In situ synthesis of leucite‐based feldspathic dental porcelain with minor kalsilite and Fe2O3 impurities

K‐Feldspar was used as a raw material for in situ synthesis of leucite particles by solid‐state reaction method. Prior to synthesis of leucite, K‐Feldspar was treated by oxalic acid (C2H2O4) to eliminate Fe content. The parameters affecting the structure and amount of Fe in K‐Feldspar was investigated to reach an optimal leaching condition. Next, kasilite removal was studied by introducing CaF2 to the composition of dental porcelain. To synthesis leucite, the prepared materials were heated up to 1450°C for 3 hours until fusion phenomena occurred, then cooled down to 865°C to permit the leucite crystals nucleate and grow. To find out the chemical composition of powder, XRF, EDX, and Atomic absorption spectroscopy were used. Fourier Transform Infrared Spectroscopy and X‐Ray Diffractometer and Scanning Electron Microscopy were employed to study the structure of mineral. Spectrophotometry was chosen to analyze whiteness index of powder after acid treatment. Differential Thermal Analysis was employed to determine the crystallization temperature. Results indicated a dramatic decrease in Fe content (0.018%wt) by employing C2H2O4 as a leachant at 50°C. In addition, whiteness index of 91% was achieved through this procedure for raw feldspar. Finally, 1%wt of CaF2 prevented formation of kalsilite. Illustration of the preparation process for leucite‐based feldspathic dental porcelain before pigmentation.