ABSTRACT

 

This research was experimental in approach. It went through the process of gathering of materials from different locations, iron filings from Buniyaminu Engineering workshop at “Randa Kano” area in Zaria, Kaduna State, Kankara kaolin from Kankara in Katsina State while ball clay was obtained from Bomo village in Zaria, Kaduna State. The materials were processed for workability, iron filings were subjected to sieve analyses into three aggregate sizes of 1.18mm, 600μm, and 300μm. Kaolin and ball clay were soaked in 50/50 percentage in water for two weeks after which they were blunged together and sieved. Iron filings of the three aggregate sizes and the un-sieved were blended into clay in varying percentages in form of test slabs, while four other slabs without iron filings were made to serve as control. Throwing test was carried out to check the throwing ability of the clay with iron filings. Test Firing was carried out between 800oC – 1100oC to determine the suitable temperature that enhanced favourably on speckle effects of iron filings on clay body. The results showed that it was possible to throw wares from clay containing iron filings. The body with iron filings shrank less as compares to the body without iron filings. The firing temperature of 1000 was found most suitable for achieving the most speckle effects of iron filings in clay body.

 

TABLE OF CONTENTS

Chapter Pages
Title page ………………………………………………………………………………………… i
Declaration ……………………………………………………………………………………… ii
Certification …………………………………………………………………………………….. iii
Dedication ………………………………………………………………………………………. iv
Acknowledgement ………………………………………………………………………………..v
Abstract …………………………………………………………………………………………..vi
Table of Content …………………………………………………………………………………vii
List of Figures ……………………………………………………………………………………xii
List of Tables …………………………………………………………………………………….xiii
List of Plates ……………………………………………………………………………………xiv
List of Appendices ………………………………………………………………………………xvi
Definition of Operational Terms ………………………………………………………………xvii
Abbreviations …………………………………………………………………………………xviii
Signs and Chemical Symbols …………………………………………………………………xviii
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CHAPTER ONE INTRODUCTION
1.0: Introduction…………………………………………………………………………………… 1
1.1: Background of the Study……………………………………………………………………..2
1.2: Statement of the Problem……………………………………………………………………..2
1.3: Aim of the Study…………………………………………………………………………………3
1.4: Objective of the Study ……………………………………………………………………….3
1.5: Research Questions…………………………………………………………………………….4
1.6: Delimitation of the Study……………………………………………………………………..4
1.7: Limitation of the Study ………………………………………………………………………………………………4
1.8: Justification of the Study……………………………………………………………………..4
1.9: Basic Assumptions …………………………………………………………………………………………………….5
1.10: Significance of the Study. …………………………………………………………………………………………6
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CHAPTER TWO LITERATURE REVIEW
2.1: Introduction …………………………………………………………………………………..7
2.2: Clay ……………………………………………………………………………………………7
2.3: Clay Body ……………………………………………………………………………………9
2.3.1: Earthenware Clay. …………………………………………………………………………11
2.3.2: Stoneware Clay. …………………………………………………………………………..12
2.3.3: Kaolin…… ………………………………………………………………………………..12
2.3.4: Secondary Clay ……………………………………………………………………………14
2.3.5: Fire Clay …………………………………………………………………………………. 15
2.4: The Nature of Iron…………. ……………………………………………………………………16
2.4.1: Cast Iron …………………………………………………………………………………..16
2.4.2: Iron as Additive………………………………………………………………………………18
2.5: Particle Size Distribution Analyses ……………………………………………………….. 19
2.6: Decorative Art …………………………………………………………………………………20
2.6.1: Burnishing …………………………………………………………………………………20
2.6.2: Screen Printing …………………………………………………………………………… 21
2.6.3: Agateware ……………………………………………………………………………….. 22
2.6.4: Magnificent Marbling;…………………………………………………………………………………………..22
2.6.5: Terra Sigillata ………………………………………………………………………………………………………23
2.6.6: Under Glaze ……………………………………………………………………………………………………….. 24
2.6.7: Glaze …………………………………………………………………………………………………………………. 24
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CHAPTER THREE METHODOLOGY
3.1:Introduction ……………………………………………………………………………….. 26
3.2: Population of the Study ……………………………………………………………………..26
3.3: Sampling ……………………………………………………………………………………26
3.4: Chemical Analyses …………………………………………………………………………26
3.5: Treatment and Processing of Raw Materials ……………………………………………….27
3.5.1: Kankara Kaolin and Bomo Clay ………………………………………………………….27
3.5.2: Iron Filings ………………………………………………………………………………..27
3.6: Ratio of Stone Ware Clay and Iron Filings in Grams/ Size of Slabs ……………………….30
3.6.1: Composition of Test Slabs ………………………………………………………………..30
3.6.2: Firing of Test Slabs ……………………………………………………………………….34
3.6.3: Shrinkage Test at Fired Stage of Test Slabs ………………………………………………34
3.7: Throwing Test ………………………………………………………………………………36
3.8: Choice of Blend and Firing Temperature used …………………………………………………..36
3.9: Production …………………………………………………………………………………..36
3.10: Drying and Firing of Decorative Wares …………………………………………………..42
xi
CHAPTER FOUR RESULTS AND DISCUSSIONS
4.0: Results and Discussions …………………………………………………………………….43
4.1: Introduction …………………………………………………………………………………43
4.2: Forming of Test Slabs ………………………………………………………………………43
4.2.1: Drying of Test Slabs ………………………………………………………………………43
4.2.2: Effects of Experimental Sample Slabs Fired at 800oC ……………………………………44
4.2.3: Effects of Experimental Sample Slabs Fired at 900oC……………………………………44
4.2.4: Effects of Experimental Sample Slabs Fired at 1000oC ………………………………….44
4.2.5: Effects of Experimental Sample Slabs Fired at 1100oC…………………………………..44
4.3: Result of Throwing Test……………………………………………………………………47
4.4: Result of Shrinkage Test ………………………………………………………………………………59
4.5: Choice of Blend and firing Temperature Employed in Making Decorative Wares…………60
4.6: Production of Decorative Wares……………………… ……………………………………60
xii
CHAPTER FIVE
5.0: Summary of Findings, Conclusion and Recommendations …………………………………68
5.1: Introduction …………………………………………………………………………………68
5.2: Findings ……………………………………………………………………………………68
5.3: Summary and Findings …………………………………………………………………………………………….70
5.4: General Recommendation ………………………………………………………………….71
5.5: Recommendation for Further Studies ………………………………………………………71
References ……………………………………………………………………………………….73

