Mechanical Strength of Enamelled Glass
Mechanical Strength of Enamelled Glass
(2016) 1:277–288
DOI 10.1007/s40940-016-0025-2
Received: 12 January 2016 / Accepted: 24 April 2016 / Published online: 13 May 2016
© Springer International Publishing Switzerland 2016
Abstract Enamelled glass has been used for many the influence of different parameters on the mechanical
years in architectural applications. It is well known that strength. Furthermore the results will be compared with
ceramic frits have a weakening effect on the mechan- the current values of the minimum bending strength
ical strength of thermally toughened glass. This fact given in the product standards.
is addressed in the relevant European product stan-
dards for thermally toughened (with or without heat Keywords Enamelled glass · Bending strength ·
soak test) and heat strengthened glass. In EN 12150- Colour · Manufacturing process
1 the minimum bending strength of thermally tough-
ened enamelled glass is given with σbB = 75N/mm2 1 General
and in EN 1863 for heat strengthened glass the value
is given with σbB = 45N/mm2 . The values are valid 1.1 Definitions
independently of the colour tint and the manufactur-
ing process of the enamel coating. As the experimental An enamel is a glass-like mass which is produced by
data for the current values were determined decades total or partial fusing principally consisting of oxides. It
ago and the background of these investigations is not is applied in one or several layers together with various
available anymore, a recent research project examined supplements to metallic or glass surfaces at temper-
influences of glass type, colour tint and the manufac- atures over 450 ◦ C (Krampe 2013, Technische Regel
turing process of the enamel by performing four point RAL-RG 529 A3 2007). The term “enamel” is used for
bending tests according to EN 1288-3. To compare the the final printed surface. The term “enamelling” is used
results with the non enamelled glass types the glass for the manufacturing process.
samples were taken from a single float glass batch. The
test results show the strength is mainly dependent on
the colour scheme, the thickness of the enamel and the 1.2 Colour scheme
temperature sequence of the fusing process itself. In the
paper some of the results will be presented especially Essentially the dye powder consists of the following
main components: flow system (70–95 %) and pig-
I. Maniatis (B)
ment system (5–30 %). After firing the transparent
Universität der Bundeswehr München, Neubiberg,
Germany and soft glass-flow surrounds the colour pigments con-
e-mail: [email protected] tained in the dye and binds these together permanently.
M. Elstner The adhesion to the glass results from ionic bondings
AGC Interpane, Plattling, Germany of the SiO groups (Krampe 2013). Table 1 lists the most
123
278 I. Maniatis, M. Elstner
important components for the colours examined in the The experimental data for the current values were
research project (black, red and white). determined decades ago and the scientific background
of these investigations is unknown. Up to now there
have been only a few systematic investigations exam-
ining the reasons for the reduction in strength (see
1.3 Strength Krampe 2013). In (Krampe 2013) following feasible
causes for the stress reduction are given:
From an architectural and manufacturer’s perspective • Differentials in thermal expansion coefficient
important considerations for enamelled glass are: aes- • Fineness of grind
thetics, function (i.e. use as solar-control glass with an • Firing penetration and porosity of the enamel
additional functional coating added to the enamelled • Leaching processes within the boundary layer of
surface), manufacturing process, visual assessment and the glass to the enamel
application. • Changes in thermal conditions during the firing
However for the proper dimensioning of the glaz- process
ing, the characteristic strength values of the glass types In (Krampe 2013) the thermal conditions during the
must be known. The values given in EN 12150-1 (EN thermal toughening process are examined in detail.
12150-1:2000-11) and EN 1863-1 (EN 1863-1:2012-
02) for enamelled thermally toughened safety glass
(fully toughened glass—FT) with or without heat soak 2 Manufacturing
test (HST) and heat strengthened glass (HS) have been
used for many years (see Table 2). The reduced val- 2.1 Colour application process
ues compared with those of non enamelled glass show
that such ceramic frits have a weakening effect on the There exist different processes for applying the colour
mechanical strength of thermally toughened glass. The on the glass surface. These are, essentially: roller coat-
values are independent of the colour tint and the man- ing, screen printing, digital printing, and “curtain” coat-
ufacturing process of the enamel coating. ing. Usually the enamel coating is applied on the “air
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Investigations on strength of enamelled glass 279
surface” of the float glass (that is to say, on the opposite Using the screen printing process the glass edges
side to the tin bath surface). During the thermal tough- generally remain paint-free but can display a slight
ening process of thermally toughened safety glass or bulging or beading of colour in the border area. If appli-
heat strengthened glass the ceramic coating is fused cations with visible edges are planned the manufac-
and firmly bound together with the glass. In Sect. 2.2 turer must be informed beforehand. With this process
these processes are described according to (BF-Bulletin it is possible to carry out multi-coloured printings: for
015 2014). example, a so-called “double screen printing” whereby
two different colours are recognizable on each pane-
2.1.1 Roller coating surface looked at. The manufacturer should always be
consulted on issues of tolerances (e.g. of congruency).
