Preparation and characterization of cordierite glass–ceramics for bonding solar thermal transmission pipelines

TiO₂ was employed to develop cordierite glass–ceramics for thermal transmission pipeline binders by a melt-quenching method. The effects of TiO₂ on the phase composition, microstructure, and physical properties of glass–ceramics were studied. In addition, the thermal shock resistance of the glass–ceramics based binder was investigated. The results showed the formation of α cordierite could be increased by adding 1.0 wt% TiO₂, thereby improving bending strength and decreasing the coefficient of thermal expansion. However, a 3-5 wt% TiO₂ additive resulted in massive generation of µ cordierite, which exhibited a negative effect on the above performances. After crystallization at 1000°C for 2 h, sample B1 (1 wt% TiO₂ additional) displayed the best overall properties. It was demonstrated that cordierite glass–ceramics were satisfactory materials as heat transmission pipeline binders when the C2 binder (40 wt% frit, 60 wt% as-prepared sample B1) was applied, which had a good thermal shock resistance.     

Microstructure and performances of corundum−mullite composite ceramics for heat transmission pipelines: Effects of Ho2O3 additive content

Ho₂O₃ was employed to improve the microstructural densification and performances of pressureless sintered corundum–mullite ceramic composites. This study investigated the influences of Ho₂O₃ addition on the microstructure, physical properties and thermal shock resistances of the composites. The results indicated that sample AH5 (80 wt% Al₂O₃, 20 wt% coal series kaolin, and 5 wt% additional Ho₂O₃), which was sintered at 1550 °C, showed the best comprehensive properties. In this Al₂O₃-rich and SiO₂-poor system, a reaction between the Ho₂O₃ and Al₂O₃–SiO₂ system produced an Ho₂O₃–Al₂O₃–SiO₂ liquid phase. This liquid phase increased the microstructural densification and resulted in a lower sintering temperature. The generation of mullite and holmium disilicate during thermal shocks improved the thermal shock resistance. The high bending strength and satisfactory thermal shock resistance of the as-prepared corundum–mullite ceramic composites showed their potential for use in heat transmission pipelines.     

Preparation and properties of porous SiC–Al2O3 ceramics using coal ash

In this paper, we first reported that porous SiC–Al₂O₃ ceramics were prepared from solid waste coal ash, activated carbon, and commercial SiC powder by a carbothermal reduction reaction (CRR) method under Ar atmosphere. The effects of addition amounts of SiC (0, 10, 15, and 20 wt%) on the postsintering properties of as-prepared porous SiC–Al₂O₃ ceramics, such as phase composition, microstructure, apparent porosity, bulk density, pore size distribution, compressive strength, thermal shock resistance, and thermal diffusivity have been investigated. It was found that the final products are β-SiC and α-Al₂O₃. Meanwhile, the SEM shows the pores distribute uniformly and the body gradually contacts closely in the porous SiC–Al₂O₃ ceramics. The properties of as-prepared porous SiC–Al₂O₃ ceramics were found to be remarkably improved by adding proper amounts of SiC (10, 15, and 20 wt%). However, further increasing the amount of SiC leads to a decrease in thermal shock resistance and mechanical properties. Porous SiC–Al₂O₃ ceramics doped with 10 wt% SiC and sintered at 1600°C for 5 hours with the median pore diameter of 4.24 μm, room-temperature compressive strength of 21.70 MPa, apparent porosity of 48%, and thermal diffusivity of 0.0194 cm²/s were successfully obtained.     

An investigation of conductivity,microstructure and stability of HfO2–ZrO2–Y2O3–Al2O3 electrolyte compositions for high-temperature oxygen measurement

