Two-step preparation of fly ash-based composites for microwave absorption

To develop a novel utilization avenue for fly ash (FA), the Co-loaded FA (CoFA) was constructed utilizing FA as raw material to acquire the enhanced microwave absorption (MA) performance. In this study, the CoFA composites were fabricated by a two-step method, including the construction of FA-based ceramic matrix and a subsequent loading of magnetic components. The results of XRD, SEM, and elemental mapping images revealed that Co particles generated from the carbothermal reduction were well dispersed over the interior and surface of matrix. Compared with pure FA, the as-prepared CoFA composites demonstrated the impressive MA performances, which were attributed to the good impedance matching, conduction loss, and interfacial polarization effect between the matrix and Co. When the annealing temperature kept at 700°C, the minimum reflection loss (RL_min) of as-prepared CoFA700 reached up to −40.5 dB and the broad absorption band was measured to be 4.7 GHz with a thickness of 2.0 mm, which was superior to pure FA. Our strategy might provide a new direction to the fabrication of high-efficient MA materials derived from FA.     

The effect of ionic contaminants on the early-age properties of alkali-activated fly ash-based cements

Alkali-activated fly ash-based cements are concrete binders that utilise fly ash as their major solid raw material. The solid particles are activated using concentrated silicate and hydroxide solution to produce high-strength products. Due to the highly alkaline nature of the solution, precipitation of the reactive species, both from the solids and from the solution, proceeds at a very fast rate. This renders short setting times, which can be advantageous or disadvantageous depending on the practical situation. The present work examines the effects of inorganic salt addition towards the setting and rheological characteristics of the early pastes. Compressive strength, Fourier transform infrared spectroscopy (FTIR) and X-ray diffractograms were collected to examine the hardened products. It was found that calcium (Ca) and magnesium (Mg) salts shortened the setting time by providing heterogeneous nucleation centers in the initial paste solution. Potassium salts retarded setting only to the cements, which used less sodium silicate in the initial solution for activation. Managed ionic contamination can be used to increase the product early strength. However, its long-term effects still need to be identified.     

Nano-crystal glass-ceramics obtained from high alumina coal fly ash

Glass has been obtained by melting high alumina coal fly ash with fluxing additives. A thermal treatment was employed to convert the obtained glass into nano-crystal glass-ceramics. X-ray diffraction (XRD) patterns show that the main crystalline phases in both the glass-ceramics are anorthite (CaAl₂Si₂O₈) and wollastonite (CaSiO₃). The crystals are homogeneously dispersed within the parent glass. The average crystal size is below 200 nm. Physical and mechanical properties, such as density, thermal expansion coefficient, hardness, and bending strength, of the glass have been examined and the corresponding microstructures are discussed. The results demonstrate that the glass-ceramics have potential for a wide range of construction application.     

Effect of preparation conditions on mechanical,dielectric and microwave absorption properties of SiC fiber/mullite matrix composite

Silicon carbide fiber-reinforced mullite matrix (SiC_f/Mu) composites were fabricated via an infiltration and sintering method. Effects of sintering parameters on microstructure, mechanical, dielectric and microwave absorption properties of SiC_f/Mu composites have been investigated. The flexural strength is significantly improved with increasing sintering temperature, and the highest flexural strength of 213?MPa is obtained in vacuum at 1000?°C for 2?h. The performances of composites with different holding time are further studied at 1000?°C. The flexural strengths of composites sintered at 1000?°C for 2 and 4?h reach 213 and 219?MPa, respectively. The failure displacement of the composite sintered at 1000?°C for 4?h reaches 0.39?mm. The excellent microwave absorption properties are achieved for the composite sintered at 1000?°C for 2?h. The minimum reflection loss (RL) reaches ?38?dB with a thickness of 2.9?mm?at 12?GHz and the effective absorbing bandwidth (RL?≤??10?dB) with a thickness of 3.4?mm covers the whole X?band, which indicate that SiC_f/Mu composite is a good candidate for microwave absorbing materials. These results provide valuable solutions to obtaining structural-functional materials for microwave absorption applications in civil and military areas.     

