Innovative low-melting glass compositions containing fly ash and blast furnace slag

The investigation of new glass compositions is crucial to expand the possible applications of glass, from the typical applications for building engineering, in the form of cast blocks or floated glass, to more advanced technologies, such as 3D-printed glass or glass to metal connections. Despite the intense research activity and new glass compositions being investigated every day, there has been little innovation or evolution in the composition of architectural glass. This is partially explained by the fact that a substantial part of glass research is not relevant to practical large-scale applications. This thesis is more concerned about the development of compositions with optimized properties than the studies of the short- and intermediate-range structure of a theoretical glass that would hardly find a practical application. Thus, these compositions are inexpensive and appropriate to mass production, utilizing conventional melting techniques. Since the high melting temperatures and the brittleness are two important drawbacks of glass, this work aims to improve both properties. The modification of the properties is achieved via changes in the composition of the glass, using compounds such as phosphorus pentoxide, aluminium oxide and boron oxide. Then, the choice of different glass formers and modifiers contributes to the development of compositions with lower melting and glass transition temperatures. The reduction of the melting temperature allows a saving of energy during the manufacturing and recycling processes. The structures of the glasses differ from the standard soda-lime and borosilicate glasses, leading to a different mechanical behaviour. For instance, an anisotropic structure, which could exhibit a better mechanical performance than standard glasses. Furthermore, these new compositions incorporate up to 35% of slag and fly ash in their formulas. The valorization of these by-products that would otherwise have been previously discarded reduces costs and gas emission. The developed compositions have high water resistance, amorphous structure proved by x-ray diffraction and indentation toughness comparable to a standard soda-lime glass. The coloration of the samples varies depending on the composition and, for the samples containing slag, depending on the melting temperature. In this case, melting at higher temperatures allows the production of colorless glass. The color of the glasses is mainly influenced by the presence of sulfur and iron oxide. In conclusion, this thesis describes the development of new glass compositions containing fly ash and slag. The focus of the work is on the improvement of the properties and a comparison of performance of these new compositions with the glasses currently used in building engineering. The promising results point to the possibility of expansion of the current applications of glass.