Effect of spray process on dielectric properties of APS-deposited CaO–B2O3–SiO2 glass-ceramic coatings

Low-dielectric properties are highly desirable for successful realization of thermal spray coatings in electromagnetic wave absorption. Herein, CaO–B₂O₃–SiO₂ (CBS) glass-ceramic coatings are prepared via high-enthalpy atmospheric plasma spraying (HE-APS) method, and the influence of spraying power on physical and dielectric properties of APS-deposited CBS coatings is systematically investigated. Under high-power conditions, the increase in liquid phase hinders the discharge of gases and leads to an increase in the porosity of CBS coatings. The experimental results reveal that the coating density decreases and coating porosity increases with the increase of spraying power. Based on the crystallization behavior of CBS coatings, an excellent low-dielectric crystalline phase (β-CaSiO₃) was obtained after heat treatment at 800 °C. According to the dielectric mixing rule of composite materials, the density and permittivity exhibit the same trend and a minimum permittivity of 5.74 is obtained.     

Low pressure plasma-sprayed Al2O3 and Al2O3/SiC nanocomposite coatings from different feedstock powders

This paper describes a preliminary investigation of a nanocomposite ceramic coating system, based on Al₂O₃/SiC. Feedstock Al₂O₃/SiC nanocomposite powder has been manufactured using sol-gel and conventional freeze-drying processing techniques and then low pressure plasma sprayed onto stainless steel substrates using a CoNiCrAlY bond coat. Coatings of a commercial Al₂O₃ powder have also been manufactured as a reference for phase transformations and microstructure. The different powder morphology and size distribution resulting from the different processing techniques and their effect on coating microstructure has been investigated. Phase analysis of the feedstock powders and of the as-sprayed coatings by X-ray diffractometry (XRD) and nuclear magnetic resonance (NMR) showed that the nano-scale SiC particles were retained in the composite coatings and that equilibrium α-Al₂O₃ transformed to metastable γ- and δ-Al₂O₃ phases during plasma spraying. Other minority phases in the sol-gel Al₂O₃/SiC nanocomposite powder such as silica and aluminosilicate were removed by the plasma-spraying process. Microstructure characterisation by scanning electron microscopy (SEM) of the as-sprayed surface, polished cross-section, and fracture surface of the coatings showed evidence of partially molten and unmolten particles incorporated into the predominantly lamella microstructure of the coating. The extent of feedstock particle melting and consequently the character of the coating microstructure were different in each coating because of the effects of particle morphology and particle size distribution on particle melting in the plasma.     

High strength and hardness BNNSs/Al2O3 composite ceramics prepared by hot-press sintering of in-situ composite BNNSs/Al2O3 powder

In this paper, BNNSs/Al₂O₃ composite powder was prepared by in-situ reaction using borate nitridation method and BNNSs/Al₂O₃ composite ceramics were prepared by hot-pressing sintering. This method achieves uniform mixing of BNNSs and Al₂O₃ ceramic matrix and reduces the introduction of impurities in the processing process. The BNNSs/Al₂O₃ composite ceramics have excellent bending strength (549.4 MPa), fracture toughness (5.18 MPa m^1/2) and hardness (21.3 GPa). The high hardness of composite ceramics is attributed to high grain boundary strength and density. The reinforcing mechanisms of ceramics include BNNSs pull-out, BNNSs bridging, crack deflection as well as the transgranular fracture and intergranular fracture of Al₂O₃ matrix.     

Research on the preparation of Ni/Al2O3 powder by fluidized crystallization granulation–hydrogen reduction

This paper proposes a new process route for the preparation of Ni/Al₂O₃ composite powder through fluidized crystallization granulation–hydrogen reduction and investigates the effects of process feasibility, nickel concentration, nucleation method, and hydrogen reduction on Ni/Al₂O₃-coated powder. The decrease in nickel concentration, heterogeneous nucleation, and natural air-drying properties of precursor particles was beneficial to the formation of a complete and uniform cladding layer, and the increase in hydraulic retention time could improve the thickness of the cladding layer. The optimum process involves a nickel concentration of 50 mg/L; hydraulic residence time of 75 h to ensure heterogeneous nucleation; two-step hydrogen reduction of precursor particles to obtain a complete and uniform Ni/Al₂O₃ cladding layer; and a powder surface nickel content of 59.5%.     

