Microstructure and Oxide Ion Conductivity in a Dense La9.33(SiO4)6O2 Oxy-Apatite

Oxy-apatites are one of the most promising oxide ion conducting electrolytes for intermediate-temperature solid oxide fuel cells, those operating close to 950 K. La_9.33(SiO₄)₆O₂ has the simplest stoichiometry among the oxy-apatite family of compounds, and the range of oxide ion conductivity reported for dense ceramic pellets is very high, almost two orders of magnitude at a given temperature. The spread in conductivity values including porous pellets is obviously larger. Here, we show that dense pellets of La_9.33(SiO₄)₆O₂ ceramics prepared by three different methods, conventional, spark plasma, and reaction sintering (RS), have different bulk conductivities. Bulk activation energies are equal for all the samples studied. Furthermore, the grain boundary conductivity cannot be described by the simple brick-layer model. These experimental findings suggest segregation at the grain boundary region, with slightly different compositions for different sintering conditions, likely leaving the grain interior with a compositional gradient. A two-step RS led to dense pellets with the highest bulk and grain boundary oxide ion conductivities.     

Zircon Synthesis via Sintering of Milled SiO2 and ZrO2

The formation of zircon (ZrSiO₄) via sintering of milled SiO₂ and ZrO₂ powders was studied, and the effects of slurry vs dry milling, sintering time, and particle size on zircon yield were examined. It was found that very high zircon yields could be obtained via slurry milling, cold pressing, and sintering of the oxide precursors. The controlling factor in determining zircon yield was found to be the particle size of the SiO₂ and ZrO₂ powders. Zircon yield as a function of sintering time was examined, and found to be similar to previous studies in which sol-gel precursors seeded with zircon were used. SEM studies reveal a homogeneous product with particle sizes on the order of 1–5 µm. It was found that complete reaction to zircon can be achieved from a once-through milling, pressing, and sintering process of SiO₂-ZrO₂ powders.     

Density and Ionic Conductivity of Sintered (CeO2)0.82(GdO1.5)o.18

A study is presented on sintering of the mixed oxide (CeO₂)_0.82(GdO_1.5)_0.18 where the density of the green samples, the density of the sintered samples, and the ionic conductivity of O²- ions in the sintered samples were measured. The dependence of these three parameters on the method of preparation of the powder and on the pressure in pressing of the green samples was determined. The pressures used varied from 25 to 1200 MPa. The different preparation methods used resulted in powders of different degree of mixing of the two oxides, which then determined the compositional homogeneity of the samples when sintered. An apparent relation exists between compositional homogeneity and ionic conductivity as well as density. However, when high pressures (∼1000 MPa) were applied, densities up to 98 % of theoretical value were obtained. A temperature dependence of the activation energy in seemingly homogeneous samples is attributed to a higher dopant concentration in the grain boundary than in the grain bulk.     

Zirconium Aluminum Carbides: New Precursors for Synthesizing ZrO2–Al2O3 Composites

ZrO₂–Al₂O₃ nanocrystalline powders have been synthesized by oxidizing ternary Zr₂Al₃C₄ powders. The simultaneous oxidation of Al and Zr in Zr₂Al₃C₄ results in homogeneous mixture of ZrO₂ and Al₂O₃ at nanoscale. Bulk nano- and submicro-composites were prepared by hot-pressing as-oxidized powders at 1100°–1500°C. The composition and microstructure evolution during sintering was investigated by XRD, Raman spectroscopy, SEM, and TEM. The crystallite size of ZrO₂ in the composites increased from 7.5 nm for as-oxidized powders to about 0.5 μm at 1500°C, while the tetragonal polymorph gradually converted to monolithic one with increasing crystallite size. The Al₂O₃ in the composites transformed from an amorphous phase in as oxidized powders to θ phase at 1100°C and α phase at higher temperatures. The hardness of the composite increased from 2.0 GPa at 1100°C to 13.5 GPa at 1400°C due to the increase of density.     