Mechanical properties of graphene platelet-reinforced alumina ceramic composites

Alumina (Al₂O₃) ceramic composites reinforced with graphene platelets (GPLs) were prepared using Spark Plasma Sintering. The effects of GPLs on the microstructure and mechanical properties of the Al₂O₃ based ceramic composites were investigated. The results show that GPLs are well dispersed in the ceramic matrix. However, overlapping of GPLs and porosity within ceramics are observed. The flexural strength and fracture toughness of the GPL-reinforced Al₂O₃ ceramic composites are significantly higher than that of monolithic Al₂O₃ samples. A 30.75% increase in flexural strength and a 27.20% increase in fracture toughness for the Al₂O₃ceramic composites have been achieved by adding GPLs. The toughening mechanisms, such as pull-out and crack deflection induced by GPLs are observed and discussed.     

Microwave dielectric properties and compatibility with silver electrode of novel low-fired Ba4CuTi11O27 ceramic

A novel low-fired microwave dielectric ceramic with composition of Ba₄CuTi₁₁O₂₇ was prepared by a conventional solid-state reaction method. A single-phase Ba₄CuTi₁₁O₂₇ ceramic could be well densified after sintering above 950 °C for 4 h in air. A refinement using X-ray powder diffraction data was carried out in the Rietveld method using the parameters of Ba₄Ti₁₂O₂₇ as a starting model. Ba₄CuTi₁₁O₂₇ ceramic sintered at 975 °C has a monoclinic structure (C12/m1) with lattice parameters of a=19.8061(4) Å, b=11.4456(2) Å, c=9.9131(2) Å, β=108.8988(15) Å, V=2126.08(8) Å³, Z=4. The Ba₄CuTi₁₁O₂₇ ceramics exhibited a low sintering temperature (~975 °C) and good microwave dielectric properties with Q×f value of 15,040 GHz, ε_r of 36.3 and τ_f value 11.9 ppm/°C. More importantly, the Ba₄CuTi₁₁O₂₇ dielectrics demonstrated good chemical compatibility with Ag when sintered at 950 °C, keeping excellent microwave dielectric properties with Q×f=12,130 GHz, ε_r=36.1, τ_f=12.1 ppm/°C, which indicates that Ba₄CuTi₁₁O₂₇ ceramic is a candidate for LTCC devices.     

Controllable dielectric properties and strong electromagnetic wave absorption properties of SiC/spherical graphite-AlN microwave-attenuating composite ceramics

Fully dense SiC/spherical graphite-AlN microwave-attenuating composite ceramics were manufactured via hot-pressing sintering, in which, apart from the primary SG (spherical graphite) attenuating agent, 5–30 wt% semiconductive α-SiC was employed as the second attenuating agent. The incorporation of SiC contributed to a slightly decreasing electrical conductivity and enhanced polarization relaxation. Controllable complex permittivities were obtained, namely, both the real and imaginary permittivities exhibit first a decrease and then an increase with the SiC addition, and which delivers an optimized impedance matching of the composites. RL_min values below ?10 dB (more than 90% absorption) were achieved by all the composites containing 5–20 wt% SiC with the sample thickness of 1–1.4 mm, and the absorption performance characteristics were significantly tunable by controlling the of SiC content at 8.2–12.4 GHz. Impressively, a superior reflection loss of ?46 dB (1.1 mm) and wide effective absorption bandwidth of 2.1 GHz were achieved at a 5 wt% SiC content, respectively, rendering SiC/SG–AlN composites a potential ultra-thin and highly efficient microwave-attenuating ceramic candidate.     

Novel high dielectric constant and low loss PTFE/CNT composites

Spherical Ca_0.55Nd_0.3TiO₃ ceramic filled polytetrafluoroethylene composites (abbreviated as PTFE/CNT) with different filler volume fractions were prepared. The effects of filler volume fraction on microstructure, dielectric properties and thermal property were studied by scanning electron microscope, vector network analyzer and thermal dilatometer, respectively. The SEM results show that spherical particles are advantageous to reduce the porosity in the interphase which would increase the dielectric loss. Moreover, both the dielectric constant and dielectric loss increased with the increasing volume fraction of CNT microspheres. The high dielectric constant and low dielectric loss composite can be prepared when the ceramic volume fraction is 50?V%: ε_r =?12, tan?δ?=?8.5?×?10^?4 (at 10?GHz). Different models were used to predict the dielectric constant of composite, and the effective medium theory shows the least deviation from the experiment. The experimental coefficient of thermal expansions of composites with different volume fractions were less than theoretical data due to the change from loosely bound polymer chain to tightly bound polymer chain which would restrain the coefficient of thermal expansions of composites.     

