Reactive Synthesis of a Porous Calcium Zirconate/Spinel Composite with Idiomorphic Spinel Grains

Porous CaZrO₃/MgAl₂O₄ composites were synthesized in air by pressureless reactive sintering of an equimolar mixture of dolomite (CaMg(CO₃)₂), monoclinic zirconia ( m -ZrO₂), and α-alumina powders, with a 0.5 wt% lithium fluoride additive. The reaction behavior of the mixed powders (with/without LiF additive) was studied using high-temperature X-ray diffraction. A bulk porous composite resulted from sintering at 1300°C for 2 h (in a nearly closed container, so as to increase the LiF-doping effect), which consisted of fine grains (CaZrO₃ and MgAl₂O₄, ∼0.5–1 μm) and well-grown idiomorphic ones (MgAl₂O₄ octahedra ∼ 2–4 μm). The idiomorphic spinel grains were located around the inner walls of relatively large pores. The composite showed appreciably high bending strength (σ_f= 110 ± 8 MPa for a porosity of 31%). The porous CaZrO₃/MgAl₂O₄ composites can be applied as high-temperature filters and lightweight structural components.     

Polymorphism and Thermodynamic Stability of Zn7Sb2O12

The composition Zn_2.33Sb_0.67O₄ (or Zn₇Sb₂O₁₂) exists in two polymorphic forms. The thermodynamically stable, low-temperature orthorhombic β form transforms to the high-temperature cubic α-polymorph with a spinel structure at 1225°±25°C. The transformation is fully reversible but slower in the α→β direction and therefore, it is easy to preserve the high-temperature α-polymorph to lower temperatures where it is kinetically stable but thermodynamically metastable. It is also possible to synthesize the α-polymorph directly at low temperatures, e.g., 900°C. This synthesis, of a phase that is thermodynamically stable only at high temperatures, but which has sufficient kinetic stability to exist metastably at low temperatures, represents an example of Ostwald's law of successive reactions in which the first phase to crystallize from a reaction mixture is not necessarily the equilibrium phase of lowest free energy. The crystal structure of the α-polymorph has been confirmed by Rietveld refinement of X-ray powder diffraction data to be an inverse spinel, (Zn)[Sb_2/3Zn_4/3]O₄, in which octahedral sites contain a disordered, random mixture of Zn and Sb and tetrahedral sites are fully occupied by Zn.     

New Strategies for Preparing NanoSized Silicon Nitride Ceramics

We report the preparation of nanosized silicon nitride (Si₃N₄) ceramics via high-energy mechanical milling and subsequent spark plasma sintering. A starting powder mixture consisting of ultrafine β-Si₃N₄ and sintering additives of 5-mol% Y₂O₃ and 2-mol% Al₂O₃ was prepared by high-energy mechanical milling. After milling, the powder mixture was mostly transformed into a non-equilibrium amorphous phase containing a large quantity of well-dispersed nanocrystalline β-Si₃N₄ particles. This powder precursor was then consolidated by spark plasma sintering at a temperature as low as 1600°C for 5 min at a heating rate of 300°C/min. The fully densified sample consisted of homogeneous nano-Si₃N₄ grains with an average diameter of about 70 nm, which led to noticeable high-temperature ductility and elevated hardness.     

Lowering Crystallization Temperatures by Seeding in Structurally Diphasic Al2O3-MgO Xerogels

Thermal reactions in 93% Al₂O₃-7% MgO and 95.8% Al₂O₃-4.2% MgO gels seeded with α-Al₂O₃, MgAl₂O₄, α-Fe₂O₃, and SiO₂, sols were investigated by differential thermal analysis to determine the extent of nucleation catalysis of solid-state reactions. Seeding with α-Al₂O₃ lowered the α-Al₂O₃ crystallization temperature in these xerogels by 100° to 150°C. Spinel seeds have much less effect on the γ-α transition, and α-Fe₂O₃ and SiO₂ seeds do not affect it significantly. Isostructural seeding of gels may therefore permit lower ceramic processing temperatures.     