In Situ Reaction of B2O3 with AlN and/or Si3N4 to Form BN-Toughened Composites

BN-toughened oxide matrix composites were formed by the in situ reaction of B₂O₃ with Si₃N₄ and/or AlN. A lowtemperature transient liquid phase aids densification at <1000°C, and the process tends to produce an intrinsically homogeneous microstructure. Mechanical properties and microstructure of the composites formed in situ were compared to those of composites prepared by conventional means from oxide and BN powders. Fracture toughness and flexural strength of the nearly isotropic in situ formed composites ranged from 2.82 to 3.66 MPa · m^1/2 and 130 to 320 MPa, respectively, with Young's moduli of 100 to 110 GPa. Densities achieved ranged from 90% to 97% of estimated theoretical densities. The strength and toughness values are intermediate to the extreme values for the anisotropic composites formed by hot-pressing mixed powders.     

Application of Compositionally Diphasic Xerogels for Enhanced Densification: The System Al2O3-SiO2

Stoichiometric mullite (71.38 wt% Al₂O₃-28.17 wt% SiO₂) and 80 wt% Al₂O₃-20 wt% SiO₂ gels were prepared by the single-phase and/or diphasic routes. Dense sintered bodies were prepared from both sets of gels in the Al₂O₃-SiO₂ system. Apparent densities of 96% and 97% of theoretical density were measured for the diphasic (using two sols) mullite samples sintered at 1200° and 1300°C for 100 min, respectively; this compared with 85% and 94% for the single-phase xerogels under the same conditions, and to much lower values for mullite prepared from conventional mixed powders. The microstructure of the mullite pellets from diphasic xerogel precursors is also considerably finer.     

Sintering of Partially Stabilized Zirconia by Microwave Heating Using ZnO–MnO2–Al2O3 Plates in a Domestic Microwave Oven

Partially stabilized zirconia (PSZ) powders were fully densified by microwave heating using a domestic microwave oven. Pressed powder compacts of PSZ were sandwiched between two ZnO–MnO₂–Al₂O₃ ceramic plates and put into the microwave oven. In the first step, PSZ green pellets were heated by self-heating of ZnO–MnO₂–Al₂O₃ ceramics (1000°C). In the second step, the heated PSZ pellets absorbed microwave energy and self-heated up to a higher temperature (1250°C), leading to densification. The density of PSZ obtained by heating in the microwave oven for 16 min was 5.7 g/cm³, which was approximately equal to the density of bodies sintered at 1300°C for 4 h or 1400°C for 16 min by the conventional method. The average grain size of the sample obtained by this method was larger than the average grain size of samples sintered by the conventional method with a similar heating process.     

Processing and Sintering of Ultrafine MgO-ZrO2 and (MgO, Y2O3)-ZrO2 Powders

Chemical coprecipitation was used to produce ultrafine and easily sinterable MgO-stabilized and (MgO, Y₂O₃) stabilized ZrO₂ powders. The sintering behavior is very sensitive to post-precipitation washing because "hard" agglomerates form when the precipitated gels are washed with water, whereas "soft" agglomerates form when they are washed with ethanol. The soft agglomerates pack uniformly, resulting in homogeneous shrinkage of powder compacts to near-theoretical density. The hard agglomerates result in compacts which have regions of localized densification and a signifiint fraction of residual porosity.     

Fabrication and High-Temperature Phase Stability of Mo(Al,Si)2—MoSi2 Intermetallics

A two-step processing technique was used to make dense, homogeneous intermetallics in the Mo(Al,Si)₂—MoSi₂ system. A variation of self-propagating high-temperature synthesis was used, in which starting pellets were nucleated at room temperature to make intermetallic powders from metallic precursors, followed by uniaxial hot pressing at 1600°—1800°C to achieve densification. The samples were held at the hot-pressing temperatures for several hours; therefore, this study also provided qualitative phase-stability information. The solubility limit of Al for Si in MoSi₂ was <5% at 1800°C. Samples that had 10% Al substituted for Si yielded approximately equal amounts of MoSi₂ and Mo(Al,Si)₂.     