Influence of different introduction modes of metal Ag into plasma sprayed Al2O3 coating on tribological properties

Al₂O₃ coating and Al₂O₃/Ag (10%) composite coating were prepared on the surface of GH4169 superalloy by the atmospheric plasma spraying technology. And an in-situ synthesis method was applied to introduce the Ag particles into a part of Al₂O₃ coatings to obtain Al₂O₃/Ag(synthesis) composite coating. Then, the microstructure and mechanical properties of these three Al₂O₃-based coatings were systematically studied in this work. In order to reveal the lubrication characteristics of Ag, their friction tests were carried out at room temperature (RT), 400 °C, 600 °C and 800 °C, respectively. The results showed that both microstructure and mechanical properties of Al₂O₃/Ag(synthesis) composite coating were better than that of Al₂O₃/Ag (10%) composite coating because many pores and cracks produced during the direct spraying. Although the friction coefficients of two kinds of composite coatings were close to that of Al₂O₃ coatings at RT, their wear rates were both greatly decreased due to the introduction of Ag. In addition, the lubricating performance of Ag was not enough to reduce their friction coefficients when friction temperature is lower than 600 °C. However, the friction coefficients of these composite coatings were both reduced to about 0.3 at 800 °C . At this time, the Al₂O₃/Ag(synthesis) composite coating also exhibited a lower wear rate because of its dense microstructure and excellent mechanical properties.     

Multi-functional Al2O3-coated separators for high-performance lithium-ion batteries: Critical effects of particle shape

The technology of coating polyolefin-type separators with ceramics is gradually developing as an effective method to improve the safety of lithium-ion batteries (LIBs). However, the powder properties of ceramics can adversely affect the surface structure and ionic conductivity of separators; therefore, a new approach is required regarding the powder properties that affect the performance of the separator. Herein, the effect of the Al₂O₃ particle shape on the physical properties of Al₂O₃-coated separators and the performance of LIBs is investigated. In the separator coated with angular-shaped Al₂O₃ particles (Al₂O₃-A), the pores in the coating layer are uniformly distributed, improving physical properties such as porosity and wettability. The thermal shrinkage of separator is <10% when exposed to 150 °C for 1 h, considerably smaller than that of the commercial polyethylene separator (approximately 83%) under the same conditions. Moreover, the Al₂O₃-A-coated separator shows the highest ionic conductivity (0.531 mS cm⁻¹), and the LiNi_0.8Mn_0.1Co_0.1O₂/Al₂O₃-A-coated separator/Li battery displays improved stability than using the polyethylene separator under a current density of 5C. This proposes approach to improve the separator's performance through the shape control of ceramic particles paves the way for separators to contribute to the high-temperature safety and long cycle life of batteries.     

Effect of YAG content on creep resistance and mechanical properties of Al2O3-YAG composite

Comprehensive study on effect of YAG amount on densification, creep resistance and room-temperature mechanical properties of Al₂O₃-YAG composite pressureless sintered at 1600 °C was conducted. The main goal was to optimize the amount of YAG in order to fabricate a composite with improved creep resistance and sufficiently good room-temperature mechanical properties. The composite was made by mixing a commercially available Al₂O₃ powder with fine YAG powder obtained by glycine-nitrate combustion synthesis starting from aluminum nitrate and yttrium nitrate. Increased driving force for sintering of fine YAG powder allowed fabrication of dense Al₂O₃-YAG composite with up to 30 vol% YAG. The presence of YAG was found to be very effective in improving creep resistance of Al₂O₃-YAG composite. Large Y³⁺ ions blocked diffusion along Al₂O₃ grain boundaries, reduced diffusivity and therefore enhanced creep resistance of Al₂O₃-YAG composite which continuously increased as the YAG amount increased. Тhe presence of YAG was also found to improve mechanical properties such as hardness and elastic modulus. The improvement of these properties was ascribed to increased density of Al₂O₃-YAG composites owing to high sintering activity of YAG powder. While fracture strength of the composite can be as high as that of monolithic Al₂O₃, fracture toughness of composite decreased continuously as the YAG content increased. The decrease was ascribed to transgranular fracture of both YAG and Al₂O₃ grains in samples containing larger amounts of YAG. The proper balance between fracture toughness and creep resistance was found in composite containing 18 vol% YAG which had considerably improved creep resistance accompanied by a relatively small decrease in fracture toughness.     