The flat glass plane is passed beneath a ribbed rubber The printing of selected patterned glass panes is also
roller which transfers the enamel paint onto the surface possible but, once again, the manufacturer should be
of the glass. This ensures a regular, even and homoge- consulted about it beforehand.
neous distribution of the paint across the entire surface
of the pane. Typically, the ribbed pattern of the roller 2.1.3 Digital printing
is visible if the pane is examined from up close (on
the enamelled side). Normally, however, these “ribs” The ceramic colour is applied directly onto the glass
are barely visible when the glass is observed from the surface using a process which is comparable to an
front side (looking through the pane). Furthermore, inkjet printer. The thickness of colour application can
a so-called “starry sky” effect (numerous very small vary and is generally thinner than using roller coat-
imperfections) can sometimes emerge in the enamel. ing, screen printing or “curtain” coating processes. It
Due to the nature of this application process a cer- appears, depending on the colour chosen, either opaque
tain “colour overrun” is possible on all edges of the or translucent. A high print resolution of up to 720
pane, this overrun can be slightly corrugated especially dpi is possible at present. Typical for this manufactur-
on longitudinal edges (viewed in the direction of the ing process are minor visible stripes in the direction
movement of the roller unit). The edge surface, how- of printing which are unavoidable due to the produc-
ever, remains, as a rule, paint-free. For this reason, the tion technique. Using the digital printing process the
manufacturer should be consulted beforehand about the glass edges generally remain paint-free but can display
position of installation. Usually roller printed enam- a slight bulging or beading of colour in the border area.
elled glasses are not suitable for vision glass applica- If applications with visible edges are planned the man-
tions, if so these must always be discussed with the ufacturer must be informed beforehand. The printing
manufacturer beforehand. edges are, in the direction of printing, exactly straight
but are, transversal to the print direction, slightly ser-
2.1.2 Screen printing rated. A certain paint spray may also occur along the
printing edges. In the case of dot-, hole- and text-
In contrast to the printing process just described, within motifs the printing edges may display a serration which,
this process the paint can either be applied across the like the mentioned spray, is only visible if the pane is
entire surface or, alternatively, in defined areas. The examined from up close. Above all the digital print-
colour is applied to the glass surface on a horizon- ing process is suitable for complex multi-coloured grid
tal screen printing frame through a narrow-meshed designs or for images. It is less suitable for mono-
screen using a flood bar. The thickness of paint applied chrome printing across the entire surface of a glass
depends on the breadth of the screen’s meshes and on pane.
the thread diameter. However the paint application is
generally thinner than using roller or “curtain” coating 2.1.4 “Curtain” coating
and appears, depending on the colour chosen, either
opaque or translucent. Typical for this manufacturing The glass pane passes horizontally a so-called “curtain”
process are minor stripes both in the direction of print- and its entire surface becomes covered with colour. By
ing and also transversal to this direction, as well as adjusting the quantity of paint poured out and the speed
certain occasionally occurring spots of haze. with which the pane passes through the “curtain”, the
123
280 I. Maniatis, M. Elstner
thickness of the coating can be controlled within a rela- ing which products need to be applied in which per-
tively wide range. In case of a slight uneven pouring lip centages.
stripes of various degrees of thickness in longitudinal
direction (direction of pouring) can be caused. Vision
glass applications must always be discussed with the 2.2 Fusing process
manufacturer beforehand. The “colour overrun” at the
edges is significantly greater than in the case of roller At a furnace temperature of approximately 620–720 ◦ C
coating and can only be avoided through great effort. If (corresponding to glass temperatures of approximately
paint-free visible edges are wanted, this must be spec- 620–660 ◦ C) the ceramic colour is fused into the glass.