 

 

CHAPTER ONE

1.0 INTRODUCTION
The concept of design seems to have found its way into the making of ceramics for daily use and it is necessary as well as consistent with the aesthetic needs of today’s society. It represents a thought-shift of modern society and is consistent with the developmental speed of modern society. In the design and decoration of ceramics for daily use, the decorative pattern design should be achieved using a number of design techniques. Not only do these designs arouse visual impressions, they also impart emotional responses to their consumers.
According to Freebies (2013), decorating ceramics is one of the most rewarding aspects of working in clay. It is the time when you can add colour and life to a bare clay surface that can show off your creative talents. There are scores of decorating techniques available and here are five successful techniques that are sure to add that extra flair to your work that will make it a masterpiece. Five Great Pottery Decorating Techniques: A how-to guide for decorating ceramics with slip transfers, Chinese brush techniques, ceramic slip, sgraffito, and more explains the ins and outs of these ever-popular ceramic decorating techniques!
The first use of platinum for the decoration of ceramics was as a so-called silver lustre over a brown earthenware body. Although it was only discovered in the middle of the eighteenth century, sufficient was already known about the properties of platinum for it to come into commercial use as a ceramic decorating medium by the end of that century. This took place in the English Potteries of Staffordshire. (Wynn, 1959).
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The idea of decorative ceramics is one that has taken a large portion of productions in the specialization, whether tableware or decorative, all have elements of aesthetics depending on how it is put into use. Decorative ceramics which are of different shapes and styles includes ; vases, jars, planters, storage jars, tiles of different types to mention but a few. To make decorative wares, one has to decide on the suitable body and decorative technique that will suit one’s purpose.
1.1 Background of the Study
The world is changing, as the human race advances and as a result, the urge and tastes for improved ways of life keep emerging. This has brought about innovations and improvements in ideas which cover the entire spheres of the human life. According to Webster (2011) “innovation is an improvement to something already existing”. The idea of innovation is important in whatever field including ceramics for the advancement of the specialization. A ceramist is at liberty to manipulate clay bodies to suit his purpose for either aesthetics or function or both. The driving force behind this research is predicated on the above purpose engaging iron filings as the motivator.
Peterson (2011) views clay body as the actual clay mixture that is used in forming objects. It may have one specific type of clay in it, but it is more likely to consist of a mixture of different types of clay. Other additives may also be introduced into the mixture and each specific material used is included to give the clay a particular attribute. For example, materials may be added to aid plasticity, to lower or raise the clay body’s maturing temperature, or change its fired coloration. Iron filings was used here as an experimental additive to explore the possibilities of achieving both decorative and functional vessels. Iron filings was anticipated to give a unique outcome on clay body for decorative effects when fired to suitable temperature. The need for
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advancement becomes important especially when there are locally sourced materials that could possibly be incorporated into the clay body for decorative effects.
1.2 Statement of the Problem
Iron filings which are a by-product in the Engineering field, is got as a result of grinding, filing and reconditioning of problematic motor engine blocks in order to make them work well. The material comes in different aggregate sizes in semi-powdered form and it is grey in colour. It is sometimes used in glaze formulation as flux which lowers the glaze maturing temperature. It was perceived that iron filings when mixed into clay body should have a unique effect on the body.
The problem of this study is that iron filings has not been exhaustively used in ceramics for decorative effects in clay bodies aside the use in glazes as oxide and flux. This leaves a gap of decorative possibility of these filings. The feasibility of utilizing cast iron filings in clay body for the production of decorative ceramics should fill the gap.
1.3 Aim of the Study
