and functional performances of PUR foam composites has been analyzed. The use of 60 php as the filler reduced the hardness of the foams by approximately 30% and increased their comfort factor from 3 to 5.     

Nickel Wick by Continuous Freeze-Casting: Influences of the Particle Size on the Capillarity and Mechanical Properties

The aim of this work was to study the effect of the particle size range, the freeze casting temperature and sintering temperature on the capillarity performance and mechanical properties of Ni wicks manufactured by freeze-casting. The use of Ni/camphene-polystyrene suspensions creates wicks with an open porosity above 80% and average pore sizes of 38 μm to 17 μm by tailoring the particle size ranges and freezing temperatures employed. The incorporation of PS and the use of a continuous freeze-casting process reduces the particle sedimentation and generates a highly interconnected pore structure with regular pore sizes across the sample. The capillarity performances exhibit a fast and complete water adsorption, especially in Ni wicks freeze-casted at 10 °C and sintered at 800 °C, but only when the smaller particle size range is used do Ni wicks achieve sufficient mechanical strength.     

Thermal Insulation and Sound Absorption Properties of Open-Cell Polyurethane Foams Modified with Bio-Polyol Based on Used Cooking Oil

The main goal of this work was to evaluate the thermal insulation and sound absorption properties of open-cell rigid polyurethane foams synthesized with different contents of cooking oil-based polyol. The content of the applied bio-polyol as well as flame retardant (triethyl phosphate) in the foam formulation had a significant influence on the cellular structures of the materials. The open-cell polyurethane foams were characterized by apparent densities in the range 16–30 kg/m³. The sound absorption coefficients of the polyurethanes with various contents of bio-polyol were determined using the standing wave method (Kundt’s tube) in the frequency range of 100–6300 Hz. The effect of the content of the bio-polyol and flame retardant on the coefficient of thermal conductivity (at average temperatures of 0, 10 and 20 °C) as well as the compressive strength (at 20 and −10 °C) was analyzed. Different trends were observed in terms of the thermal insulation properties and sound absorption ability of the open-cell polyurethanes due to the addition of bio-polyol. In conclusion, it is necessary to use systems containing both petrochemical and bio-based raw materials.     

Sintering Temperature,Frequency, and Temperature Dependent Dielectric Properties of Na0.5Sm0.5Cu3Ti4O12 Ceramics

NSCTO (Na_0.5Sm_0.5Cu₃Ti₄O₁₂) ceramics have been prepared by reactive sintering solid-state reaction where the powder was prepared from the elemental oxides by mechanochemical milling followed by conventional sintering in the temperature range 1000–1100 °C. The influence of sintering temperature on the structural and dielectric properties was thoroughly studied. X-ray diffraction analysis (XRD) revealed the formation of the cubic NSCTO phase. By using the Williamson–Hall approach, the crystallite size and lattice strain were calculated. Scanning electron microscope (SEM) observations revealed that the grain size of NSCTO ceramics is slightly dependent on the sintering temperature where the average grain size increased from 1.91 ± 0.36 μm to 2.58 ± 0.89 μm with increasing sintering temperature from 1000 °C to 1100 °C. The ceramic sample sintered at 1025 °C showed the best compromise between colossal relative permittivity (ε′ = 1.34 × 10³) and low dielectric loss (tanδ = 0.043) values at 1.1 kHz and 300 K. The calculated activation energy for relaxation and conduction of NSCTO highlighted the important role of single and double ionized oxygen vacancies in these processes.     

Study of a Waste Kaolin as Raw Material for Mullite Ceramics and Mullite Refractories by Reaction Sintering

A deposit of raw kaolin, located in West Andalusia (Spain), was studied in this work using a representative sample. The methods of characterization were X-ray diffraction (XRD), X-ray fluorescence (XRF), particle size analysis by sieving and sedimentation, and thermal analysis. The ceramic properties were determined. A sample of commercial kaolin from Burela (Lugo, Spain), with applications in the ceramic industry, was used in some determinations for comparison purposes. The kaolin deposit has been produced by alteration of feldspar-rich rocks. This raw kaolin was applied as an additive in local manufactures of ceramics and refractories. However, there is not previous studies concerning its characteristics and firing properties. Thus, the meaning of this investigation was to conduct a scientific study on this subject and to evaluate the possibilities of application. The raw kaolin was washed for the beneficiation of the rock using water to increase the kaolinite content of the resultant material. The results indicated that the kaolinite content of the raw material was 20 wt % as determined by XRD, showing ~23 wt % of particles lower than 63 µm. The kaolinite content of the fraction lower than 63 µm was 50 wt %. Thus, an improvement of the kaolinite content of this raw kaolin was produced by wet separation. However, the kaolin was considered as a waste kaolin, with microcline, muscovite and quartz identified by XRD. Thermal analyses by Thermo-Dilatometry (TD), Differential Thermal Analysis (DTA) and Thermo-Gravimetry (TG) allowed observe kaolinite thermal decomposition, quartz phase transition and sintering effects. Pressed samples of this raw kaolin, the fraction lower than 63 µm obtained by water washing and the raw kaolin ground using a hammer mill were fired at several temperatures in the range 1000–1500 °C for 2 h. The ceramic properties of all these samples were determined and compared. The results showed the progressive linear firing shrinkage by sintering in these samples, with a maximum value of ~9% in the fraction lower than 63 µm. In general, water absorption capacity of the fired samples showed a decrease from ~18–20% at 1050 °C up to almost zero after firing at 1300 °C, followed by an increase of the experimental values. The open porosity was almost zero after firing at 1350 °C for 2 h and the bulk density reached a maximum value of 2.40 g/cm³ as observed in the ground raw kaolin sample. The XRD examination of fired samples indicated that they are composed by mullite, from kaolinite thermal decomposition, and quartz, present in the raw sample, as main crystalline phases besides a vitreous phase. Fully-densified or vitrified materials were obtained by firing at 1300–1350 °C for 2 h. In a second step of this research, it was examined the promising application of the previous study to increase the amount of mullite by incorporation of alumina (α-alumina) to this kaolin sample. Firing of mixtures, prepared using this kaolin and α-alumina under wet processing conditions, produced the increase of mullite in relative proportion by reaction sintering at temperatures higher than 1500 °C for 2 h. Consequently, a mullite refractory can be prepared using this kaolin. This processing of high-alumina refractories is favoured by a previous size separation, which increases the kaolinite content, or better a grinding treatment of the raw kaolin.