In search of better ionically conducting ceramics for high temperature oxygen fuel cells and sensors, the conductivity and microstructure of the HfO₂–ZrO₂–Y₂O₃ system with 15 mol% of Y₂O₃ and the HfO₂–ZrO₂–Y₂O₃–Al₂O₃ system with 50 mol% of Al₂O₃ have been investigated with X-ray diffractometry (XRD), scanning electron microscopy (SEM) and conductivity measurements as a function of temperature. The stability of electrolyte compositions was studied by continuously monitoring conductivity as a function of time at 1000°C. A majority of the investigated samples exhibited linear Arrhenius plots of the lattice conductivity as a function of temperature. In the HfO₂–ZrO₂–Y₂O₃–Al₂O₃ electrolyte systems the parameter pe′ was measured at a temperature range of 1000–1400°C. The HfO₂–ZrO₂–Y₂O₃–Al₂O₃ electrolyte systems have also showed better thermal shock resistance than the ZrO₂–Y₂O₃ systems. A comparison between the ageing of ZrO₂- and HfO₂-based electrolyte systems, as a result of long time annealing at a temperature of 1000°C, indicated that the degradation of the HfO₂-based system at a temperature of 1000°C and above is 1.5 times lower than the degradation of the ZrO₂-based systems.     

Cyclic thermal shock resistance of h-BN composite ceramics with La2O3–Al2O3–SiO2 addition

The effects of La₂O₃–Al₂O₃–SiO₂ addition on the thermal conductivity, coefficient of thermal expansion (CTE), Young's modulus and cyclic thermal shock resistance of hot-pressed h-BN composite ceramics were investigated. The samples were heated to 1000 °C and then quenched to room temperature with 1–50 cycles, and the residual flexural strength was used to evaluate cyclic thermal shock resistance. h-BN composite ceramics containing 10 vol% La₂O₃–Al₂O₃ and 20 vol% SiO₂ addition exhibited the highest flexural strength, thermal conductivity and relatively low CTE, which were beneficial to the excellent thermal shock resistance. In addition, the viscous amorphous phase of ternary La₂O₃–Al₂O₃–SiO₂ system could accommodate and relax thermal stress contributing to the high thermal shock resistance. Therefore, the residual flexural strength still maintained the value of 234.3 MPa (86.9% of initial strength) after 50 cycles of thermal shock.     

Porous ceramics based on high-thermal-stability Al2O3–ZrO2 nanofibers for thermal insulation and sound absorption applications

Al₂O₃ fibers are promising candidates for porous ceramics, but the sudden growth of grains in the fibers above 1200 °C will limit their applications for high temperature. Herein, we reported the successful fabrication of the Al₂O₃–ZrO₂ nanofibers by electrospinning and the nanofiber-based porous ceramics by a combination of gel-casting, freeze-drying and high-temperature sintering. Results show that the addition of Zr could greatly improve the thermal stability (up to 1400 °C) of the Al₂O₃-based nanofibers, owing to the inhibition of the sudden growth of the grains in the fibers at high temperature. The Al₂O₃–ZrO₂ nanofiber-based porous ceramics after sintering at 1100–1400 °C possessed a multi-level pore structure and exhibited high thermal stability, ultra-high porosity (97.79–98.04%), ultra-low density (0.075–0.091 g/cm³) and thermal conductivity (0.0474–0.0554 W/mK), and excellent sound absorption performance with the average sound absorption coefficient of 0.598–0.770. These porous ceramics are expected to be employed in the fields of high-temperature thermal insulation and sound absorption.     

Fabrication of Al2O3–ZrO2 ceramics with high porosity and strength

This study describes the synthesis of ceramics, in which a micrometre-sized Al₂O₃–ZrO₂ nanopowder was used as an oxide base for the hardening of the materials. To a suspension of this mixed metal oxide, the pore-forming crystallisation additives camphor and carbamide were added to produce ceramics with thin permeable pores. Camphor crystallised in the oxide suspension in the form of single pentagonal stars and сarbamide crystallised in the form of thin elongated needles. The use of the different crystallisation additives allowed the formation of ceramics after sintering that have both permeable and complex pore morphologies, where anisotropic properties were observed using carbamide as an additive but not when camphor was used. The total porosity of the resulting ceramics was 51.3%, with a compressive strength in the range of 17.3–92.3 MPa.     

