Enhancing the thermal insulating properties of lanthanum zirconate porous ceramics via pore structure tailoring

The potentially useful role of lanthanum zirconate (La₂Zr₂O₇, LZO) porous bulk ceramics has been rarely explored thus far, much less the optimisation of its pore structure. In this study, LZO porous ceramics were successfully fabricated using a tert-butyl alcohol (TBA)-based gelcasting method, and the pore structures were tailored by varying the initial solid loading of the slurry. The as-prepared ceramics exhibited an interconnected pore structure with high porosity (67.9 %–84.2 %), low thermal conductivity (0.083–0.207 W/(m·K)), and relatively high compressive strength (1.56–7.89 MPa). The LZO porous ceramics with porosity of 84.2 % showed thermal conductivity as low as 0.083 W/(m·K) at room temperature and 0.141 W/(m·K) at 1200 °C, which is much lower than the counterparts fabricated from particle-stabilized foams owing to its unique pore structure with a smaller size, exhibiting better thermal insulating performance.     

Influence of sintering atmosphere and BN additives on microstructure and properties of porous SiC ceramics

The effects of the boron nitride (BN) content on the electrical, thermal, and mechanical properties of porous SiC ceramics were investigated in N₂ and Ar atmospheres. The electrical resistivity was predominantly controlled by the sintering atmosphere and secondarily by the BN concentration, whereas the thermal conductivity and flexural strength were more susceptible to changes in the porosity and necking area between the SiC grains. The electrical resistivities of argon-sintered porous SiC ceramics (6.3 × 10⁵ – 1.6 × 10⁶ Ω·cm) were seven orders of magnitude higher than those of nitrogen-sintered porous SiC ceramics (1.5 × 10⁻¹ – 6.0 × 10⁻¹ Ω·cm). The thermal conductivity and flexural strength of the argon-sintered porous SiC ceramics increased from 8.4–11.6 W·m⁻¹ K⁻¹ and from 9.3–28.2 MPa, respectively, with an increase in the BN content from 0 to 1.5 vol%, which was attributed to the increase in necking area and the decrease in porosity.     

Direct ink writing of silica-carbon-calcite composite scaffolds from a silicone resin and fillers

Calcite-based composite scaffolds have been successfully 3D-printed by direct ink writing, starting from a paste comprising a silicone polymer and calcite (CaCO₃) powders. The firing in nitrogen, at 600?°C, after preliminary cross-linking step at 350?°C, determined the transformation of the polymer matrix into a silica-carbon nano-composite, embedding unreacted calcite particles. Compared to previously developed silica-calcite scaffolds, obtained after firing in air, the new composites exhibited a significant strength improvement (up to ～10?MPa, for a total open porosity of 56%). The new formulation did not compromise the in vitro bioactivity and the biocompatibility of the scaffolds, as shown by dissolution studies in SBF and preliminary cell culture tests, with human fibroblasts. Due to the simplicity of the processing and the outstanding mechanical performances, the developed scaffolds are promising candidates for bone tissue engineering applications.     

Mechanical,Thermal, and Oxidation Properties of Refractory Hafnium and zirconium Compounds

The thermal conductivity, thermal expansion, Youngs Modulus, flexural strength, and brittle–plastic deformation transition temperature were determined for HfB₂, HfC_0·98, HfC_0·67, and HfN_0·92 ceramics. The oxidation resistance of ceramics in the ZrB₂–ZrC–SiC system was characterized as a function of composition and processing technique. The thermal conductivity of HfB₂ exceeded that of the other materials by a factor of 5 at room temperature and by a factor of 2·5 at 820°C. The transition temperature of HfC exhibited a strong stoichiometry dependence, decreasing from 2200°C for HfC_0·98 to 1100°C for HfC_0·67 ceramics. The transition temperature of HfB₂ was 1100°C. The ZrB₂/ZrC/SiC ceramics were prepared from mixtures of Zr (or ZrC), SiB₄, and C using displacement reactions. The ceramics with ZrB₂ as a predominant phase had high oxidation resistance up to 1500°C compared to pure ZrB₂ and ZrC ceramics. The ceramics with ZrB₂/SiC molar ratio of 2 (25 vol% SiC), containing little or no ZrC, were the most oxidation resistant.     