ified when placing the order. The total fusing cycle required amounts to approxi-
mately 40 s per millimetre of glass thickness. For proper
fusing an oxidizing atmosphere in the furnace must be
2.1.5 Summary maintained.
Should the enamel prove to be porous after the fusing
Depending on the chosen application process the process, for example due to unfavourable fusing condi-
colours need to have different viscosities. For roller tions, it can lead to a negative influence on the weather
coating, for example, more liquid colours are required resistance, the chemical stability and the mechanical
(i.e. with a higher organic part). Correspondingly each strength of the enamelled glass. In (Technical Informa-
different application procedure will require a differ- tion Ferro 2012) several possible ways of avoiding this
ent drying time. After the application of the colour the are listed:
printed pane has to be dried (at a temperature of approx-
• Improving the drying of the enamel coating before
imately 170–190 ◦ C). Then the pane is thermally tough-
fusing to optimise the burning of the organic
ened and at the same time the enamel coating is fused
medium
onto the surface of the glass.
• Increasing the quantity of energy available for the
As already mentioned depending on the chosen man-
fusing of the colour into the glass by optimising the
ufacturing process different thicknesses of the enamel
fusing conditions (raising of the temperature) or
coating will result (see Fig. 1).
• Lowering the fusing temperature of the glass
The colour systems currently available are capable
enamel by admixture of some transparent flow-
to represent a large number of colours, like for exam-
system
ple those of RAL and NCS chart of colour range. In
order to achieve a specific colour the manufacturers of The enamel produced in this way will be scratch-proof
such colour systems provide recommendations regard- as well as weather, UV and solvent resistant.
3 Quality control
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Investigations on strength of enamelled glass 281
100
95
90
85
80
[N/mm²]
75
HS screen_black
70
HS screen_white
bB
65 HS screen_red
HS_Ref
60
55
50
45
40
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
wmax [mm]
Fig. 2 Results for series ‘HS glass with screen printing on side exposed to tensile bending stress’. (Color figure online)
123
282 I. Maniatis, M. Elstner
100
95
90
85
80
[N/mm²]
75
HS roller_black
70
HS roller_white
bB
HS roller_red
65
HS_Ref
60
55
50
45
40
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
wmax [mm]
Fig. 3 Results for series ‘HS glass with roller coating on side exposed to tensile bending stress’. (Color figure online)
Screen printing Surface under Normal distribution (confidence level 54.99 69.38 47.27
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 61.63 81.29 59.10
Standard deviation 2.31 4.14 4.12
Roller coating Surface under Normal distribution (confidence level 38.39 58.36 55.32
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 46.66 66.43 59.95
Standard deviation 2.88 2.81 1.38
The results can be summed up as follows: 4.2.2 Thermally toughened (fully toughened—FT)
glass series
• The reference samples show a high dispersion of
failure stresses despite the sprinkling with corun- In Figs. 4 and 5 the failure stress values are given for
dum. each manufacturing process. Also shown are the fail-
• For the reference samples the mean value of the ure stress values for the un-enamelled reference sam-
tensile bending strength is 70.4 MPa and the frac- ples. The statistical evaluation of all series is listed in
tile value 51.9 MPa (confidence level 95 %, fractile Table 4.
5 %). The results can be summed up as follows:
• Enamel on the side exposed to tensile bending • For the reference samples the mean value of the ten-
stress: Except for the “roller coating, black” series, sile bending strength is 145.7 MPa and the fractile
the minimum bending strength of 45 MPa was value 127.2 MPa (confidence level 95 %, fractile
reached for all other colours and manufacturing 5 %). The minimum bending strength of 120 MPa
processes. for FT was reached.