Effect of adding Y2O3 on structural and mechanical properties of Al2O3–ZrO2 ceramics

The effects of adding 1–8 wt% Y₂O₃ on phase formation and fracture toughness of Al₂O₃–xZrO₂–Y₂O₃(AZY) ceramics were studied. Phase formations of the samples were characterized by the X-ray diffraction (XRD) technique. It was found that the major phase was rhombohedral-Al₂O₃, while the minor phase consisted of the monoclinic-ZrO₂, tetragonal-ZrO₂ and monoclinic-Y₂O₃. It was found that Y₂O₃ contents did not clearly influence grain shape of AZY ceramics. The results obtained from the microhardness test could be used to evaluate the fracture toughness. It was found that the smaller grains had high fracture toughness. The maximum fracture toughness of 4.827 MPa m^1/2 was obtained from 4 wt% Y₂O₃. Refinement of lattice parameters using Rietveld analysis revealed the quantitative phases of AZY ceramics. This shows that under adding Y₂O₃ conditions the proportion of tetragonal-ZrO₂ phase plays an important role for the mechanical properties of AZY ceramics.     

Fabrication and microstructure of Al2O3–ZrO2(3Y)–SiC nanocomposites

Al₂O₃–ZrO₂(3Y)–SiC composite powder was prepared by the heterogeneous precipitation method. Calcinating temperature of the powder was important to obtain dense sintered body. The nanocomposites were got by hot-pressing, and addition of ZrO₂ did not raise the sintering temperature. Some Al₂O₃ grain shape was elongated, and Al₂O₃ grain size was about μm. Nano SiC particles were observed uniformly distributing throughout the composites, and most of them were located within the matrix grains. Because SiC particles located within ZrO₂ grains influenced the phase transformation of ZrO₂, the sintering of nanocomposites, which controlled grain size and transformable ZrO₂ amount, become important to get high performance. The strength of 80 wt% Al₂O₃–15 wt% ZrO₂–5 wt% SiC nanocomposites was 555 MPa, and toughness was 3·8 MPa m^1/2, which were higher than those of monolithic Al₂O₃ ceramics. ©     

Effect of sintering time on the microstructure and stability of Al2O3–ZrO2 composite powders under microwave-assisted sintering

The function of ceramic coating is closely related to the construction technology and the quality of ceramic powders. Generally, Al₂O₃–ZrO₂ powders are rapidly sprayed on the material surface at high temperatures to obtain better performance. Improving the quality of Al₂O₃–ZrO₂ powders can make them more widely used in ceramic coating. In this paper, microwave sintering was used to enhance the sintering process of the powders, and the effect of sintering time on the microstructure, properties, and stability of Al₂O₃–ZrO₂ powders was investigated. The results proved that microwave heating could improve the crystallinity and stability of the samples. At 900 °C, the tetragonal phase content in samples with different sintering times were 63.05%, 63.25%, 62.39%, and 63.22%, respectively. The average particle sizes obtained by Gaussian fitting are 1.04 μm, 0.83 μm, 0.88 μm, 0.86 μm, respectively. The Gaussian fitting particle size data was consistent with the normal distribution. Compared with the particle size of raw material (1.10 μm), the particles were refined, and the dispersion effect was noticeable. Therefore, the best sintering time for microwave sintering Al₂O₃ stabilized zirconia was 2 h. This paper aims to provide reasonable data support for improving the preparation of high-quality Al₂O₃-PSZ ceramic powders and to guide the industrial production of Al₂O₃-PSZ powders.     

Preparation and characterization of Al2O3–25 mol% ZrO2 composites

Al₂O₃–ZrO₂ (AZ_x), with 25 mol% ZrO₂ content, was prepared using the co-precipitation method. Synthesized powders were characterized by thermal reaction using a differential thermal analysis technique (TG–DTA) and were investigated by phase formation using X-ray diffraction. It indicated that the reaction occurred at 850 °C; cubic (c)-ZrO₂ phase and Al₂O₃ were obtained. By increasing temperature to 1100 °C, tetragonal (t)-ZrO₂ phase was detected. The Al₂O₃–25 mol% ZrO₂ was sintered for 2 h in the temperature range of between 1300 and 1600 °C. The majority phases of ceramics were m-ZrO₂ and α-Al₂O₃, although a t-ZrO₂ phase also appeared as a minor phase and decreased with higher temperature. Moreover, morphology and particle size evolution have been determined via the SEM technique. SEM showed that the particles of powder are agglomerated and basically irregular in shape. An SEM micrograph of ceramics exhibits uniform microstructure without abnormal grain growth.     

