R&D at KMC: Inside the Labs
At Kyanite Mining Corporation, our quality control (QC), refractory, and investment casting labs support a wide range of testing, analysis, and troubleshooting efforts.
These labs help us evaluate materials, test customer mixes, and better understand how products behave in different applications and operating conditions.
The labs are backed by a highly experienced team specializing in refractory technology, investment casting processes, quality control systems, and materials characterization.
Our Team
Our R&D team includes Ceramic Engineer Steven Ashlock, our Technical Director and Vice President of Sales and Marketing, QC and Special Projects Manager Mike Morris, QC Lab Manager and Mining Engineer Thomas Huddleston, and QC lab team members Lisa, Vernon, Jane, and Campbell. North American Sales Manager Jeromey Wheeler also supports our R&D partnerships.
The QC Lab
The QC lab serves an important role in both day-to-day operations and ongoing R&D efforts.
This is where we handle routine quality checks like particle sizing and magnetic testing on samples. We utilize Ro-Tap machines, air sieves, and laser particle size analysis to help better understand the particle size distribution of our materials.
The lab also houses x-ray equipment that helps us better understand chemical and mineral composition. Using XRF (X-ray fluorescence) testing, we can evaluate the chemistry of our products and other materials, while XRD (X-ray diffraction) testing helps identify mineral phases within a sample, including the percentage of kyanite in an ore body.
These tools are also important when troubleshooting issues with finished materials. By analyzing mineral and glassy phases within a sample, we can often identify what may have gone wrong during processing or use.
The Refractory Lab
The refractory lab is where we test refractory mixes and evaluate how materials respond under different conditions.
Here, we press refractory bricks, make castables, and test formulations using ASTM C08 refractory testing guidelines. We also maintain a large inventory of raw materials commonly used throughout the refractory industry, which allows us to evaluate different formulations and adjustments side by side. The lab also includes milling capabilities for grinding samples to match sizes we don’t have in inventory.
The lab includes a high-temperature furnace capable of reaching 1,700 degrees C, along with equipment CCS (cold crushing strength) testing. We also evaluate properties such as density, porosity, thermal shock resistance, slag resistance, and alkali attack to better understand how materials hold up in different environments.
Other testing performed in the refractory lab includes permanent linear change (PLC) testing to measure how a material shrinks or expands after firing, along with vibration studies on castables to help optimize water levels in refractory mixes.
The Investment Casting Lab
The investment casting lab is used primarily for slurry and stucco testing.
Here, we develop and evaluate stuccos and slurries used during shell building. The lab includes high shear mixing equipment, two large slurry working tanks capable of dipping full patterns, along with equipment for applying stucco through both a fluidized bed and rainfall sander.
Testing in the investment casting lab includes drying studies using temperature- and humidity-controlled cabinets, gel testing, bacteria testing, and slurry solids evaluation using a centrifuge.
The lab also houses a roller mill for long-term slurry storage. This helps us reuse prime slurry between studies.
Shared Testing Capabilities
Some equipment is used across both the refractory and investment casting labs.
Ceramic saws allow us to cut and analyze samples customers send our way. Our vertical dilatometer allows us to measure how materials expand under heat, whether we’re evaluating investment casting shells, refractory samples, or studying how kyanite behaves at different firing times and temperatures. We also have a MOR (modulus of rupture) machine to test refractory samples and investment casting test bars for strength in 3- or 4-point bend.
Supporting Our Industry
Whether we’re evaluating a new mix, testing raw materials, or troubleshooting a critical issue, we show up with purpose. Our labs are equipped with advanced, highly specialized testing tools, and more importantly, they’re backed by a dedicated team that is deeply invested in our customers’ success. We don’t just run tests—we partner, problem-solve, and push for better outcomes every step of the way.
At the end of the day, our mission is simple: stand behind the industries we serve and do whatever it takes to help our customers succeed.