123
Investigations on strength of enamelled glass 283
155
150
145
140
135
130
σbB [N/mm2]
125
FT screen_black
120 FT screen_white
FT screen_red
115 FT_Ref
110
105
100
95
90
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
wmax [mm]
Fig. 4 Results for series ‘FT glass with screen printing on side exposed to tensile bending stress’. (Color figure online)
155
150
145
140
135
130
σbB [N/mm2]
125
FT roller_black
120 FT roller_white
FT roller_red
115 FT_Ref
110
105
100
95
90
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
wmax [mm]
Fig. 5 Results for series ‘FT glass with roller coating on side exposed to tensile bending stress’. (Color figure online)
123
284 I. Maniatis, M. Elstner
Screen printing Surface under Normal distribution (confidence level 105.02 119.34 95.63
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 110.89 133.05 109.34
Standard deviation 2.04 4.77 4.77
Roller coating Surface under Normal distribution (confidence level 85.28 103.36 99.24
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 98.46 113.96 110.08
Standard deviation 4.59 3.69 3.77
• Enamel on the side exposed to tensile bending (duration, temperature) which can have an influence
stress: For all colours and manufacturing processes on the bending strengths. In order to determine the
a minimum bending strength higher than 75 MPa influence of the individual parameters, the colour com-
was reached. positions and the fusing parameters would need to be
known. On this basis the thermal processes could be
4.2.3 Thermally toughened and heat soaked numerically simulated and optimised.
(FT-HST) glass series The samples with thinner enamel coating (screen
printing, approximately 45 μm coating thickness) tend
In Figs. 6 and 7 the failure stress values are given for to have greater strengths than thicker coatings (roller
each manufacturing process. Also shown are the failure coating, approximately 75 μm coating thickness). To
stress values for the un-enamelled reference samples. give a more precise statement, coatings of greater thick-
The statistical evaluation of all series is listed in Table 5. ness would need to be tested.
The results can be summed up as follows: The tensile bending strengths ascertained for enam-
elled glass panes are, in some cases, significantly
• For the reference samples the mean value of the ten- greater than the minimum bending strengths specified
sile bending strength is 134.4 MPa and the fractile in the product standards (enamel on the side exposed to
value 126.5 MPa (confidence level 95 %, fractile tensile bending stress), especially the enamel coatings
5 %). The minimum bending strength of 120 MPa produced by screen printing.
for FT was reached. However to use these greater bending strengths as
• Enamel on the side exposed to tensile bending characteristic strength values for dimensioning of the
stress: For all colours and manufacturing processes glazing more precise parameters would need to be
a minimum bending strength higher than 75 MPa established regarding, for example, manufacturing and
was reached. fusing processes, colour tint and colour composition
and coating thickness. The reproducibility of these
4.2.4 Summary of results parameters would also have to be proven, e.g. within
the framework of a National or European Technical
The colours investigated in the present research project Approval.
(black, red, white) and the application processes (screen
printing, rolling coating) lead to different tensile bend-
ing strengths. A result which is to be traced back essen- 4.3 Fracture mirror analysis
tially to the different colour compositions of the enam-
els (different size of the colour grains, viscosity of the 4.3.1 General
dyes, percentage of flow system, which vary depending
on the manufacturing process) as well as the different The structure and appearance of the fracture surfaces
thicknesses of their coatings. These factors lead to dif- allow for statements on the nature and size of the frac-
ferent parameters in the fusing or tempering process ture as well as on the resulting failure stresses. For this
123
Investigations on strength of enamelled glass 285
155
150
145
140
135
130
125
σbB [N/mm2]
100
95
90
85
80
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
wmax [mm]
Fig. 6 Results for series ‘FT-HST glass with screen printing on side exposed to tensile bending stress’. (Color figure online)
155
150
145
140
135
130
125
σbB [N/mm2]
120
FT-HST_roller_black
115 FT-HST roller_red
110 FT-HST roller_white
FT- HST_Ref
105
100
95
90
85
80
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
wmax [mm]
Fig. 7 Results for series ‘FT-HST glass with roller coating on side exposed to tensile bending stress’. (Color figure online)
123
286 I. Maniatis, M. Elstner
Screen printing Surface under Normal distribution (confidence level 100.33 113.59 98.08
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 105.33 121.58 104.94
Standard deviation 1.74 2.78 2.38
Roller coating Surface under Normal distribution (confidence level 79.06 81.23 88.11
tension 95 %, 5 % fractile) (MPa)
Mean value (MPa) 93.01 94.92 98.01
Standard deviation 4.85 4.76 3.44
mirror
mist
hackle
123
Investigations on strength of enamelled glass 287
hackle
Sample: HS glass, screen printed, red Sample: HS glass, screen printed, white
Tensile bending stress experimetally determined: 86.7 MPa Tensile bending stress experimetally determined: 58.1 MPa
123
288 I. Maniatis, M. Elstner
123