Design and preparation of BaO–Al2O3–SiO2–B2O3/Quartz LTCC composites with tailored coefficient of thermal expansion

In this work, by focusing on widespread problem of thermal mismatch caused by different coefficients of thermal expansion (CTE) in electronic packaging materials, low-temperature co-fired ceramic (LTCC) materials with tunable CTE values were designed. By substituting Ba²⁺ with Sr²⁺ and replacing quartz with alumina and zirconia, respectively, BaO–Al₂O₃–SiO₂–B₂O₃/quartz LTCC composites with CTE of 7.05–9.52 × 10^?6/°C were developed. Results show that major crystalline phases of LTCC composite materials are quartz and hexacelsian. By replacing quartz with alumina or zirconia, sintering behavior and subsequently thermal expansion and dielectric properties were modulated. On the other hand, substituting Ba²⁺ with Sr²⁺ can be beneficial to the densification of composite materials. The introduction of Sr²⁺ triggered mixed alkali effect and hindered the crystallization of hexacelsian phase, which can further improve mechanical properties. Finally, sandwich structure module of BaO–Al₂O₃–SiO₂–B₂O₃/quartz with gradient CTE values was obtained, which showed potential for electronic packaging with sustained thermal compatibility under cyclic temperatures.     

Novel Al2Mo3O12-PTFE composites for microwave dielectric substrates

Nowadays, microwave dielectric substrate materials have been extensively investigated to meet the requirements of rapid development in modern communications. Among them, the composites of ceramic powder filled polytetrafluoroethylene (PTFE) have been a hot topic. However, the compatibility and connectivity between the surface of ceramics and PTFE molecular chains in the samples are usually low. Herein novel PTFE based composites with different contents of Al₂Mo₃O₁₂ (20–60 wt%) modified by C₁₄H₁₉F₁₃O₃Si (F8261) coupling agent were designed and prepared. The coupling agent F8261 has been successfully grafted to the surface of Al₂Mo₃O₁₂ powders, effectively promoting the densification and dielectric properties of the composites. As the content of the modified Al₂Mo₃O₁₂ powders increases from 20 to 60 wt%, the ε_r value increases from 3.4 to 4.2, and tanδ almost remains constant at the beginning and increases with much more Al₂Mo₃O₁₂ added. The Al₂Mo₃O₁₂-PTFE composites filled with 30 wt% Al₂Mo₃O₁₂ present the optimal dielectric properties of ε_r = 3.6 and tanδ = 0.0018 with a high density of 95.6%. In addition, the electromagnetic and multiphysic simulation of a 24 GHz substrate integrated waveguide filter on the basis of the 30 wt% Al₂Mo₃O₁₂ - 70 wt% PTFE composite was carried out. It was revealed that the filter presented high stability on the electrical parameters caused by self-heating and dimension deformation due to the good microwave dielectric, thermal and mechanical properties of the substrate. These results indicate that the as-prepared 30 wt% Al₂Mo₃O₁₂ - 70 wt% PTFE composite would be a promising candidate for high-performance microwave dielectric substrates.     

Thermal conductivities of YSZ/Al2O3 composites

The thermal conductivities/diffusivities of YSZ/Al₂O₃ composites have been investigated by a laser flash technique. The thermal conductivity of the composite increases with an increase in the Al₂O₃ volume fraction, and it can be fitted well to the Maxwell theoretical model. The consistency of the thermal conductivities of the composites with the predicted values indicates the absence of obvious interfacial thermal resistances in the composites. The negligible thermal resistance effect from the YSZ and Al₂O₃ grain boundaries is due to the much lower phonon mean free path compared with the grain size in the composite. The low Kapitza resistance of the YSZ/Al₂O₃ interface is discussed in terms of the “clean” and coherent nature of the YSZ/Al₂O₃ interface, together with the small difference between the elastic properties of YSZ and Al₂O₃.     