The aim of the study is to utilize cast iron filings from in clay body for the production of decorative ceramics in order to create a unique decorative technique different from those been used frequently by potters and ceramists in Nigeria
1.4 Objectives of the Study
In actualizing the aim of this study, the following objectives were pursued:
1. Sieve iron filings into different aggregate sizes
2. Blend iron filings into varying proportion with clay body in form of test slabs
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3. Fire at a temperature of 800oC – 1100oC so as to determine suitable temperature to enhance speckle effects
4. Conduct shrinkage test on the test slabs
5. Produce decorative wares through throwing method of production from compositions with best result
1.5 Research Questions
1. What sizes of Tyler meshes will be suitable for screening the iron filings ?
2. In what proportion and clay body is Iron filing intended to be blended with?
3. To what temperature ranges will samples be fired ?
4. In what way will the shrinkage of clay and iron filings be ascertained ?
5. What method of production will be suitable for the wares?
1.6 Delimitation of the Study
This study is delimited to incorporating iron filings from Buniyaminu Engineering workshop, Randa Kano area Zaria, Kaduna State, ball clay from Bomo-Zaria, Kaduna State and kaolin from Kankara, Katsina State into a clay body for possible production of decorative ceramics.
1.7 Limitation of the Study
This study had its limitation in the area of compositions for production on the potter’s wheel. The compositions that had 15% and 20% iron fillings in clay body for throwing on the wheel became injurious to the hands as a result of the high amount and coarseness of the aggregate size of iron filings, in addition to the extra pressure that was needed to be inserted before such compositions could be centered on the wheel. This therefore is not advisable to be used on the wheel.
1.8 Justification of the Study
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“Decorative ceramics wares are items that appeal to the human sense when viewed. This is as a result of the decorative content and technique employed in the making of such wares. When one thinks of finished pots, one tends to think first of pots covered in richly colored, shiny glazes. But is that the only possibility?” (About. com pottery 2014).
In ceramics, there are several ways of decorating the pieces to appeal to the ever-increasing human aesthetic senses. In other to sustain the interest generated by decorative ceramic wares and probably increase it, there is need for more innovations to decorative techniques. It is from this frame of mind that the thought of this research work came about, so as to be able to try a different material and approach that based on existing literatures, have not been used for decorative technique of this nature.
According to lake side pottery (2014), clay shrinks both in drying and in firing. Different clay bodies shrink at different rates which can be as little as 4%, or as much as 15%. Even one percentage point can make a difference in the final product depending on the need for precision. While Aluwong (1988) reveals that Kankara kaolin has shrinkage rate of 14.5%, Bomo clay has 11% shrinkage. The presence of iron filings in the adopted clay body should serve as remedy (opener) to the high shrinkage rate of the body.
1.9 Basic Assumptions
The research is based on the following assumptions:
1. That iron filings will have decorative effect on ceramic wares (speckle)
2. That iron filings will reduce the shrinkage rate of the existing clay body
1.10 Significance of the Study
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This research is significant in the areas of education, economic, technological, and aesthetic developments of ceramics. Educationally, the uniqueness of blending clay and iron fillings will serve as reference material for ceramic artists in an attempt to develop more aesthetic clay bodies. Aesthetically, the speckle effects of iron filings on clay body further enhances the beauty of ceramic products in a unique way to satisfy higher emotions. Technologically, possibilities of incorporating iron filings in clay body formulation for the production of decorative ceramics will be converting a bi-product (waste) in the engineering field into a useful material in the ceramic specialization area.
While economically, the introduction of a foreign material (iron filings) and its unique effect is expected to create a new outlook in terms of its finishing and beauty. Perhaps this new outlook will be an added advantage that will promote marketability of ceramic products.

 

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