A high sintering temperature is required to acquire excellent performance in the production of porcelain but results in high fuel consumption. To prepare the porcelain with outstanding performance at a lower temperature, a self-produced additive containing calcium (CaK) was added into a three-component system of kaolinite–feldspar–quartz. XRD and SEM were used to characterize the samples. The toughening mechanism and Gibbs free energy were investigated. After introducing the CaK, the bending strength of the porcelain fired at 1513 K increased from 56.32 ± 0.65 MPa to 95.31 ± 0.63 MPa, which was 21.83% higher than that of the porcelain without CaK at an optimal firing temperature of 1603 K. The main crystal phase of the sample comprised mullite and quartz in the raw materials at 1453~1603 K. The anorthite was observed at 1453 K and interlocked with needle-shaped mullite at 1513 K in the porcelain after adding CaK, which resulted in the higher bending strength. Quantitative analysis indicated that the amount of anorthite decreased at 1513 K and disappeared at 1543 K; the amount of mullite increased with temperature. The Gibbs free energy of the reaction (CaO•Al₂O₃•2SiO₂ + 2(Al₂O₃•2SiO₂) → 3Al₂O₃•2SiO₂ + CaO + 4SiO₂) at high temperature was negative, which suggested that the formation of mullite (3Al₂O₃•2SiO₂) from anorthite (CaO•Al₂O₃•2SiO₂) was possible. These findings implied that the addition of CaK contributed to the appropriate phase composition and microstructure, and the excellent performance of the porcelain at a lower temperature. In addition, the transformation between anorthite and mullite was possible in the special raw material system. The results are of interest in producing anorthite/mullite ceramics at reduced sintering temperatures and the conversion between anorthite and mullite.

The molecular clusters ((HO)₃Si-O-Si(OH)₃ and (HO)₃Al-O-Si(OH)₃) representative of aluminosilicate mineral surface were employed to study the dissolution of aluminosilicate in acidic condition via density functional theory (DFT) with the M06-2X+G(d,p) methodology. The surface termination sites (Si and Al) were both tetra-coordinated and the terminal oxygen was protonated in an acidic condition. In the dissolution reaction, the calculated barrier height of the six-membered ring transition state complex containing two water molecules was predicted to be 76.13 kJ/mol, lower than that of the four-membered ring transition state complex containing one water molecule. The barrier height of the reaction decreased to 6.17 kJ/mol and was 91.90% lower than that for the Si_ter-O-Si without protonation. In addition, the calculated barrier heights for Al-terminated sites were predicted to be 22.23 kJ/mol, lower than those for the Si-terminated sites, suggesting that breaking the Al-O bond is easier than the Si-O bond in the aluminosilicate mineral surface. With the fracture of Si-O and Al-O bonds, the Si and Al release from the aluminosilicate. The results indicate that the acidic condition facilitates the release of Si and Al from the aluminosilicate, and the concentration of Al leaching from the aluminosilicate is higher than the Si.