Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.

Abstract: A precursor batch composition that can be used to make porous ceramic articles is provided. The batch composition includes a cellulose-based polymer and, in particular, a methylcellulose showing a specified micro-calorimetry thermal response fingerprint. The methylcellulose can also have a cloud point above a specified temperature.

Abstract: The disclosure relates to methods for determining mixedness of batch material for making ceramic ware, and methods for obtaining substantially consistent mixedness of batch material for making ceramic ware.

Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.

Abstract: A method of manufacturing porous ceramic articles is provided that includes forming a plurality of extruded green bodies from a ceramic precursor batch composition. The method also includes firing the extruded green bodies in a tunnel kiln to produce porous ceramic articles, periodically determining a shrinkage characteristic of at least one sample passing through the tunnel kiln, and adjusting a top soak temperature in the kiln if the shrinkage characteristic is outside of a predetermined range.

Abstract: Systems and methods for real-time, closed-loop shape control of extruded ceramic honeycomb structures are disclosed. Methods include extruding batch material through an extruder barrel and through an extruder die using at least one extrusion screw to form the extrudate, and measuring a shape of the extrudate immediately adjacent the die. The batch material water content is determined or measured, at least one of the extruder barrel and screw temperature are measured, and the extrusion screw rotation rate are measured. At least one of the batch material water content, barrel temperature, screw temperature and rotation rate is adjusted to maintain the extrudate shape to within a select tolerance.

Abstract: Methods and apparatus for making ceramic honeycombs by steps including compounding a plasticized ceramic batch mixture and forming the mixture into ceramic honeycombs by continuous extrusion, drying and firing, wherein one or more ceramic powders for the batch mixture are supplied by in-line homogenization as a powder feed having a median particle size D50 that varies from a maximum value to a minimum value by an amount not exceeding 15% of the maximum value during a 24-hour period of continuous extrusion.

Abstract: A method of making ceramic bodies having reduced shape variability. Such ceramic bodies include extruded-to-shape substrates and diesel particulate filters. Principal components analysis is used to generate a small number of uncorrelated or independent components from a larger set of inter-correlated measurements. The uncorrelated components can then be used during the forming process to control the shape of ceramic bodies and reduce variability of such shapes. A method for quantifying and subsequently reducing the shape variability of is also described.

Abstract: The disclosure relates to methods for making aluminum titanate-containing ceramic bodies, and methods for predicting shrinkage and minimizing shrinkage variability of said bodies from target size.

Abstract: A method for controlling the dimensional shrinkage or growth of AT honeycomb structures during the firing process by control of the alkali metal ion content in the AT-forming batch materials extruded into an AT green body structure that is heated to form the fired AT honeycomb structure.

Abstract: Methods for making extruded ceramic products meeting set dimensional specifications comprise subjecting a small firing sample taken from a first unfired product preform to a rapid firing treatment to determine a value for firing shrinkage or growth, and then adjusting the dimensions of succeeding unfired preforms based on that value, e.g., by adjusting wet extruded product dimensions, so that the succeeding preforms will meet the set dimensional specifications.

Abstract: A method for reducing shrinkage variability of ceramic honeycombs formed from batch mixtures including inorganic materials and a pore former. X is a cumulative amount of pore former particles having a diameter less than 37 ?m. There is a maximum value of X (Xmax) and a minimum value of X (Xmin) during a production period, and ?X=Xmax?Xmin. The method fixes an amount of pore former fines such that X ranges from 25%-71% by volume, and ?X is ?23% throughout the production period.