Enhanced electromagnetic absorption properties of Fe-doped Sc2Si2O7 ceramics

Doping transition metal elements in a crystal causes distortion and defects in the lattice structure, which change the electronic structure and magnetic moment, thereby adjusting the electrical conductivity and electromagnetic properties of the material. Fe-doped Sc₂Si₂O₇ ceramics were synthesized using the sol-gel method for application to microwave absorption. The effect of Fe-doped content on the electromagnetic (EM) and microwave absorption properties was investigated in the Ku-band (12.4–18 GHz). As expected, the dielectric and magnetic properties improve substantially with increasing Fe content. Fe doping causes defects and impurity levels, which enhance polarization loss and conductance loss, respectively. Fe replaces Sc atoms in the ScO₆ octahedral structure, creating a difference in spin magnetic moments, which increases the magnetic moment. Moreover, the magnetic coupling of Fe and O atoms occurs at the Fermi level, which benefits magnetic loss. In particular, when the Fe content is 6%, the fabricated Fe-doped Sc₂Si₂O₇ ceramics show an absorption property with absorption peaks located at 14.5 GHz and a minimum reflection loss (RL_min) of ?12.8 dB. Therefore, Fe-doped Sc₂Si₂O₇ ceramics with anti-oxidation and good microwave absorption performance have a greater potential for application in high-temperature and water-vapor environments.     

Magneto-dielectric laminated Ba(Fe0.5Nb0.5)O3-Bi0.2Y2.8Fe5O12 composites with high dielectric constant and high permeability

Magneto-dielectric laminated ceramic composites of xBa(Fe_0.5Nb_0.5)O₃-(1-x)Bi_0.2Y_2.8Fe₅O₁₂(BFN-BYIG) with high volume fractions of the giant dielectric constant material BFN (x=10, 30, 50, 70 wt%) were fabricated by the solid-state sintering method. Microstructure, dielectric and magnetic properties of the composites were investigated. The composites possess stable dielectric properties in the frequency range from 100 Hz to 1 MHz with high dielectric constant and low dielectric loss. The maximum permeability of the magneto-dielectric laminated composites reaches up to about 25. And the magnetic behaviors are strongly dependent on the mass ratio of BYIG. The results indicate that such multilayer structures of BFN/BYIG can enhance the permeability and decrease the dielectric and magnetic loss efficiently.     

Single crystal to polycrystal: Enhanced dielectric loss and electromagnetic wave absorption of MoO2 ceramic at Gigahertz

In this work, the dielectric loss behavior and electromagnetic wave absorption (EMA) property of MoO₂ ceramic from single crystal to polycrystal have been in-depth investigated. It is found that polycrystal MoO₂ shows better dielectric loss ability than single crystal MoO₂, leading to greatly enhanced EMA performance. It is determined that polarization loss occupies the dominant position in the dielectric loss of MoO₂ ceramic. This research provides new insights in understanding of dielectric loss behavior and EMA mechanism for dielectric MoO₂ crystals.     

Electrical conductivity,dielectric and microwave absorption properties of graphene nanosheets/magnesia composites

Herein, a novel microwave absorbing material with Graphene nanosheets (GNSs) as microwave absorbing filler and magnesia (MgO) as matrix were prepared by hot-pressing sintering. The composites were highly dense with a homogeneous distribution of GNSs. Electrical conductivity, dielectric and microwave absorption properties in X-band were investigated. The results revealed that the electrical conductivity of the GNSs/MgO composites showed a typical percolation-type behavior with a percolation threshold of 3.34 vol%. With GNSs content increased to 3 vol%, the real permittivity, imaginary permittivity and dielectric loss tangent of the composites increased from ～9, ～0 and ～0 to 26–43, 23–28 and 0.55–0.96, respectively. By adjusting the GNSs content, thickness and frequency, the 2.5 vol% GNSs/MgO composite shows the minimum reflection loss of ?36.5 dB at 10.7 GHz and the reflection loss below ?10 dB (90% absorption) ranges from 9.4 to 11.4 GHz with 1.5 mm thickness, exhibiting excellent microwave absorption properties.     