Phase Equilibria in the Systems NiO-Cr2,O3,-O2, MgO-Cr2O3−O2, and CdO-Cr2,O3,-O2, at High Oxygen Pressures

Phase equilibria were determined for the systems NiO-Cr₂O₃−O₂, MgO-Cr₂O₃,-O₂, and CdO-Cr₂O₃−O₂ from 450° to above 850° C and at oxygen pressures of from 2 to 3500 atm. Only two intermediate phases were found in the nickel system: NiCrO., (CrVO₄ structure) and the spinel NiCr₂O₄. The magnesium and cadmium systems are similar in that they have three analogous phases: the low-temperature α-MgCrO₄ and α-CdCrO₄ (both with the CrVO₄ structure), the high-temperature β-MgCrO₄ and β-CdCrO₄ (both with the α-MnMoO₄ structure), and the spinels MgCr₂O₄ and CdCr₂O₄. The cadmium system contains an additional phase, Cd₂CrO₅, which is primitive monoclinic.     

Transparent Nd:YAG Ceramics Fabricated Using Nanosized γ-Alumina and Yttria Powders

Neodymium (Nd):Y₃Al₅O₁₂ (YAG) ceramics of excellent transparency have been fabricated by solid-reactive sintering, using nanosized γ-Al₂O₃ and Y₂O₃ powders as the starting materials. Reaction sequences and sintering behaviors of the powder mixture were characterized by X-ray diffractometry and dilatometry. One feature of the solid reactions involving γ-Al₂O₃ is the occurrence of hexagonal YAlO₃, which is unstable and transforms to perovskite YAlO₃ (YAP) upon further heating. Because of the high reactivities of the starting nanopowders, a complete conversion of the powder mixture to YAG has been achieved by heating at 1300°C for 4 h, via Y₄Al₂O₉, hexagonal YAlO₃, and YAP phases. In-line transmittances of the 1.5 at.% Nd:YAG ceramics (doped with 0.5 wt% of tetraethyl orthosilicate) at 700 nm are 81.0% and 65.7% after vacuum sintering at 1700° and 1600°C for 5 h, respectively.     

New Glassy and Polymorphic Oxide Phases Using Rapid Quenching Techniques

Splat and other rapid quenching techniques were applied to a systematic study of simple oxides, and four new pure oxide glasses were obtained (V₂O₅, TeO₂, MoO₃, and WO₂). The high-temperature tetragonal form of WO₃ coexists with a metastable short-range-order-only phase. The structure of a new metastable high-temperature phase, δ-Ta₂O₆, resembles δ-Nb₂O₆. Predominant phases found in quenched Al₂O₃ belong to the γ-(spinel type) series.     

Phase Relationships in the Si3N4–SiO2–Lu2O3 System

Phase relationships in the Si₃N₄–SiO₂–Lu₂O₃ system were investigated at 1850°C in 1 MPa N₂. Only J-phase, Lu₄Si₂O₇N₂ (monoclinic, space group P 2₁/ c , a = 0.74235(8) nm, b = 1.02649(10) nm, c = 1.06595(12) nm, and β= 109.793(6)°) exists as a lutetium silicon oxynitride phase in the Si₃N₄–SiO₂–Lu₂O₃ system. The Si₃N₄/Lu₂O₃ ratio is 1, corresponding to the M-phase composition, resulted in a mixture of Lu–J-phase, β-Si₃N₄, and a new phase of Lu₃Si₅ON₉, having orthorhombic symmetry, space group Pbcm (No. 57), with a = 0.49361(5) nm, b = 1.60622(16) nm, and c = 1.05143(11) nm. The new phase is best represented in the new Si₃N₄–LuN–Lu₂O₃ system. The phase diagram suggests that Lu₄Si₂O₇N₂ is an excellent grain-boundary phase of silicon nitride ceramics for high-temperature applications.     

