Enhancement of Belle Fourche Shale (BFS)-based Ceramics via Cellulose Fiber Addition — 86p — Brandon Stuber, Dr. Jon Kellar

Belle Fourche Shale (BFS) is a Cretaceous-Era bentonitic shale deposit located in ND, SD, WY, and MT. Due to the high water content required for hydration, the material experiences critical failures and significant shrinkage during the drying and firing processes. Chemical additions proved effective in mitigation of cracking but results in the clay becoming too sticky to mold into bricks and pottery clay, the goal of this project. Fiber additives, which have been utilized in the arts for roughly 50 years to reduce breakage and weight, were the focus of this research. Results of paper BFS clay and plain BFS clay samples for Scanning Electron Microscopy, X-Ray Diffraction, Differential Scanning Calorimetry, Micro-Computed Tomography, and mechanical testing were compared to determine the efficacy of small-scale fiber additions to shale-based ceramics. It was determined that the fibers make no chemical difference to the ceramic, but instead physically hold the clay together until they decompose during the firing process. This sintering behavior leaves microscopic pores in the ceramic that allow for greater thermal shock resistance without reducing the capacity to hold water. Ultimately, this research would provide a use for an untapped natural resource as well as opening the door for further development of shale-based ceramics.

South Dakota Mines
Dr. Jon Kellar