Composite materials with ZrO2–TiO2 matrix and ZrO2 containing ceramic fibres

Abstract

The aim of the work reported in the present paper was to obtain composites consisting of a ZrO₂–TiO₂ matrix reinforced with ceramic fibres containing 12 wt-% ZrO₂, which are resistant to temperatures higher than1500°C. The resulting ceramic matrix consisted of 95 wt-% ZrO₂, partially stabilised with CaO, and 5 wt-% rutile TiO₂. A ceramic fibre content of 0·82 vol.-% was used and for the matrix, several grades of ZrO₂ partially stabilised with CaO were explored, prepared by dry and wet grinding for various grinding periods. Composites were prepared by uniaxial die pressing at 350 MPa and sintered at two temperatures: 1360°C for 1 h and 1500°C for 3 h. The resulting composites showed the following range of properties: total drying and firing shrinkage 0·4–3·3%; apparent density 3·51–3·96 g cm^-3; porosity 25–34%; water absorption 6–10%; bend strength 12–43 MPa. The optimum ZrO₂ grades were determined based on physical and mechanical properties, and on structural determinations carried out by thermodifferential and thermogravimetric analyses, X-ray diffraction (XRD), and scanning electron microscopy (SEM). SEM evaluation illustrated the increase in average size of crystallites typical of ZrTiO₄ solid solution as a function of temperature, from 2 μm at 1360 up to 14 μm at 1600°C, and of their tendency to sinter.     

Praseodymium-doped cubic Ca–ZrO2 ceramic stain

The cubic Ca–ZrO₂ structure has been used as host for preparing a yellow ceramic stain using praseodymium as dopant. Samples with Ca_xPr_0.1Zr_0.9−xO₂ (X=0.14, 0.17, 0.2) compositions have been prepared by the ceramic method (CE) and by several gel processing techniques: the colloidal method (CG), the gelatine method (GE), the citrate method (CI) and a polymeric route (PG). Fired samples have been evaluated as ceramic pigments following enameling with the powders in ceramic glazes. The results show that a yellow ceramic pigment is obtained in all samples without significative differences among the different methods and compositions. This yellow ceramic pigment has been identified as a Pr–(Ca–ZrO₂) solid solution.     

Structural parameters and oxygen ion conductivity of Y2O3–ZrO2 and MgO–ZrO2 at high temperature

The oxygen ion conductivity of zirconia-based solid electrolytes doped with 8 mol% Y₂O₃–ZrO₂ (YSZ) and 9 mol% MgO–ZrO₂ (Mg-PSZ) at high temperature was investigated in terms of their thermal behavior and structural changes. At room temperature, YSZ showed a single phase with a fluorite cubic structure, whereas Mg-PSZ had a mixture of cubic, tetragonal and some monoclinic phases. YSZ exhibited higher ionic conductivity than Mg-PSZ at temperatures from 600 °C to 1250 °C because of the existence of the single cubic structure and low activation energy. A considerable increase in the conductivity with increasing temperature was observed in Mg-PSZ, which showed higher ionic conductivity than YSZ within the higher temperature range of 1300–1500 °C. A monoclinic-to-tetragonal phase transformation was found in Mg-PSZ and the lattice parameter of the cubic phase increased at 1200 °C. The phase transformation and the large lattice free volume contributed to the significant enhancement of the ionic conductivity of Mg-PSZ at high temperatures.     

Free Radical Formation in ZrO2–SiO2Sol–Gel Derived Catalysts

Zirconia–silica mixed oxides have been prepared by the sol–gel method using zirconium butoxide and tetraethoxysilane as starting materials. The samples were sulfated using sulfuric acid as alkoxide hydrolysis catalyst or by impregnation with sulfuric acid of a sample previously prepared using HCl as alkoxide hydrolysis catalyst. In thermally treated samples, an intense EPR signal was observed for the sample prepared using HCl, while the EPR signal was lower in the sulfated samples. FTIR–pyridine adsorption spectra showed that Brønsted and Lewis acidity is developed in the sulfated samples. The formation of two types of Brønsted sites depending upon the sulfating method used is proposed. The catalytic activity of the samples was evaluated in isopropanol andn-butanol dehydration. The mechanism by which sulfation is achieved and the Brønsted-type site formed are discussed.     

