Mullitization of Diphasic Aluminosilicate Gels

Recent studies have shown that the mullitization of diphasic aluminosilicate matrices comprising transitional alumina and amorphous silica occurs via a nucleation and growth process. Nucleation is preceded by a temperature-dependent incubation period. Following this incubation period, rapid nucleation of mullite occurs, producing about 1.8 × 10¹¹ nuclei/cm³, which remains constant throughout the rest of the transformation. Both incubation and mullite growth are thermally activated processes with apparent activation energies of 987 ± 63 and 1070 ± 200 kJ/mol, respectively. The growth rate of mullite grains under isothermal conditions is time dependent. An interpretation of these results is proposed on the basis of the nucleation and growth concepts of LaMer and Dinegar which supports the concept that the growth rate of mullite grains is controlled by the dissolution of transitional alumina into the amorphous matrix.     

Mullite for Structural, Electronic, and Optical Applications

Mullite (3Al₂O₃·2SiO₂) is becoming increasingly important in electronic, optical, and high-temperature structural applications. This paper reviews the current state of mullite-related research at a fundamental level, within the framework of phase equilibria, crystal structure, synthesis, processing, and properties. Phase equilibria are discussed in terms of the problems associated with the nucleation kinetics of mullite and the large variations observed in the solid-solution range. The incongruent melting behavior of mullite is now widely accepted. Large variations in the solid solubility from 58 to 76 mol% alumina are related to the ordering/disordering of oxygen vacancies and are strongly coupled with the method of synthesis used to form mullite. Similarly, reaction sequences which lead to the formation of mullite upon heating depend on the spatial scale at which the components are mixed. Mixing at the atomic level is useful for low-temperature (<1000°C) synthesis of mullite but not for low-temperature sintering. In contrast, precursors that are segregated are better suited for low-temperature (1250° to 1500°C) densification through viscous deformation. Flexural strength and creep resistance at elevated temperatures are significantly affected by the presence of glassy boundary inclusions; in the absence of glassy inclusions, polycrystalline mullite retains >90% of its room-temperature strength to 1500°C and displays very high creep resistance. Because of its low dielectric constant, mullite has now emerged as a substrate material in high-performance packaging applications. Interest in optical applications mainly centers on its applicability as a window material within the mid-infrared range.     

Hybrid control algorithm to improve both stable impedance range and transparency in haptic devices

An ideal haptic device should transmit a wide range of stable impedances with maximum transparency. When using active actuators, transparency improvement algorithms tend to decrease the range of attainable impedances. Passive actuators can transmit high impedances stably, but are not sufficient alone for transparency. In this study, a hybrid force control algorithm employing active and passive actuators was developed to improve the stable impedance range and transparency in haptic devices. A new transparency-Z-width plot is proposed as a way to evaluate the stable impedance range and transparency together. The hybrid control algorithm uses parameters to share the torque demand between two actuators with smooth transition. These parameters were determined and an artificial neural network (ANN) was used to extend them to the entire achievable impedance range. The algorithm was tested experimentally on a 1-DOF haptic device. The transparency experiments employed an excitation motor located at the user side of the device to evaluate various algorithms in time and frequency domains. Results showed that the proposed hybrid control algorithm enables simulation of higher range of impedances with higher transparency than the conventional algorithms.     

Sintering with Rigid Inclusions: Pair Interactions

The interaction between two spherical, rigid inclusions in an infinite, linearly viscous, densifying medium has been studied. The stresses in the vicinity of the two spheres are highly anisotropic, with significantly enhanced rates of densification in the gap between these particles. A pairwise-additive approximation for the densification rate of the composite is presented and compared with the composite-sphere and self-consistent models described by Scherer.     