Mechanochemical Synthesis of Magnesium Aluminate Spinel Powder at Room Temperature

MgAl₂O₄ spinel was successfully synthesized using a mechanochemical route that avoided the formation and calcination of its precursors at high temperatures. The method involved a single step in which γ-Al₂O₃–MgO, AlO(OH)–MgO, and α-Al₂O₃–MgO mixtures were milled at room temperature under air atmosphere. The formation of MgAl₂O₄ occurred faster with γ-Al₂O₃ than with AlO(OH) or α-Al₂O₃. After 140 h, the mechanochemical treatment of the γ-Al₂O₃–MgO mixture yielded 99% of MgAl₂O₄.     

High-Temperature Transmission Electron Microscopy and X-Ray Powder Diffraction Studies of Polymorphic Phase Transitions in Ba4Nb2O9

Polymorphic phase transitions in Ba₄Nb₂O₉ were studied by thermal analyses, high-temperature transmission electron microscopy and X-ray powder diffractometry. Two stable polymorphs were isolated, low-temperature α-modification and high-temperature γ-modification, with the endothermic phase transition at 1176°C. The α→γ transformation is accompanied by the formation of a 120° domain structure, which is a consequence of hexagonal→orthorhombic unit cell reconstruction. Reheating the presintered γ-Ba₄Nb₂O₉ results in the formation of a metastable γ'-modification (formerly known as β-polymorph) in the temperature range between 360° and 585°C, before the γ→α transformation at 800°C. Above ∼490°C Ba₄Nb₂O₉ becomes moderately sensitive to a loss of BaO. In air the surface of Ba₄Nb₂O₉ grains decomposes to nanocrystalline Ba₅Nb₄O₁₅ and BaO, which instantly reacts with atmospheric CO₂ to form BaCO₃. Surface reaction delays γ→α transformation up to 866°C in air. In vacuum the loss of BaO is even more enhanced and consequently the formation of minor Ba₃Nb₂O₈ phase is observed above 1150°C.     

Preparation and Properties of Hydrothermally Stable γ-Alumina Membranes

Supported mesoporous γ-Al₂O₃ membranes deteriorate and blister in steam-containing environments at high temperatures. This deterioration led us to the development of a new type of supported γ-Al₂O₃ membrane with significantly improved stability under hostile conditions. Two measures were taken to achieve this result. First, the γ-Al₂O₃ itself was stabilized by an addition of 6 mol% La₂O₃ to suppress pore growth of the mesoporous structure. Second, the adherence of the γ-Al₂O₃ membrane to the α-Al₂O₃ support was significantly improved by application of phosphate bonding between the membrane layer and the support, using an Al(H₂PO₄)₃ precursor solution. Membranes applied without phosphate bonding were separated from the α-Al₂O₃ support during high-temperature steam treatment, resulting in complete loss of separative properties. The newly developed membranes could be operated for 100 h at 600°C in H₂O/CH₄= 3/1 (by volume) at 2.5 MPa total pressure with no delamination or cracking in the membrane–support interface and with no significant pore growth in the γ-Al₂O₃ membrane.     

Synthesis of Metal Phosphates Using SiP2O7

A new, alternative, route to the synthesis of metal phosphates, using SiP₂O₇ as a reagent, was studied. The reaction of SiP₂O₇ with metal oxides yields a solid mixture of silica and metal phosphates; its reaction with metal fluorides yields solid metal phosphates and gaseous mixtures of SiF₄ and POF₃ .     