Structural studies of a ZrO2–CeO2 doped system

The local structure around Zr, Ce and dopant atoms (Fe and Ni) in the ZrO₂–CeO₂ system investigated by X-ray absorption spectroscopy (XAS) is reported to better understand the tetragonal phase stabilization process of zirconia. The first coordination shell around Zr atoms is not sensitive to the introduction of dopants or to an increase in the ceria content (from 12 to 20 mol%). Ce ions maintain the eight-fold coordination as in CeO₂, but with an altered bond distance. The formation of vacancies resulting from reduction of Ce atoms can be discarded, because XANES spectra clearly show that Ce ions are preferentially in a tetravalent state. XANES and EXAFS experiments at the Fe K-edge evidence that the local order around Fe is quite different from that of the Fe₂O₃ oxide. On the one hand, ab initio EXAFS calculations show that iron atoms form a solid solution with tetragonal ZrO₂. The EXAFS simulation of the first coordination shell around iron evidences that the substitution of zirconium atoms by iron ones generates oxygen vacancies into the tetragonal network. This is a driven force for the tetragonal phase stabilization process. For Ni doped samples, EXAFS results show that Ni–O mean bond length is similar to the distance found in the oxide material, i.e., NiO compound. Besides this result, no evidence of similar solid solution formation for Ni-doped systems has emerged from the EXAFS analysis.     

Experimental study of the SnO2–ZrO2 phase diagram

The study of the SnO₂–ZrO₂ phase diagram in the 1230–1750 °C temperature range has shown the existence of an immiscibility gap, leading to two (Zr_1−xSn_x)O₂ and (Sn_1−yZr_y)O₂ limited solid solutions. Four compositions were synthesised for each solid solution, leading to pure phases, which were characterised by room-temperature and high-temperature X-ray diffraction. The unit-cell parameters of tetragonal (Sn_1−yZr_y)O₂, monoclinic (Zr_1−xSn_x)O₂ and tetragonal (Zr_1−xSn_x)O₂ were determined and correlated with the content of the substituted atom. The monoclinic to tetragonal and reverse reactions for the (Zr_1−xSn_x)O₂ series were also characterised (transition temperatures) when varying the tin mole fraction.     

Thermodynamic calculation of Ms in ZrO2–CeO2–Y2O3 system

The difference of Gibbs free energy between tetragonal and monoclinic phases in ZrO₂–CeO₂–Y₂O₃ as a function of composition and temperature is thermodynamically calculated from the three related binary systems. In 8 mol% CeO₂–0.5 mol% Y₂O₃–ZrO₂, the equilibrium temperature between tetragonal and monoclinic phases, T₀, is obtained as 832.5 K and the M_s temperature of this alloy with a mean grain size of 0.90 μm is calculated as 249.9 K using the approach derived by Hsu et al. [J. Mater. Sci., 18(1983)3206; 20(1985)23; Acta Metall., 37(1989)3091; Acta Metall. Mater., 39(1991)1045; Mater. Trans. JIM, 37(1996)1284], which is in good agreement with the experimental one of 253 K.     

Microstructure and properties of CaO–ZrO2–SiO2 glass–ceramics prepared by sintering

For the development of a new wear resistant and chemically stable glass-ceramic glaze, the CaO–ZrO₂–SiO₂ system was studied. Compositions consisting of CaO, ZrO₂, and SiO₂ were used for frit, which formed a glass-ceramic under a single stage heat treatment in electric furnace. In the sintered glass-ceramic, wollastonite (CaSiO₃) and calcium zirconium silicate (Ca₂ZrSi₄O₁₂) were crystalline phases composed of surface and internal crystals in the microstructure. The internal crystal formed with nuclei having a composition of Ca_1.2Si_4.3Zr_0.2O₈. The CaO–ZrO₂–SiO₂ system showed good properties in wear and chemical resistance because the Ca₂ZrSi₄O₁₂ crystals positively affected physical and mechanical properties.     

Synthesis of mesoporous SiO2–ZrO2 mixed oxides by sol–gel method

A series of SiO₂–ZrO₂ mixed oxides were prepared by sol–gel method in the presence of directing agent, with variable amounts of ZrO₂ between pure silica and pure zirconia, with the aim to obtain catalytic materials suitable as solid acid catalysts. SiO₂–ZrO₂ mixed oxides differ from the two pure starting oxides. While SiO₂ has a low OH density without peculiar acid character, the introduction of increasing amounts of Zr increases the density of the acid sites in the materials. Furthermore both SiO₂/ZrO₂ molar ratio and drying procedure are able to influence the physico-chemical characteristics (textural properties, acid sites distribution, etc.) of these mixed oxides.     

Mechanical and functional properties of Al2O3–ZrO2–MWCNTs nanocomposites

Multi-walled carbon nanotubes (MWCNTs) are often reported as additives improving mechanical and functional properties of ceramic composites. However, despite tremendous efforts in the field in the past 20 years, the results are still inconclusive. This paper studies room temperature properties of the composites with polycrystalline alumina matrix reinforced with 0.5–2 vol.% MWCNTs (composites AC) and zirconia toughened alumina with 5 vol.% of yttria partially stabilised zirconia (3Y-PSZ) containing 0.5–2 vol.% of MWCNTs (composites AZC). Dense composites were prepared through wet mixing of the respective powders with functionalised MWCNTs, followed by freeze granulation, and hot-pressing of granulated powders. Room temperature bending strength, Young's modulus, indentation fracture toughness, thermal and electrical conductivity of the composites were studied, and related to their composition and microstructure. Slight increase of Young's modulus, indentation fracture toughness, bending strength, and thermal conductivity was observed at the MWCNTs contents ≤1 vol.%. At higher MWCNTs contents the properties were impaired by agglomeration of the MWCNTs. The DC electrical conductivity increased with increasing volume fraction of the MWCNTs.     