Sintering, Microstructure, Hardness, and Fracture Toughness Behavior of Y2O3-CeO2-ZrO2

A wet-chemical approach is applied to derive fine powders with compositions 11 mol% CeO₂-ZrO₂, 1 mol% YO_1.5-10 mol% CeO₂-ZrO₂, 12 mol% CeO₂-ZrO₂, and 2 mol% YO_1.5-10 mol% CeO₂-ZrO₂ by the coprecipitation method. The characteristics of the as-derived powders are evaluated through thermal analysis and electron microscopy. The sintering behavior of the calcined powders is carried out at 1400° and 1500°C for 1 to 10 h. Sintered density higher than 98% of theoretical is achieved for sintering at 1400°C for several hours. The as-sintered density dependence on the sintering condition is related to the extent of tetragonal-to-monoclinic phase transformation as well as the associated microcracks. Partial substitution by Y₂O₃ in CeO₂-ZrO₂ results in reduced grain size and tends to stabilize the tetragonal structure. Y₂O₃ is more effective than CeO₂ with respect to the grain size refinement and tetragonal stability. In addition, Y₂O₃ substitution in CeO₂-ZrO₂ increases the hardness, while it decreases the fracture toughness.     

Microstructure and Electrical Properties of MgAl2O4 Thin Films for Humidity Sensing

Active elements for humidity sensors based upon MgAl₂O₄ thin films or sintered pellets were investigated. Thin films were deposited on Si/SiO₂ substrates by radiofrequency (rf) sputtering. Sintered MgAl₂O₄ pellets were prepared by traditional ceramic processing. Scanning electron microscopy (SEM) analysis showed that the thin films were rather dense and homogeneous, made up of clustered particles of about 20–30 nm, while the pellets showed a wide pore-size distribution. X-ray photoelectron spectroscopy (XPS) demonstrated that the thin films have a stoichiometry close to that of MgAl₂O₄. Sintered MgAl₂O₄ is crystalline, while it is disordered in thin-film form. The presence of two different components of the Al 2 p peaks was correlated with the structural difference between pellets and thin films. The relationship between good film–substrate adhesive properties and the chemical composition at the interface was studied. The electrical properties of the sensing elements were studied at 40°C in environments at different relative humidity (RH) values between 2% and 95%, using ac impedance spectroscopy. MgAl₂O₄ thin films showed interesting characteristics in terms of their use in humidity-measurement devices. Resistance versus RH sensitivity values showed variations as high as 4 orders of magnitude in the RH range tested for thin films, and 5 orders of magnitude for pellets. The differences in the electrical behavior of MgAl₂O₄ pellets and thin films were correlated with their different microstructures.     

Electrophoretic Deposition of Dense La0.8Sr0.2Ga0.8Mg0.115Co0.085O3−δ Electrolyte Films from Single-Phase Powders for Intermediate Temperature Solid Oxide Fuel Cells

La_0.8Sr_0.2Ga_0.8Mg_0.115Co_0.085O_3−δ (LSGMC) powders were prepared by polymeric precursor synthesis, using either polyvinyl alcohol (PVA) or citric acid (CA) as complexing agents. The powders were synthesized using different ratios between the complexing agent and the cations dissolved in solution. The obtained polymer gel precursors were dried and calcined at temperatures between 1000° and 1450°C. Single-phase LSGMC powders were obtained at a firing temperature of 1450°C, using PVA and a molar ratio between the hydroxylic groups and the total cations of 3:1. Phase-pure LSGMC powders were used to sinter (1490°C, 2 h) thick pellets. The functional properties of LSGMC pellets were assessed by electrochemical impedance spectroscopy. The electrical conductivity values and the apparent activation energies in different transport regimes were in agreement with literature data. The same LSGMC powders were deposited by electrophoretic deposition (EPD) on a green membrane containing lanthanum-doped ceria (La_0.4Ce_0.6O_{2− x} , LDC), a binder, and carbon powders. The LSGMC/LDC bi-layer obtained by EPD was cofired at 1490°C for 2 h. A dense and crack-free 8-μm-thick LSGMC film supported on a porous skeleton of LDC was obtained. The combined use of proper powder synthesis and film processing routes has thus proven to be a viable way for manufacturing anode-supported LSGMC films.     