Influence of dextrin content and sintering temperature on the properties of coal fly ash-based tubular ceramic membrane for flue gas moisture recovery

In this paper, in order to reduce the preparation cost of high-performance ceramic membrane, coal fly ash-based tubular ceramic membrane for flue gas moisture recovery was prepared, and its properties were optimized from two aspects: pore-forming agent (dextrin) content and sintering temperature. The results show that the ceramic membrane with dextrin content of 3 wt.% and sintering temperature of 1150 ℃ has the best performance. Through characterization, the ceramic membrane exhibits an open porosity of 42.0 %, mechanical strength of 26.6 MPa, average pore size of 0.49 μm, pure water flux of 5616 L/(m² barh). And, it has excellent corrosion resistance in acid and alkali. In addition, the flue gas moisture recovery performance of coal fly ash-based tubular ceramic membrane was studied experimentally. The highest water recovery ratio and the highest recovered water flux is 87.7 % and 6.01 kg/(m² h, respectively.     

Varistor and dielectric properties of SiO2 doped SnO2-Zn2SnO4 ceramic composites

In this work, SiO₂ doped SnO₂-Zn₂SnO₄ ceramic composites with excellent varistor and dielectric properties were prepared through traditional ceramic processing. The obtained nonlinear coefficient α was as high as 9.6, and the breakdown electrical field EB and leakage current density JL was as low as 5.9 V/mm and 62 μA/cm², respectively. At a low frequency of 40 Hz, the relative permittivity εr measured at room temperature was higher than 2.5×10⁴. The nonlinear decrease of the semicircle diameter in the complex impedance spectra with increasing DC bias voltage indicates that the grain boundary effect is an important origin of the varistor and giant permittivity properties. With an increase of temperature, the relaxor peak of the imaginary part M″ of the complex electric modulus shifted to high frequency and the activation energy E_a obtained from the M″ spectrum was about 0.31 eV, much lower than the grain boundary barrier height ϕ_b. The results suggest that other mechanisms may also be responsible for the giant permittivity property besides grain boundary barriers.     

Production of ceramic glass foam of low thermal conductivity by a simple method entirely from fly ash

Ceramic glass foam/foams (CGF) from two different F-class fly ashes were produced via a well-known simple conventional sintering method using sodium silicate (Na₂SiO₃) as a foaming and fluxing agent. The research aimed to understand the effects of each fly ash, Na₂SiO₃ ratio, and sintering conditions on the properties and microstructure to produce a commercial CGF of low thermal conductivity. The chemical composition of fly ash from the thermal power plants of Tunçbilek and Seyitömer were quite similar but had different melting temperatures and microstructures. While the foam structure was successfully obtained at 1100 °C with 30 wt.% Na₂SiO₃ from Tunçbilek fly ash, a similar structure was obtained at 1150 °C from the Seyitömer fly ash. The effects of Na₂SiO₃ content and sintering temperature on the properties and microstructure of the CGF from the Tunçbilek fly ash of a lower melting point, in particular, were investigated systematically. The optimal sintering temperatures were determined to be 1200, 1150, and 1100 °C at the highest fly ash ratios of 90, 80 and 70 wt.%, respectively. The CGF were produced with 69.76–75.43% porosity, 0.55–0.69 gr/cm³ bulk density, 3.2–5.35 MPa compressive strength and 0.10–0.21 W/(m K) of low thermal conductivity. XRD results showed that optimal CGF samples mainly contained spinel, quartz and hematite crystal phases and amorphous phase. In this research, a thermal insulation material was successfully produced using an industrial waste completely with a well-known simple method. It is thought that this will contribute beneficially to the environment and the economy.     

Structural,electromagnetic, and dielectric properties of lithium-zinc ferrite ceramics sintered by pulsed electron beam heating

Structural, electromagnetic, and dielectric properties of Li_0.4Fe_2.4Zn_0.2O₄ lithium-zinc ferrite sintered by 2.4 MeV pulsed electron beam heating at 1050 °С for 2 h were investigated. The formation of ferrite with a single-phase cubic spinel structure was confirmed by X-ray diffraction analysis. The average grain size of ferrite ceramic was determined by SEM analysis and its value was 1.7 µm. The radiation-thermal sintered samples are characterized by a saturation magnetization of 67.8 emu/g, the Curie temperature of 508 °C, AC electrical resistivity of 2.4×10⁴ Ω cm (at 25 °C). The frequency dependences of permittivity and the loss tangent were obtained in (20 – 2×10⁶) Hz frequency range. The behavior of ε′ is characterized by high dispersion caused by relaxation polarization in the investigated frequency range. The results were compared to the LiZn ferrite characteristics sintered by traditional thermal heating.     