Preparation of Al2O3–SiC composite powder from kyanite tailings via carbothermal reduction process

ABSTRACT

Al₂O₃–SiC composite powders were prepared from kyanite tailings mixed with 20% excess carbon coke via carbothermal reduction (CR) reaction. The optimised synthesis condition for synthesising Al₂O₃–SiC composite powders was at 1600°C for 6?h. The equilibrium relationship curves of the condensed phases were presented and the temperature dependence of the phase composition was also studied. The results show that irregular Al₂O₃ and SiC grains first formed at 1500°C, and the elements C, O, Al, and Si randomly distributed in the each crystal particles. The amount of Al₂O₃–SiC composites increased with the increasing synthesis temperature and reaction time. Finally, Al₂O₃–SiC composite bulk materials were further prepared by pressureless sintering using the synthesised Al₂O₃–SiC composite powders as raw materials, and their mechanical properties were investigated in detail. All these results indicate that the CR method can offer a niche application for the development of kyanite tailings.     

Low thermal conductivity in porous SiC–SiO2–Al2O3–TiO2 ceramics induced by multiphase thermal resistance

The introduction of multiple heterogeneous interfaces in a ceramic is an efficient way to increase its thermal resistance. Novel porous SiC–SiO₂–Al₂O₃–TiO₂ (SSAT) ceramics were fabricated to achieve multiple heterogeneous interfaces by sintering equal volumes of SiC, SiO₂, Al₂O₃, and TiO₂ compacted powders with polysiloxane as a bonding phase and carbon as a template at 600 °C in air. The porosity could be controlled between 66% and 74% by adjusting the amounts of polysiloxane and the carbon template. The lowest thermal conductivity (0.059 W/(m·K) at 74% porosity) obtained in this study is an order of magnitude lower than those (0.2–1.3 W/(m·K)) of porous monolithic SiC, SiO₂, Al₂O₃, and TiO₂ ceramics at an equivalent porosity. The typical specific compressive strength value of the porous SSAT ceramics at 74% porosity was 3.2 MPa cm³/g.     

Preparation,characterization and hydrotreating performances of ZrO2–Al2O3-supported NiMo catalysts

A series of Al₂O₃–ZrO₂ composite supported NiMo catalysts with various ZrO₂ contents were prepared. Several techniques including XRD, SEM, N₂ physisorption, H₂-TPR, and UV–vis DRS were used for typical physico-chemical properties characterization of the ZrO₂–Al₂O₃ composite supports and their NiMo/ZrO₂–Al₂O₃ catalysts. The test results showed that the composite supports prepared by the chemical precipitation method existed as amorphous phase in the samples with insufficient contents of ZrO₂, and the incorporation of ZrO₂ into supports provided a better dispersion of NiMo species, which made their reductions become easier. The pyridine-adsorbed FT-IR results indicated that the Lewis acid sites of catalysts increased significantly by the introduction of ZrO₂ into the supports. The activities of these catalysts for diesel oil hydrodesulfurization (HDS) and hydrodenitrogenation (HDN) were evaluated in a high pressure micro-reactor system. The results showed that the ZrO₂–Al₂O₃-supported NiMo catalysts with suitable ZrO₂ contents exhibited much higher catalytic activities than that of Al₂O₃-supported one, and when the ZrO₂ contents were 15% and 5%, the NiMo/Al₂O₃–ZrO₂ catalysts presented the highest HDS and HDN activities, respectively.     

Preparation and study of the mechanical and optical properties of infrared transparent Y2O3–MgO composite ceramics

In this study, fine Y₂O₃–MgO composite nanopowders were synthesized via the sol–gel method. Dense Y₂O₃–MgO composite ceramics were fabricated by pre-sintering the green body in air at different temperatures for 1 h and then subjecting the sintered bodies to hot isostatic pressing at 1300°C for 1 h. The effects of pre-sintering temperature on the microstructural, mechanical, and optical properties of the resulting ceramics were studied. The average grain size of the ceramics was increased, whereas their hardness and fracture toughness were decreased with increasing pre-sintering temperature. A maximum fracture toughness of 1.42 MPa·m^1/2 and Vickers hardness of 10.4 GPa were obtained. The average flexural strength of the ceramics was 411 MPa at room temperature and reached 361 MPa at 600°C. A transmittance of 84% in the 3–5 µm region was obtained when the composite ceramics were sintered at 1400°C. Moreover, a transmittance of 76% in the 3–5 µm region was obtained at 500°C.     