Ultra-Fine Ba2Ti9O20 Powders Synthesized by Inverse Microemulsion Processing and their Microwave Dielectric Properties

A double–inverse microemulsion (IME) process is used for synthesizing nano-sized Ba₂Ti₉O₂₀ powders. The crystallization of powders thus obtained and the microwave dielectric properties of the sintered materials were examined. The IME-derived powders are of nano-size (∼21.5 nm) and possess high activity. The BaTi₅O₁₁, intermediate phase resulted when the IME-derived powders were calcined at 800°C (4 h) in air. However, high-density Ba₂Ti₉O₂₀ materials with a pure triclinic phase (Hollandite like) can still be obtained by sintering such a BaTi₅O₁₁ dominated powders at 1250°C/4 h. The phase transformation kinetics for the IME-derived powders were markedly enhanced when air was replaced by O₂ during the calcinations and sintering processes. Both the calcination and densification temperatures were reduced by around 50°C compared with the process undertaken in air. The microwave dielectric properties of sintered materials increase with the density of the samples, resulting in a large dielectric constant ( K ≅39) and high-quality factor ( Q × f ≅28 000 GHz) for samples possessing a density higher than 95% theoretical density, regardless of the sintering atmosphere. Overfiring dissociates Ba₂Ti₉O₂₀ materials and results in a poor-quality factor.     

Oxygen Evolution During MnO-Mn3O4 Dissolution in a Borosilicate Melt

Foam evolution during dissolution of MnO-Mn₃O₄ pellets and powders in borosilicate glass was recorded photographically. The pellets were placed horizontally in transparent crucibles, covered with molten glass, and held at 1150°C. If the Mn₃O₄ content in pellets was more than 31 wt%, they developed foam after an initial foamless period. The length of the foamless period decreased and the duration of foaming increased as the Mn₃O₄ content increased. Batches prepared from MnO-Mn₃O₄ powders and frit, and soaked at 1150°C, foamed without an initial foamless period. The foam developed and collapsed before the set temperature was established within the melt and rose to a higher level than foam produced by pellets. Thermogravimetry of batches heated in 1 atm (∼10⁵ Pa) of O₂ shows oxidation at 400° to 600°C followed by mass loss due to volatilization and oxygen evolution.     

Preparation of an Alkali-Element-Doped CeO2-Sm2O3 System and Its Operation Properties as the Electrolyte in Planar Solid Oxide Fuel Cells

The ionic conductivity of the ceria-samaria (CeO₂-Sm₂O₃) system is higher than that of yttria-stabilized zirconia and other CeO₂-based oxides. In this study, a small amount of alkali-element-doped CeO₂-Sm₂O₃ solid solution was prepared. This solid solution was characterized by measuring the powder density and the chemical composition. Moreover, its electrochemical properties were investigated in the temperature range from 700° to 1000°C. It was found that a small amount of alkali-element-doped CeO₂ solid solution enhanced the ionic conductivity. The power density of an oxygen-hydrogen fuel cell for alkali-element-doped CeO₂-Sm₂O₃ ceramics exhibited high values at low temperatures such as 700° to 800°C. It is concluded that the improved fuel cell performance can be attributed to the high stability of this composition in the fuel atmosphere.     