SiO2/Al2O3 ratio dependence of microstructures and dielectric properties in barium strontium titanate glass ceramics

(Ba, Sr)TiO₃-Al₂O₃-SiO₂ glass ceramic system with various SiO₂/Al₂O₃ ratios was investigated by X-ray diffractometry (XRD), scanning electron microscopy (SEM), dielectric spectroscopy and impedance spectroscopy. The XRD results demonstrated that the proper SiO₂/Al₂O₃ ratio could promote the crystallization of the major crystalline phase from the glass matrix. The dielectric property investigations showed that the dielectric constant passes through a maximum value while the dielectric breakdown strength has a minimum value with increasing SiO₂/Al₂O₃ ratio. Meanwhile, the complex impedance analyses suggest the resistance of the glass-crystal interface rapidly decreases and the capacitance of the crystal slightly decreases with the increase of SiO₂/Al₂O₃ ratio. The relaxation mechanisms of the (Ba, Sr)TiO₃ glass ceramics changed from localized relaxation to long range conductivity as the SiO₂/Al₂O₃ ratio was increased from 1.43 to 1.83. The variations in the dielectric response and the activation energy of the glass-crystal interface in the (Ba, Sr)TiO₃ glass ceramics with the ratio of 2.40 could be attributed to the crystallization of fresnoite phase.     

Incorporating sugarcane bagasse ash into Al2O3 ceramic tapes

High-temperature co-fired ceramic (HTCC) technology aims to incorporate fluxing materials into ceramic tapes to decrease the sintering temperature. In this context, we incorporate waste from sugarcane bagasse ash (SCBA) into alumina (Al₂O₃) tapes. We report an experimental investigation of the structural, physical, mechanical, and dielectric properties of the Al₂O₃ tape with the addition of the SCBA waste. The tape casting technique prepared the ceramic tape. The materials under study were characterized by rheology, thermogravimetry, dilatometry, X-ray diffraction, scanning electron microscopy, relative density, Vickers microhardness, mechanical resistance, and dielectric measurements. The dilatometry results confirm that the addition of the SCBA waste remarkably reduces the sintering temperature of the Al₂O₃ tape to 1200°C. The physical, mechanical, and dielectric properties are improved with the addition of the SCBA waste, which makes our discoveries attractive from an environmental and economic point of view. Besides, the stabilization and high dielectric constant of the Al₂O₃-SCBA tape becomes a promising material for aircraft turbine applications.     

Effects of Al2O3 addition on sintering behaviour,microstructure, and physical properties of Al2O3/vitrified bond CBN composite

The effects of Al₂O₃ content on the sintering behaviour, microstructure, and physical properties of Al₂O₃/vitrified bonds (SiO₂–Al₂O₃–B₂O₃–BaO–Na₂O–Li₂O–ZnO–MgO) and Al₂O₃/vitrified bond cubic boron nitride (CBN) composites were systematically investigated using X-ray diffraction, differential scanning calorimetry, dilatometry, scanning electron microscopy, and X-ray photoelectron spectroscopy. Various amounts of Al₂O₃ promoted the formation of BaAl₂Si₂O₈ and γ-LiAlSi₂O₆, increasing the relative crystallinity of the Al₂O₃/vitrified composite from 85.0 to 93.2%, resulting in residual compressive stress on BaAl₂Si₂O₈, thereby influencing the thermal behaviour and mechanical properties of the Al₂O₃/vitrified composite. The bulk density, porosity, flexural strength, hardness, and thermal conductivity of 57.5 wt% Al₂O₃ sintered at 950 °C were 3.12 g/cm³, 6.1%, 169 MPa, 90.5 HRC, and 4.17 W/(m·K), respectively. The coefficient of thermal expansion of the bonding material was 3.83 × 10^?6 °C^?1, which was comparable to that of CBN, and the number of N–Al bonds were increased, which boosted the flexural strength of the Al₂O₃/vitrified CBN composite to 81 MPa. The excellent mechanical properties, compact structure, and suitable interfacial bonding state with the CBN grains of the Al₂O₃/vitrified composite make it a promising high-performance bonding material for superhard abrasive tools.     