Optimization of microstructure and mechanical properties of oscillatory pressure sintered ZrO2–Al2O3-SiCp ceramics

Zirconia ceramic is a significant structural material, but its use under some extreme circumstances is limited by its mechanical properties. In this work, SiC particles (SiCp) were added into alumina toughened zirconia ceramics to prepare ZrO₂–Al₂O₃-SiCp ceramics with high performance by using oscillatory pressure sintering (OPS). Results showed that the best OPS temperature of 1600 °C was obtained, and the optimal SiCp particle size and content were 200 nm and 10 vol% respectively. Under these conditions, the specimen exhibited higher mechanical properties including Vickers hardness of 15.43 GPa, bending strength of 1162 MPa and fracture toughness of 6.36 MPa m^1/2. Moreover, it was found that the atomic matching between ZrO₂/SiCp, Al₂O₃/SiCp, and ZrO₂/Al₂O₃ was much higher, showing the coherent interface relationship. Therefore, it was favorable for enhanced mechanical properties of as-prepared ZrO₂–Al₂O₃-SiCp ceramics.     

Preparation and pore-forming mechanism of MgO–Al2O3–CaO-based porous ceramics using phosphorus tailings

A simple strategy for preparing MgO–Al₂O₃–CaO-based porous ceramics (MACPC) with high strength and ultralow thermal conductivity has been proposed in this work based on the raw material of phosphorus tailings. The effects of phosphorus tailings content, carbon black addition and heat treatment temperature on the properties of MACPC were studied, and their pore-forming mechanism during sintering was revealed. The results showed that the main phase composition of MACPC was magnesia alumina spinel and calcium aluminate after sintering at 1225 °C. Furthermore, the MACPC exhibited excellent comprehensive properties when 60 wt% phosphorus tailings and 40 wt% alumina were added, whose apparent porosity was 62.8%, cold compressive strength was 14.8 MPa, and the thermal conductivity was 0.106 W/(m·K) at 800 °C. The synchronously enhanced strength and thermal insulation properties of MACPC were related to the formation of uniformly distributed micropores (<2 μm) and passages in the matrix, which originated from the decomposition of phosphorus tailings and the burnt out of carbon black during the sintering process. The preparation of MACPC with high temperature resistance and excellent mechanical and thermal insulation properties with the raw material of phosphorus tailings provided an effective method for the high-value utilization of phosphorus tailings.     

Development and evaluation of Al2O3–ZrO2 composite processed by digital light 3D printing

Digital Light Processing (DLP) is a promising approach to fabricate delicate ceramic components with high-fidelity structural features. In this work, the alumina and zirconia/alumina ceramic suspensions with low viscosity and high solid loading (40 vol%) were prepared specifically for DLP 3D printing. After debinding and sintering, the final parts were obtained without any defects. The surface morphologies and mechanical properties of alumina (Al₂O₃) and zirconia toughened alumina (ZTA) composites were investigated and the results showed that the final parts exhibited high relative densities and good interlayer combination at the sintering temperature of 1600 °C. Comparing with the Al₂O₃, the ZTA composites exhibited significantly enhanced density (99.4%), bending strength (516.7 MPa) and indentation fracture toughness (7.76 MPa m^1/2).     

Sintering behavior of Cr2O3–Al2O3 ceramics

We investigated the sintering behavior of Cr₂O₃–Al₂O₃ ceramic materials. In our observation of the isothermal shrinkage behavior of Cr₂O₃–Al₂O₃ ceramic, the activation energy of sintering reaction was measured to be 102 kJ/mol, that is, the near value of the activation energy of diffusion of Al ions in Al₂O₃ single crystal. Therefore the diffusion of cations is believed to control the sintering behavior of this material. With the addition of TiO₂, (the compound chosen to accelerate the diffusion of cations) to Cr₂O₃–Al₂O₃, the sintering behavior was accelerated.