Fabrication and properties of porous anorthite/mullite ceramics with both high porosity and high strength

Porous anorthite/mullite ceramics with both high porosity and high strength have been successfully fabricated by foam-gelcasting and pressureless sintering technology, using α-Al₂O₃, SiO₂, and CaCO₃ as starting materials and MnO₂ as sintering aids. The porous mullite ceramics prepared in this study had 83.3% porosity and 0.3 W/m·K thermal conductivity, exhibited compressive strength value as high as 6.1 MPa. The samples fabricated with mullite content of 30 mol% possessed 79.4% porosity and 5.9 MPa compressive strength showed thermal conductivity as low as 0.19 W/m·K. With the addition of MnO₂, the properties of the prepared materials varied slightly when mullite content changed in a large scale. The results showed that the addition of MnO₂ promoted the reaction, affected sintering and grain growth, and contributed to high strength and low-thermal conductivity.     

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.     

Fabrication of cordierite foam ceramics using direct foaming and slip casting method with plaster moulds

The cordierite foam ceramics were successfully fabricated using direct foaming and slip casting method with plaster moulds. Kaolin, attapulgite and magnesium oxide were used as starting materials with Arabic gum added as the dispersant. The samples were sintered at 1200°C, and then the microstructure, porosity, bulk density and thermal conductivity were characterised. The results show that the cordierite foam ceramics had a porous structure of open cells and the struts had abundant small pores. The maximum open porosity achieved 87·65% with a bulk density of 329 kg m^??3, and the thermal conductivity was as low as 0·095 W (m K)^??1. Therefore, these cordierite foam ceramics show promise for use as the thermal insulator.     

Preparation and properties of porous alumina with inter-locked platelets structure

Porous alumina ceramics with alumina platelets was prepared by vapor-solid reaction sintering of AlOF mesophase gas by the reaction of HF and Al₂O₃. The effect of heating treatment temperatures on porosity, the formation of inter-locked platelets structure and compressive strength of porous alumina ceramics was determined by Archimedes' method, XRD, SEM and compressive tests. The results indicated that after heating at temperatures from 1300 °C to 1600 °C, the porosity of alumina ceramics decreased from 61.6% to 48.4%. Increasing the heating treatment temperature was beneficial to form inter-locked structure between alumina platelets. The maximum compressive strength of porous ceramics with porosity of 48.4% can reach 29.8 MPa heated at 1600 °C; this strength was attributed to the strong bonding between the alumina platelets.     

Characteristics of porous mullite developed from clay and AlF3·3H2O

Porous mullite with interlocked needle shape microstructure was developed from China clay and aluminium fluoride trihydrate (AlF₃·3H₂O). The effects of various parameters like sintering temperature, sintering time and the amount of AlF₃·3H₂O on the phase evolution, microstructure and porosity have been studied. Quantitative analysis of mullite was carried out using X-ray diffraction combined with Rietveld-RIR method (Internal standard method). Porous mullite ceramics with 62% open porosity have been prepared at a relatively lower temperature of 1400?°C. The results show that the nucleation of mullite can be achieved from 700?°C onwards using hydrated aluminium fluoride without the formation of intermediate topaz crystals. The high amount of water vapour produced within the system during the in-situ reaction has a crucial role in deciding the reaction mechanism.     

Electrical,thermal, and mechanical properties of porous silicon carbide ceramics with a boron carbide additive

The effects of the boron carbide (B₄C) content and sintering atmosphere on the electrical, thermal, and mechanical properties of porous silicon carbide (SiC) ceramics were investigated in the porosity range of 58.3%–70.3%. The electrical resistivities of the nitrogen-sintered porous SiC ceramics (∼10^–1 Ω·cm) were two orders of magnitude lower than those of argon-sintered porous SiC ceramics (∼10¹ Ω·cm). Both the thermal conductivities (3.3–19.8 W·m^–1·K^–1) and flexural strengths (8.1–32.9 MPa) of the argon- and nitrogen-sintered porous SiC ceramics increased as the B₄C content increased, owing to the decreased porosity and increased necking area between SiC grains. The electrical resistivity of the porous SiC ceramics was primarily controlled by the sintering atmosphere owing to the N-doping from the nitrogen atmosphere, and secondarily by the B₄C content, owing to the B-doping from the B₄C. In contrast, the thermal conductivity and flexural strength were dependent on both the porosity and necking area, as influenced by both the sintering atmosphere and B₄C content. These results suggest that it is possible to decouple the electrical resistivity from the thermal conductivity by judicious selection of the B₄C content and sintering atmosphere.     