Subsolidus Phase Equilibria and Ordering in the System ZrO2-Y2O3

The subsolidus phase relations in the entire system ZrO₂-Y₂O₃ were established using DTA, expansion measurements, and room- and high-temperature X-ray diffraction. Three eutectoid reactions were found in the system: ( a ) tetragonal zirconia solid solution→monoclinic zirconia solid solution+cubic zirconia solid solution at 4.5 mol% Y₂O₃ and ∼490°C, ( b ) cubic zirconia solid solutiow→δ-phase Y₄Zr₃O₁₂+hexagonalphase Y₆ZrO₁₁ at 45 mol% Y₂O₃ and ∼1325°±25°C, and ( c ) yttria C -type solid solution→wcubic zirconia solid solution+ hexagonal phase Y₆ZrO₁₁ at ∼72 mol% Y₂O₃ and 1650°±50°C. Two ordered phases were also found in the system, one at 40 mol% Y₂O₃ with ideal formula Y₄Zr₃O₁₂, and another, a new hexagonal phase, at 75 mol% Y₂O₃ with formula Y₆ZrO₁₁. They decompose at 1375° and >1750°C into cubic zirconia solid solution and yttria C -type solid solution, respectively. The extent of the cubic zirconia and yttria C -type solid solution fields was also redetermined. By incorporating the known tetragonal-cubic zirconia transition temperature and the liquidus temperatures in the system, a new tentative phase diagram is given for the system ZrO₂-Y₂O₃.     

Electrochemical Determination of the Gibbs Energy of Formation of MgAl2O4

The standard Gibbs energy of formation of the spinel MgAl₂O₄ from component oxides, MgO and α-Al₂O₃, has been determined in the temperature range 900 to 1250 K using a solid-state cell incorporating single-crystal CaF₂ as the solid electrolyte. The cell can be represented as—Pt,O₂,MgO+MgF₂|CaF₂|MgF₂+MgAl₂O₄+α-Al₂O₃,O₂,Pt—The standard Gibbs energy of formation from binary oxides, computed from the reversible emf, can be represented by the expression—capdelta G °_f,ox=−23600 − 5.91 T (±150) J/mol—The 'second-law' enthalpy of formation of MgAl₂O₄ obtained in this study is in good agreement with high-temperature solution calorimetric studies reported in the literature.     

Kinetics of Solid-State Reaction of Bi2O3 and Fe2O3

Solid-state reactions of equimolar mixtures of Bi₂O₃ and Fe₂O₃ from 625° to 830°C and their kinetics were investigated. The reaction rates were determined from the integrated X-ray diffraction intensities of the strongest peaks of the reactants and products. The activation energy for the formation of BiFeO₃ was 96.6±9.0 kcal/mol; that for a second-phase compound, Bi₂Fe₄O₉, which formed above 675°C, was 99.4±9.0 kcal/mol. Specific rate constants for these simultaneous reactions were obtained. The preparation of single-phase BiFeO₃ from the stoichiometric mixture of Bi₂O₃ and Fe₂O₃ is discussed.     

Effect of Yttria on Interfacial Reactions Between Titanium Melt and Hot-Pressed Yttria/Zirconia Composites at 1700°C

Various Y₂O₃/ZrO₂ samples were fabricated by hot pressing, whereby Y₂O₃ was mutually dissolved or reacted with ZrO₂ as a solid solution or Zr₃Y₄O₁₂. Hot-pressed samples were allowed to react with Ti melt at 1700°C for 10 min in argon. Microstructural characterization was conducted using X-ray diffraction and analytical electron microscopy. The Y₂O₃/ZrO₂ samples became more stable with increasing Y₂O₃ because Y₂O₃ was hardly reacted and dissolved with Ti melt. The incorporation of more than 30 vol% Y₂O₃ could effectively suppress the reactions in the Ti side, where only a very small amount of α-Ti and β'-Ti was found. When ZrO₂ was dissolved into Ti on the zirconia side near the original interfaces, Y₂O₃ reprecipitated in the samples containing 30%–70 vol% Y₂O₃, because the solubility of Y₂O₃ in Ti was very low. In the region far from the original interface, α-Zr, Y₂O₃, and/or residual Zr₃Y₄O₁₂ were found in the samples containing more than 50 vol% Y₂O₃ and the amount of α-Zr decreased with increasing Y₂O₃.     

The System SiO2–P2O2

Phase relations in the binary system between SiO₂-P₂O₅ and SiO₂ were investigated by the quenching method using sealed platinum tubes to prevent the loss of P₂O₅. The compound Si0₂-P₂O₅ exists in two forms, the low-temperature β form inverting sluggishly but reversibly to the high-temperature β form at 1030°C. The β form melts congruently at 1290°C. The compound 2SiO₂-P₂O₅ melts incongruently at 1120°C to a silica-rich liquid and SiO_a-P₂O₅. In the region between 5 and 25 mole % PO₂, reactions were so sluggish that no data could be obtained by quenching.     