YCrO3/Al2O3 Core‐Shell Design: The Effect of the Nanometric Al2O3‐Shell on Dielectric Properties

We report a novel strategy to improve the dielectric properties of the biferroic YCrO₃ ceramic compound through interface conduction control by means of an insulating Al₂O₃ using a core‐shell design. The YCrO₃ particles were covered with several layers of insulating Al₂O₃ using the atomic layer deposition technique to produce the core‐shell structure. TEM images reveal homogeneous and well‐defined Al₂O₃ coatings of ~8, ~60, and ~130 nm thickness. XRD shows the Al₂O₃‐shell to be amorphous. The dielectric characteristics of the sintered nano‐composite were investigated in the 100 Hz–1 MHz frequency range and temperature between 300 and 580 K. As the Al₂O₃‐shell thickness covering the YCrO₃ particles is increased, a decrease of the dielectric permittivity, loss tangent and AC conductivity values was found in the whole range of temperatures and frequencies. Furthermore, the rounded hysteresis loop, typical of conductive ceramic is restored as the insulating Al₂O₃ layer becomes thicker. This behavior is explained because the insulating Al₂O₃‐shell acts as internal barrier layer localizing the surface charges on the sintered grain boundaries. This fact was confirmed by Electron Beam Induced Current technique where a clear contrast at the grain boundaries confirms the charge localization at the YCrO₃/Al₂O₃ interface. These results also reveal that the Al₂O₃‐shell induces another conductive mechanism when the insulating Al₂O₃ layer becomes thicker. Nonetheless, this new strategy is an effective approach to suppress the parasitic conductivity in polycrystalline multiferroic ceramics and increasing thus the multifuncionality.     

Effect of Al2O3 particles on mechanical and tribological properties of Al–Mg dual-matrix nanocomposites

This article aims to manufacture homogenous dual-matrix Al–Mg/Al₂O₃ nanocomposite from their raw materials and give insight into the correlation between powder morphology, crystallite structure and their mechanical and tribological properties. Al–Mg dual-matrix reinforced with micro/nano Al₂O₃ particles was manufactured by a novel double high-energy ball milling process followed by a cold consolidation and sintering. Microstructure and phase composition of the prepared samples were characterized using FE-SEM, EDS and XRD inspections. Mechanical and wear properties were characterized using compression and sliding wear tests. The results showed that a milling of Mg with Al₂O₃ particles in an initial step before mixing with Al has the beneficial of well dispersion of Al₂O₃ nanoparticles in Al–Mg dual matrix. The Al–Mg dual matrix reinforced with nano-size Al₂O₃ showed 3.29-times smaller crystallite size than pure Al. Moreover, the hardness and compressive strength are enhanced by adding nano-size Al₂O₃ with Al–Mg dual matrix composite while the ductility is maintained relatively high. Additionally, the wear rate of this composite was reduced by a factor of 2.7 compared to pure Al. The reduced crystallite size, the dispersion of Al₂O₃ nanoparticles and the formation of (Al–Mg)_ss were the main improvement factors for mechanical and wear properties.     

Carbon nanotube/graphene oxide‐added CaO‐B2O3‐SiO2 glass/Al2O3 composite as substrate for chip‐type supercapacitor

A CaO‐B₂O₃‐SiO₂ (CBS) glass/40 wt% Al₂O₃ composite sintered at 900°C exhibited a dense microstructure with a low porosity of 0.21%. This composite contained Al₂O₃ and anorthite phases, but pure glass sintered at 900°C has small quantities of wollastonite and diopside phases. This composite was measured to have a high bending strength of 323 MPa and thermal conductivity of 3.75 W/(mK). The thermal conductivity increased when the composite was annealed at 850°C after sintering at 900°C, because of the increase in the amount of the anorthite phase. 0.25 wt% graphene oxide and 0.75 wt% multi‐wall carbon nanotubes were added to the CBS/40 wt% Al₂O₃ composite to further enhance the thermal conductivity and bending strength. The specimen sintered at 900°C and subsequently annealed at 850°C exhibited a large bending strength of 420 MPa and thermal conductivity of 5.51 W/(mK), indicating that it would be a highly effective substrate for a chip‐type supercapacitor.     