3D printing of porous scaffolds BaTiO3 piezoelectric ceramics and regulation of their mechanical and electrical properties

A series of porous scaffolds of piezoelectric ceramic barium titanate (BaTiO₃) were successfully fabricated by Digital Light Processing (DLP) 3D printing technology in this work. To obtain a high-precision and high-purity sample, the debinding sintering profile was explored and the optimal parameters were determined as 1425 °C for 2h. With the increase of scaffolds porosity from 10% to 90%, the compressive strength and piezoelectric coefficient (d₃₃) decreased gradually. The empirical formulas about the mechanical and piezoelectric properties were obtained by adjusting BaTiO₃ ceramics with different porosity. In addition, the distribution of potential and stress under 100 MPa pressure were studied by the finite element method (FEM).     

Influence of phosphorus pentoxide on crystallisation,microstructure and mechanical properties of potassium fluorophlogopite glass ceramics

Abstract

Potassium fluorophlogopite glass ceramics were prepared. Differential thermal analysis showed that there were two exothermic peaks at ～750 and 950°C, corresponding to the Avrami exponent ～1·5 and 2·0. Spherical particles were found using a scanning electron microscope when the glass ceramics were heat treated at 750 and 800°C. With the increase in heat treatment temperature, a kind of lamellar crystals was gradually formed, and the shape of crystals changed from spherical to lamellar when the Avrami exponent changed from 1·5 to 2·0. Mechanical tests showed that material cutting and bending strength increased, while the Vickers hardness decreased with the increasing of P₂O₅ content and heat treatment temperature.     

SiC-based porous ceramic carriers for heat-conductive phase change materials through carbothermal reduction method

Iron tailings remain the environment-damaging waste from the iron ore, and high porosity porous ceramics are an attractive material to “turn waste into treasure.” To improve the thermal conductivity, porous ceramics with high silicon carbide content have been prepared by carbothermal reduction sintering process using argillaceous fine-grained iron tailings with high silica content. The carbothermal reduction reaction mechanism and the components and properties of samples in sintering process are investigated. The results show that reaction components in the tailings are mainly SiO₂ and Fe₂O₃ and liquid phase is generated rapidly between 1200°C and 1300°C, producing foaming effect and significantly improving the porosity. Moreover carbothermal reduction of SiO₂ occurs above 1300°C. After sintering at 1600°C for 2 hours, the apparent porosity and thermal conductivity of porous iron tailing ceramics are 81.1% and 0.58 W/(m·K), respectively. Compared with the ordinary porous iron tailing ceramics with the same porosity, the thermal conductivity of those herein is increased by 6.6 times. This study is instructive for the development of low-cost preparation technology of phase change material carriers.     

Effect of carbon content on electrical,thermal, and mechanical properties of porous SiC ceramics with B4C and C additives

The electrical, thermal, and mechanical properties of porous SiC ceramics with B₄C-C additives were investigated as functions of C content and sintering temperature. The electrical resistivity of porous SiC ceramics decreased with increases in C content and sintering temperature. A minimal electrical resistivity of 4.6 × 10^?2 Ω·cm was obtained in porous SiC ceramics with 1 wt% B₄C and 10 wt% C. The thermal conductivity and flexural strength increased with increasing sintering temperature and showed maxima at 4 wt% C addition when sintered at 2000 °C and 2100 °C. The thermal conductivity and flexural strength of porous SiC ceramics can be tuned independently from the porosity by controlling C content and sintering temperature. Typical electrical resistivity, thermal conductivity, and flexural strength of porous SiC ceramics with 1 wt% B₄C-4 wt% C sintered at 2100 °C were 1.3 × 10^?1 Ω·cm, 76.0 W/(m·K), and 110.3 MPa, respectively.     

Combustion synthesis and characteristics of aluminum oxynitride ceramic foams

Aluminum oxynitride (AlON) ceramic foams were prepared by combustion synthesis using Al and Al₂O₃ as starting materials under high nitrogen pressure. By introducing Al(NO₃)₃·9H₂O into reactants as active pore-forming agent, AlON ceramic foams with well-distributed pores were cost-effectively fabricated. The influences of Al(NO₃)₃·9H₂O content on the combustion process, pore content and structure were studied systematically. The experiment results showed that porous AlON ceramics containing evenly distributed and noncontiguous pores were obtained when Al(NO₃)₃·9H₂O content was 30%, in which the closed porosity of 80% was found by Archimedes’ method. Pore distribution measured by mercury intrusion porosimetry indicated that pores with several types of diameter were formed in the foams because of the different conditions of pore fusion and molten viscosity.     