Slip-Cast Ce0.8Sm0.2O1.9 Cone-Shaped SOFC

Cone-shaped Sm-doped CeO₂ (Ce_0.8Sm_0.2O_1.9, SDC) electrolyte cylinders have been fabricated using the slip-casting technique. A single solid oxide fuel cell has been prepared by applying a Sm_0.5Sr_0.5CoO₃ cathode on the outside of the cylinders and a NiO–SDC (7:3 wt%) anode on the inside. The open circuit voltage of the cell was 0.93 V at 400°C, and a maximum power density of about 300 mW/cm² at 700°C was obtained with humidified hydrogen (3% H₂O) as the fuel and ambient air as the oxidant. Impedance results showed that the performance of the cell was mainly influenced by the ohmic resistance of the electrolyte.     

Low Temperature Sintering of Zn3Nb2O8 Ceramics from Fine Powders

A possibility to produce microwave (MW) dielectric materials by liquid-phase sintering of fine particles was investigated. Zn₃Nb₂O₈ powders with a grain size 50–300 nm were obtained by the thermal decomposition of freeze-dried Zn–Nb hydroxides or frozen oxalate solutions. The crystallization of Zn₃Nb₂O₈ from amorphous decomposition products was often accompanied by the simultaneous formation of ZnNb₂O₆. Maximum sintering activity was observed for single-phase crystalline Zn₃Nb₂O₈ powders obtained at the lowest temperature. The sintering of as-obtained powders with CuO–V₂O₅ sintering aids results in producing MW dielectric ceramics with a density 93%–97% of the theoretical, and a Q × f product up to 36 000 GHz at sintering temperature ( T _s)≥680°C. The high level of MW dielectric properties of ceramics was ensured by intensive grain growth during the densification and the thermal processing of ceramics.     

Low-Temperature High-Pressure Consolidation of Amorphous Al2O3–15 mol% Y2O3

This study examined pressure consolidation of amorphous Al₂O₃–15 mol% Y₂O₃ powders prepared by co-precipitation and spray pyrolysis. The two amorphous powders had similar true densities and crystallization sequences. Uniaxial hot pressing was carried out at 450°–600°C with a moderate pressure of 750 MPa. The co-precipitated powder could be hot pressed to a maximum relative density of 98% and remained amorphous. Pressure adversely affected the densification of the spray-pyrolyzed powder by favoring an early crystallization of γ-Al₂O₃ phase at 580°C. Plastic deformation of the amorphous phase is believed to be responsible for the large densification of the amorphous powders.     

Microstructure and Electrical Properties of Chemically Prepared Nb2O5-Doped SrTiO3 Ceramics

Chemically homogeneous SrTiO₃ powders of submicrometer size were obtained by alcohol dehydration and subsequent calcination of citrate/format solutions. Nb₂O₅-doped SrTiO₃ was prepared with various Sr:Ti ratios resulting in an anomalous increase in the dielectric constant ( K 'up to ∼8000) for donor-doped SrO-excess SrTiO₃. No semiconducting behavior was observed for donor-doped TiO₂-excess SrTiO₃ when fired in air. Therefore, a "brick-wall" type of microstructure was formed as a result of the excess SrO, giving rise to anomalously high dielectric constants.     

Synthesis of Ba2RCu4O8 (R = Y, Sm) Superconductors at Oxygen Pressure of 1 atm by Spray-Frozen/Freeze-Drying Method

Precursor powders for high- T_c Ba₂RCu₄O₈ (R = Y, Sm) superconductors were successfully prepared through spray-frozen/freeze-drying (SF/FD) of a mixed aqueous solution that included the respective compounds according to the stoichiometric composition. These SF/FD powders were used to obtain ceramic superconductors composed of single-phase orthorhombic Ba₂RCu₄O₈ (R = Y, Sm) by sintering at an oxygen pressure of 1 atm. Critical temperatures measured were 84 K and 76 K for Ba₂YCu₄O₈ and Ba₂SmCu₄O₈, respectively, comparable to the previously reported values for these superconductors prepared under high oxygen pressure (100 atm). The present result was assumed attributable to the highly homogeneous powders.