Spikes on Frit Castings

Credit: The Crucible.com

It is frequent to have castings from frit with spikes, needles, or prickles around the edges. 

Causes

These spikes result from the glass touching the edge of the mould or separator during the hottest part of the firing. The glass particles first begin to compact as the glass rises toward the fusing temperatures. As the temperature increases toward the casting temperature it begins to expand both horizontally and vertically from that compact mass. As it cools, the glass sinks down and retreats from the edge. This movement leaves some small bits of glass stuck to the sides. The glass contracts as it cools, leaving the spikes as it contracts from its hottest state. 

Avoidance

The usual recommendation is to mound frit in the middle and let it flow to the outside. Still, the glass flows to the outside of the mould at casting temperature and it touches the sides. Leaving the risk of creating spikes. Accurate measuring of the amount of glass to charge the mould with is important. With the right amount of glass, the mould will not be overfilled and so, reduce the spiking. 

Measuring the weight of glass for the mould is not difficult. In many cases, the manufacturer of the mould has done the work for you. If you need to calculate the weight of glass required for the mould, it is not difficult. A method is given here. In short, you use a dry fill of the mould. Measure the volume (using the metric system) and multiply by the specific gravity to get the weight in grams. 

Larger chunks of glass tend to produce fewer spikes than smaller frit. Usually longer soaks at top temperature are required to fully form the glass with smaller frit. It is also possible to drip glass into the mould from a pot suspended above the mould. Accurate measurement of the weight will still be important. But add 100gms/4oz. to the amount to allow for the glass that will stick to the pot.

My view is that with dams, it is better to use a straight sided shape with fibre cushioning around the outside. When annealed and cool, clean it well. Then fire polish with a slow ramp to 540°C/1000°F followed by a quick ramp to the fire polish temperature. This will polish the sides of the piece that were in contact with fibre paper.