The aim of this study is to assess the process of synthesizing potassium-based geopolymers (KGL) into leucite ceramics with regard to five variables, namely, alkaline solution ratio (R), sintering time (S), calcining temperature (T), mixing time (M), and curing time (C). Under these conditions, the specimens were tested by the viscosity test, the mechanical properties test, X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, and scanning electron microscopy (SEM) to understand the geopolymerization reactions and the characteristics of the KGL network. The results indicate that a KOH to K2O/SiO2 ratio of 1:1 promotes the reaction within metakaolin. XRD analysis of the KGL shows that, when the temperature is 1100 °C, the phase transforms into the leucite phase. Moreover, XRD analysis, mechanical properties, and FTIR all indicate improved characteristics when the curing time increases from 1 to 8 h. This might be attributed to the enhancement of the strong interaction between the matrix and the alkaline solution upon achieving adequate time to complete the geopolymerization process and forming a more stable three-dimensional structure. The formulation which formed the purest leucite phase consisted of: a 1:1 alkaline solution ratio, 10 min mixing time, 8 h curing time, 1200 °C calcining temperature, and 2 h sintering time.
Keywords: ceramics; leucite; potassium-based geopolymers.