Wet Milling of Fe/Al/Al2O3 and Fe2O3/Al/Al2O3 Powder Mixtures

Wet milling of Al₂O₃-aluminide alloy (3A) precursor powders in acetone has been investigated by milling Fe/Al/Al₂O₃ and Fe₂O₃/Al/Al₂O₃ powder mixtures. The influence of the milling process on the physical and chemical properties of the milled powders has been studied. Particle refinement and homogenization were found not to play a dominant role, whereas plastic deformation of the metal particles leads to the formation of dislocations and a highly disarranged polycrystalline structure. Although no chemical reactions among the powder components in Fe₂O₃/Al/Al₂O₃ powder mixtures were observed, the formation of a nanocrystalline, ordered intermetallic FeAl phase in Fe/Al/Al₂O₃ powder mixtures caused by mechanical alloying was detected. Chemical reactions of Fe and Al particle surfaces with the atmosphere and the milling media lead to the formation of highly porous hydroxides on the particle surfaces. Hence the specific surface area of the powders increases, while the powder density decreases during milling. The fraction of Fe oxidized during milling was determined to be 0.13. The fraction of Al oxidized during milling strongly depends on the metal content of the powder mixture. It ranges between 0.4 and 0.8.     

Phase Equilibria in the System SrO-CdO-V2O5

Phase equilibria in the system SrO-CdO-V₂O₅ in air were established from data obtained by DTA, quenching, and high-temperature solid-state reaction experiments. The SrO-V₂O₅ boundary system contains 4 compounds at SrO to V₂O₅ molar ratios of 4:1, 3:1, 2:1, and 1:1. A fifth compound with a molar composition of ∼10:3 with the apatite crystal structure was also found; it may, however, be a hydroxyapatite phase. The CdO-V₂O₅ system contains the compounds 3CdO·V₂O₅, 2CdO·V₂O₅, and CdO·V₂O₅. The latter compound exhibits a rapid reversible polymorphic transition at 180°C. Complete solid solubility exists in the SrO-CdO system. The most probable compatibility relations were determined from the data available for the SrO-CdO-V₂O₅ ternary system. Limited solid solubility exists between SrO·V₂O₅ and CdO·V₂O₅, and the high-temperature CdO·V₂O₅ polymorph is stabilized to room temperature by solid solution of SrO·V₂O₅. Evidence for the existence of 2 ternary compounds with limited local solid solubility is also presented.     

Synthesis of Celsian (BaAl2Si2O8) from Solid Ba-Al-Al2O3-SiO2 Precursors: I, XRD and SEM/EDX Analyses of Phase Evolution

An intimate Ba-Al-Al₂O₃-SiO₂ powder mixture, produced by high-energy milling, was pressed to 3 mm thick cylinders (10 mm diameter) and hexagonal plates (6 mm edge-to-edge width). Heat treatments conducted from 300° to 1650°C in pure oxygen or air were used to transform these solid-metal/oxide precursors into BaAl₂Si₂O₈. Barium oxidation was completed, and a binary silicate compound, Ba₂SiO₄, had formed within 24 h at 300°C. After 72 h at 650°C, aluminum oxidation was completed, and an appreciable amount of BaAl₂O₄ had formed. Diffraction peaks consistent with hexagonal BaAl₂Si₂O₈, BaAl₂O₄, β-BaSiO₃, and possibly β-BaSi₂O₅ were detected after 24 h at 900°C. Diffraction peaks for BaAl₂O₄ and BaAl₂Si₂O₈ were observed after 35 h at 1200°C, although SEM analyses also revealed fine silicate particles. Further reaction of this silicate with BaAl₂O₄ at 1350° to 1650°C yielded a mixture of hexagonal and monoclinic BaAl₂Si₂O₈. The observed reaction path was compared to prior work with other inorganic precursors to BaAl₂Si₂O₈.