Mineralogy and microstructure of sintered lignite coal fly ash☆

Lignite coal fly ash from the ‘Nikola Tesla’ power plant in Yugoslavia has been characterised, milled, compacted and sintered to form monolithic ceramic materials. The effect of firing at temperatures between 1130 and 1190 °C on the density, water accessible porosity, mineralogy and microstructure of sintered samples is reported. This class C fly ash has an initial average particle size of 82 μm and contains siliceous glass together with the crystalline phases quartz, anorthite, gehlenite, hematite and mullite. Milling the ash to an average particle size of 5.6 μm, compacting and firing at 1170 °C for 1 h produces materials with densities similar to clay-based ceramics that exhibit low water absorption. Sintering reduces the amount of glass, quartz, gehlenite and anhydrite, but increases formation of anorthite, mullite, hematite and cristobalite. SEM confirms the formation of a dense ceramic at 1170 °C and indicates that pyroplastic effects cause pore formation and bloating at 1190 °C.     

Synthesis,characterization, and dielectric properties of low loss LaBO3 ceramics

The preparation, sintering behaviour, and dielectric properties of low loss LaBO₃ ceramics have been investigated. Single-phase LaBO₃ powder was synthesized by the conventional solid-state ceramics route and dense ceramics (relative density >96%) with uniform microstructure (grain size ～30 μm) were obtained by sintering at 1300 °C in air. The electrical conductivity of LaBO₃ follows the Arrhenius law and the related activation energies for electrical conduction of bulk and grain boundary are 0.62 eV and 0.90 eV, respectively. The LaBO₃ ceramics sintered at 1300 °C exhibit excellent microwave dielectric properties with a relative permittivity, ?_r ～ 11.8, a quality factor, Q × f₀ value ～76,869 GHz (at ～15 GHz), and a negative temperature coefficient of resonant frequency τ_f ～ ?52 ppm/°C.     

Fabrication and properties of in situ silicon nitride nanowires reinforced porous silicon nitride (SNNWs/SN) composites

The in situ silicon nitride nanowires reinforced porous silicon nitride (SNNWs/SN) composites were fabricated via gelcasting followed by pressureless sintering. SNNWs were well distributed in the porous silicon nitride matrix. The tip-body appearance suggested a VLS growth mechanism. The flexural strength and elastic modulus of the prepared composites can achieve 84.3?±?3.9?MPa and 23.3?±?2.0?GPa respectively (25?°C), while the corresponding porosity was 40.7?vol.%. Remarkably, the strength retention rate of the composites at 1400?°C was up to 66.1%. This is due to the excellent thermal stability of SNNWs and silicon nitride matrix. Also, the fracture toughness of the composites was improved to ～42% larger than pure porous silicon nitride ceramics because of the bridging effect of the NWs and the interlocking effect of β-Si₃N₄ crystals. In addition, a good thermal shock resistance and dielectric properties were indicated. The good overall performance made SNNWs/SN composites promising candidate for advanced high-temperature applications.     

Carbon fiber reinforced composites from industrial waste for microwave absorption and electromagnetic interference shielding applications

Lightweight materials with hybrid microstructures are getting great attention in the area of electromagnetic wave absorption. In the present study, carbon fiber and fly ash reinforced composites are prepared by mixing them with ground granulated blast furnace slag, followed by compaction and sintering at 1000 °C under an argon atmosphere. Akermanite-gehlenite was observed to be the primary crystalline phase present in the prepared samples. Porous composites are obtained with the addition of fly ash and carbon fiber as they inhibit densification. The resultant microstructure has homogeneous carbon fiber dispersion and uniform fly ash anchoring on the matrix phase. This enhanced interface polarization, defect polarization, electron transportation, and impedance matching characteristics of the composites. Hence, the developed composites' microwave absorption and electromagnetic interference shielding properties exhibited an outstanding performance at low thickness with a reflection loss value of ?41.24 dB and total shielding effectiveness of 42.29 dB at the X-band.