The chemical durability of SrO–MgO–ZrO2–SiO2 glasses in strongly alkaline environments

A large region of glass formation was found in the system SrO–MgO–ZrO₂–SiO₂ and some properties have already been reported. Detailed studies have shown that glasses with only 40 wt% silica unusually durable in 1 M NaOH and also in model cement extract solutions. Glasses with higher silica contents are more easily attacked; zirconia and magnesia are the constituents giving the best durability. These results suggest that these glasses could be of interest for reinforcement of cement and concrete.     

Vapor-Phase Dehydration of 1,3-butanediol over CeO2–ZrO2 Catalysts

The dehydration of 1,3-butanediol was investigated over CeO₂–ZrO₂ catalysts prepared by impregnation at temperatures of 325–375 °C. Pure CeO₂ selectively catalyzed the dehydration of 1,3-butanediol to form 3-buten-2-ol and 2-buten-1-ol, while pure ZrO₂, which was less active than pure CeO₂, catalyzed the dehydration to 3-buten-1-ol. In the CeO₂/ZrO₂ catalyst in which CeO₂ was supported on zirconia, the presence of a small amount of CeO₂ suppressed the formation of 3-buten-1-ol and induced the dehydration of 1,3-butanediol to form 3-buten-2-ol and 2-buten-1-ol and the subsequent dehydrogenation of 3-buten-2-ol to form 3-buten-2-one and butanone. The activity would be related to the redox features of CeO₂. The monoclinic phase of zirconia support decreased while the cubic CeO₂ phase increased as CeO₂ content was increased. In contrast, in the ZrO₂/CeO₂ catalyst in which ZrO₂ was supported on cubic CeO₂, only the cubic CeO₂ phase was observed and ZrO₂ species appeared in the form of a solid solution of CeO₂–ZrO₂ with fluorite structure. Regardless of zirconia loading, ZrO₂ species did not affect the catalytic activity of ZrO₂/CeO₂, which was controlled by CeO₂ species.     

Phase relations in ZrO2–La2 Zr2O7–Y2 Zr2O7system

Abstract

The phase relations in the system ZrO₂–La₂Zr₂O₇– Y₂Zr₂O₇ have been investigated using X-ray diffraction. Mixed oxide phase assemblages were prepared by hydrolysing zirconium butoxide with solutions of Y and La nitrates, followed by drying, calcining, and sintering. The cubic zirconia phase can accept into solid solution the larger, non-cubic stabilising lanthanum ion in the presence of a suitable proportion of the cubic stabilising oxide of yttrium. As the amount of the larger rare earth element ion is increased formation of pyrochlore and tetragonal type compounds is favoured.     

Autothermal Reforming of Methane Over CeO2–ZrO2–La2O3 Supported Rh Catalyst

Autothermal reforming of methane was studied over La-doped ceria–zirconia-supported Rh catalysts. The CH₄ conversion increased from 49 to 60% on increasing the content of La³⁺ from 5 to 15%, while further increase in the La³⁺ content led to a slight decrease on both CH₄ conversion and H₂ selectivity. H₂-TPR and UV–vis DRS spectrum showed that the interaction between Rh and the support was enhanced by increasing the content of La. We speculated that a so-called “Rh–La interfacial species” was formed on the surface of the support, which played an important role in catalytic activity. The balance between exposed Rh and the “Rh–La interfacial species” was necessary to improve the catalytic activity. Upon increasing the Rh loading on 15% La-doped ceria–zirconia support, the balance was built, i.e., CH₄ conversion increased from ~60 to 69% by increasing Rh loading from 0.1 to 0.5 wt% and only 2% conversion was elevated by doubling the Rh loading from 0.5 to 1.0 wt%.     