Aerosol-deposited Al2O3/PTFE hydrophobic coatings with adjustable transparency

With the wide range of requirements for architectural glass, such as transparency, opacity, and hydrophobicity, there is a need to address the issues in the complexity of convention methods. Thus, considering functionality and applicability in various architectural windows, hydrophobic alumina/polytetrafluoroethylene (Al₂O₃/PTFE) composite layers with transparency or opacity were transferred to commercial architectural glass using a facile aerosol deposition (AD) process. We successfully fabricated hydrophobic coating layers with high transmittance (only a 0.03% difference from sheet glass) by optimizing the PTFE content in Al₂O₃ using solution-based synthesized powders to enable a uniform surface topology. The opaque hydrophobic Al₂O₃/PTFE coating layers exhibit a transmittance of approximately 0% with excellent hydrophobicity of 130°. Remarkably, this opaque film was successfully employed onto a large deposition area, curved substrate, and micro-patterned regions. It is believed that our AD-prepared composite layers have great potential for architectural glass in terms of economic feasibility and versatility.     

Formation mechanism of Al2O3-YAG amorphous ceramic coating deposited via atmospheric plasma spraying

Al₂O₃-YAG (Al₅Y₃O₁₂) amorphous ceramic coatings exhibit excellent crack propagation resistance under harsh wear services due to the amorphous phase contributing to the plastic deformation performance of the coating. However, the formation mechanism of the amorphous phase is ambiguous. This study mainly investigated the formation mechanism of Al₂O₃-YAG amorphous coating prepared by atmospheric plasma spraying from the perspective of crystallization chemistry. Nano and microsized powders with low eutectic point ratio were selected as feedstock for comparison. X-ray diffraction, scanning electron microscope, and electron backscattered diffraction were used to analyze the phase composition, morphologies, phase distribution, and structure of the coating. It is concluded that the significant thermodynamically stable structure of polycompound with high coordination numbers of cations prioritized crystallizing in the Al₂O₃-YAG melt, but it needed more time to crystallize and hardly crystallized in the limited time during plasma spraying. Therefore, the selection of as-sprayable powder should also be considered the critical factor for preparing amorphous coatings. The nanoscale or submicro scale powder distributed uniformly with low eutectic point ratio was chosen as the feedstock to ensure the powder droplets diffuse sufficiently during deposition.     

Enhanced dielectric characteristics of Ba0.94Bi0.04(Fe0.5Nb0.5)O3 coated with SiO2 and SiO2/Al2O3 over a broad frequency and temperature range

Pure phase of Ba_0.94Bi_0.04(Fe_0.5Nb_0.5)O₃ (BBFN) nano-particles were obtained by chemical co-precipitation method. The core-shell structure of BBFN@SiO₂ and BBFN@SiO₂/Al₂O₃ particles and the target ceramics were successfully prepared by aqueous chemical coating approach. The microstructures and dielectric properties of BBFN@SiO₂ and BBFN@SiO₂/Al₂O₃ were studied. Both the BBFN@SiO₂ and BBFN@SiO₂/Al₂O₃ samples show significantly decreased dielectric loss and good frequency and temperature stability on relative permittivity. Compared to the rapid decline of relative permittivity of BBFN@SiO₂, the synergistic effect of SiO₂ and Al₂O₃ in BBFN@SiO₂/Al₂O₃ ceramics made the relative permittivity of which remains a relatively high level with very low dielectric loss, making it more suitable in colossal permittivity applications. Based on the impedance analysis, the grain boundary effect and IBLC models play the important role for the improvement of dielectric properties of BBFN@SiO₂/Al₂O₃ samples.