Transient liquid phase diffusion process for porous mullite ceramics with excellent mechanical properties

Porous mullite ceramics were fabricated by the transient liquid phase diffusion process, using quartz and fly-ash floating bead (FABA) particles and corundum fines as starting materials. The effects of sintering temperatures on the evolution of phase composition and microstructure, linear shrinkage, porosity and compressive strength of ceramics were investigated. It is found that a large amount of quartz and FABA particles can be transformed into SiO₂-rich liquid phase during the sintering process, and the liquid phase is transient in the Al₂O₃-SiO₂ system, which can accelerate the mullitization rate and promote the growth of mullite grains. A large number of closed pores in the mullite ceramics are formed due to the transient liquid phase diffusion at elevated temperatures. The porous mullite ceramics with high closed porosity (about 30%) and excellent compressive strength (maximum 105?MPa) have been obtained after fried at 1700?°C.     

Manufacture of Si3N4-SiCN composite bulks with hierarchical pore structure

Si₃N₄-SiCN ceramic foams with hierarchical pore architecture were formed by protein-based gelcasting and precursor infiltration and pyrolysis. The primary pore structure (>100 μm) was generated by protein gelation and precursor ceramization, while the secondary pore structure (10–50 μm) originated from the cell windows after pyrolysis. The network of Si₃N₄ nanowires and the voids among ceramic particles formed the tertiary pore structure (<2 μm). The obtained Si₃N₄-SiCN ceramics had a density of 0.45–0.66 g/cm³ and an open porosity of 72.7–82.8 vol.%. The porous bulks possessed a compressive strength of up to 16.9 ± 1.1 MPa (72.7 vol.% open porosity) at room temperature and 8.6 ± 0.2 MPa at 800 °C. A good gas permeability of the ceramics was indicated with a tested value of 3.27 cm³cm/(cm²·s·kPa). The excellent mechanical property, permeability together with the hierarchical pore structure enabled the Si₃N₄-SiCN composite bulks promising for industrial filtration applications.     

Recycling photovoltaic silicon waste for fabricating porous mullite ceramics by low-temperature reaction sintering

In this study, porous mullite ceramics with coral-like structures were fabricated at a low temperature of 900 °C by using photovoltaic silicon waste (PSW) as the silicon source directly. The effects of additive content and sintering temperature on the mullitization reaction of green bodies were studied. The results showed that ammonium molybdate tetrahydrate molybdenum (H₂₄Mo₇N₆O₂₄·4H₂O) as an additive could reduce the reaction temperature for mullitization from 1100 °C to 900 °C. The research on the influence of catalyst on material properties showed that porous mullite ceramics with a flexural strength of 52.83 MPa, a 41.78 % porosity, a sintering expansion rate of 0.49 % and an average pore size of 0.23 μm could be fabricated by introducing 7.5 % H₂₄Mo₇N₆O₂₄·4H₂O at the sintering temperature of 1000 °C. This study develops an environment-friendly recycling method of PSW and provides a new idea for the low-cost preparation of porous mullite ceramics with high purity.     

Effects of porosity on electrical and thermal conductivities of porous SiC ceramics

The effects of porosity on the electrical and thermal conductivities of porous SiC ceramics, containing Y₂O₃–AlN additives, were investigated. The porosity of the porous SiC ceramic could be controlled in the range of 28–64 % by adjusting the sacrificial template (polymer microbead) content (0–30 wt%) and sintering temperature (1800–2000 °C). Both electrical and thermal conductivities of the porous SiC ceramics decreased, from 7.7 to 1.7 Ω⁻¹ cm⁻¹ and from 37.9 to 5.8 W/(m·K), respectively, with the increase in porosity from 30 to 63 %. The porous SiC ceramic with a coarser microstructure exhibited higher electrical and thermal conductivities than those of the ceramic with a finer microstructure at the equivalent porosity because of the smaller number of grain boundaries per unit volume. The decoupling of the electrical conductivity from the thermal conductivity was possible to some extent by adjusting the sintering temperature, i.e., microstructure, of the porous SiC ceramic.     

Direct ink writing of porous cordierite honeycomb ceramic

Herein, we fabricated honeycomb ceramics with different porosities and pore shapes via the layer-by-layer deposition of cordierite (2MgO·2Al₂O₃·5SiO₂) particle ink, obtaining proper rheological properties using a direct-writing technology. No collapses as well as minimal cracking and bending were observed in the internal structure of the samples after calcination. We measured and compared the internal porosity and specific surface area of honeycomb ceramics with the same pore shape but different pore dimensions, as well as the same pore dimension but different pore shapes. The samples were both loaded with an γ-Al₂O₃ washcoat and Pd-based catalyst using the same method for the catalytic combustion of toluene. The different porosity and pore shape influenced the catalytic efficiency. This study may provide some useful guidelines for fabrication of honeycomb ceramics by direct writing technology, which could be used to remove volatile organic pollutants(VOCs).