Thermodynamic prediction of the nonstoichiometric phase Zr1–zCezO2–x in the ZrO2–CeO1.5–CeO2 system

A thermodynamic estimation of the ZrO₂–CeO₂ and ZrO₂–CeO_1.5 systems, as well as the cubic phase in the CeO_1.5–CeO₂ system has been developed and the complex relation between the nonstoichiometry, y, in Ce_zO_2–y and the oxygen partial pressure at different temperatures is evaluated. The behavior of the nonstoichiometry phase Zr_1–zCe_zO_2–x is described based on the thermodynamic estimation in the ZrO₂–CeO₂, CeO_1.5–CeO₂ and ZrO₂–CeO_1.5 systems. Additionally, the interdependence among miscellaneous factors, which can be used to describe the change in oxidation states of cerium such as the oxygen partial pressure, the CeO_1.5 fraction in CeO_1.5–CeO₂ in the quasi-ternary system, the nonstoichiometry y and the difference between the activity of CeO₂ and CeO_1.5 are predicted. The calculated results are found to be very useful to explain the influence of pressureless sintering at different O₂ partial pressures on the mechanical properties of CeO₂-stabilised ZrO₂ ceramics     

Liquid Immiscibility Phenomena in Melts of the ZrO2–FeO–Fe2O3 System

The ZrO₂–FeO _x melts prepared by induction melting in a cold crucible in air are investigated experimentally. It is found that the immiscibility region exists in the liquid phase. The theoretical fusibility curves (calculated according to the authors' DIATRIS 1.2 program) for the ZrO₂–FeO–Fe₂O₃ system are compared with the experimental temperatures of the formation of the secondary phase, liquidus and solidus lines, and X-ray microprobe spectroscopic and X-ray powder diffraction data for quenched and slowly cooled samples. It is demonstrated that the immiscibility region in the liquid phase in an air atmosphere is observed in the temperature range 1870–2230°C and the concentration range 34–82 wt % ZrO₂.     

TiO2–ZrO2 mixed oxide as a support for hydrotreating catalyst

Pure TiO₂, ZrO₂ and TiO₂–ZrO₂ mixed oxides are prepared by urea hydrolysis. Hydrotreating catalysts containing 12 wt% molybdenum are prepared using these oxides and characterized by BET surface area, pore volume, XRD and oxygen chemisorption. It is observed that oxides produced by the method of urea hydrolysis have higher surface area as compared to those available commercially. With increasing zirconia content in the mixed oxide, the surface area increases and a maximum value is obtained for a mixed oxide having Ti and Zr molar ratio of 65/35. XRD results indicate that mixed oxides are poorly crystalline in nature. Thiophene hydrodesulfurization, cyclohexene hydrogenation and tetrahydrofuran hydrodeoxygenation are taken as model reactions for evaluating catalytic activities. It is found that both O₂ uptake and catalytic activities increase with increasing zirconia content in mixed oxide and reach maximum values for the 12 wt% Mo/TiO₂–ZrO₂ (65/35) catalyst. With further increases in zirconia content, O₂ uptake and catalytic activities decrease and the lowest values are observed for the pure ZrO₂ supported catalyst.     

Carbothermal production of ZrB2–ZrO2 ceramic powders from ZrO2–B2O3/B system by high-energy ball milling and annealing assisted process

Zirconium diboride (ZrB₂)-zirconium dioxide (ZrO₂) ceramic powders were prepared by comparing two different boron sources as boron oxide (B₂O₃) and elemental boron (B). The production method was high-energy ball milling and subsequent annealing of powder blends containing stoichiometric amounts of ZrO₂, B₂O₃/B powders in the presence of graphite as a reductant. The effects of milling duration (0, 2 and 6 h), annealing duration (6 and 12 h) and annealing temperature (1200–1400 °C) on the formation and microstructure of ceramic powders were investigated. Phase, thermal and microstructural characterizations of the milled and annealed powders were performed by X-ray diffractometer (XRD), differential scanning calorimeter (DSC) and transmission electron microscope (TEM). The formation of ZrB₂ starts after milling for 2 h and annealing at 1300 °C if B₂O₃ is used as boron source and after milling for 2 h and annealing at 1200 °C if B is used as boron source.     

Propane Oxidative Dehydrogenation on V–Sb/ZrO2 Catalysts

The catalytic properties of V–Sb/ZrO₂ and bulk Sb/V catalysts for the oxidative dehydrogenation of propane were studied. Samples were characterized by nitrogen adsorption, temperature-programmed reduction, temperature-programmed pyridine desorption and photoelectron spectroscopic techniques. Vanadia promotes the transition of tetragonal to monoclinic zirconia and the formation of ZrV₂O₇. Surface V and Sb oxide species do not appear to interact among them below monolayer coverage, but SbVO4 forms above monolayer. Simultaneously the excess of antimony forms α-Sb₂O₄. Activity and selectivity show no dependence on the acidity of the catalysts. However, there is a strong dependence of activity/selectivity on composition; surface vanadium species are active for propane oxidative dehydrogenation and the presence of Sb, affording rutile VSbO₄ phase makes the system selective to C₃H₆, this is believed to be related to the redox cycle involving dispersed V⁵⁺ species and lattice reduced vanadium site in the rutile VSbO₄ phase.