Consolidation Behavior of Flocculated Alumina Suspensions

The consolidation behavior of flocculated alumina suspensions has been analyzed as a function of the interparticle energy. Consolidation was performed by a centrifugal force field or by gravity, and both the time-dependent and equilibrium density profiles were measured by a gamma-ray absorption technique. The interparicle energy at contact was controlled by adsorbing fatty acids of varying molecular weight at the alumina/decalin interface. We found that strongly attractive interactions result in a particle network which resists consolidation and shows compressible behavior over a large stress range. The most weakly flocculated suspension showed an essentially incompressible, homogeneous density profile after consolidation at different centrifugal speeds. We also found a significant variation in the maximum volume fraction, φ_m, obtained, with φ_m∼ 0.54 for the most strongly flocculated suspension to φ_m∼ 0.63 for the most weakly flocculated suspension. The compresive yield stresses show a behavior which can be fitted to a modified power law. In this paper, we discuss possible correlations between the fitting parameters and physical properties of the flocculated suspensions.     

Reversible Cluster Aggregation and Growth Model for Graphene Suspensions

We present a reversible cluster aggregation model for 2‐D macromolecules represented by line segments in 2‐D; and, we use it to describe the aggregation process of functionalized graphene particles in an aqueous SDS surfactant solution. The model produces clusters with similar sizes and structures as a function of SDS concentration in agreement with experiments and predicts the existence of a critical surfactant concentration (C_crit) beyond which thermodynamically stable graphene suspensions form. Around C_crit, particles form dense clusters rapidly and sediment. At C ? C_crit, a contiguous ramified network of graphene gel forms which also densifies, but at a slower rate, and sediments with time. The deaggregation–reaggregation mechanism of our model captures the restructuring of the large aggregates towards a graphite‐like structure for the low SDS concentrations. © 2017 American Institute of Chemical Engineers AIChE J, 63: 5462–5473, 2017     

Multifunctional and Low-Density Inorganic Nanocomposites

We summarize our recent studies on the use of low-density nanoporous silica structures prepared through templating of a self-assembling disordered liquid-crystalline L ₃ phase, as a matrix for use in numerous applications, including sensing, optical data storage, drug release, and structural. The silica matrix exhibits low density (0.5 g cm⁻³ to 0.8 g cm⁻³ for monoliths, 0.6 g cm⁻³ to 0.99 g cm⁻³ for fibers) coupled with high surface areas (up 1400 m² g⁻¹) and void volumes (65% or higher). High-surface-area coatings are used to increase the sensitivity of mass-detecting quartz crystal microbalances to over 4000 times that of uncoated crystals. Monoliths, films, and fibers are produced using the templated silica gel. Once dried and converted to silica, the nanostructured material exhibits high fracture strength (up to 35 MPa in fibers) and Young’s modulus (30 GPa to 40 GPa in fibers). These values are, respectively, two orders of magnitude and twice those of nanostructured silicas having comparable densities.     

Off-line multiresponse optimization of electrochemical surface grinding by a multi-objective programming method

The objective of this study is to optimize electrochemical grinding (ECG) process responses simultaneously by an off-line multiresponse optimization methodology. The responses considered as objectives are side and bottom overcuts, surface finish, spindle load, total metal removal rate, and wheel wear. Materials of 304 Stainless Steel are ground by the ECG process. The process variables optimized for the above objectives include electrolyte type, wheel material, grit size, grit concentration, d.c. voltage, electrolyte flow rate, wheel speed, feed rate, and ripple effect. A simple weighting method transforms the multi-objective problem into a single-objective programming format and then, by parametric variation of the weights, the set of non-dominated optimum solutions are obtained. It is shown in this paper that the multi-objective optimization methodology can be applied for an ECG operation, and that the optimal operating conditions for any given set of weights can be obtained depending upon the objectives.     

Size and expansion ratio analysis of micro nozzle gas flow

Size and expansion ratio effects on the flowfield are investigated for micro converging-diverging nozzles. Numerical computations are conducted by using two dimensional augmented Burnett equations and Navier-Stokes equations that were derived from the Boltzmann equation. The Maxwell-Smoluchowski slip boundary condition is used for adiabatic walls, and Steger-Warming flux vector splitting scheme is applied to the convective inviscid flux terms. The results from the augmented Burnett equation are compared with Navier-Stokes and Direct Simulation Monte Carlo (DSMC) results. Then, nozzle-size analysis is conducted for between 2 µm and 100 µm throat width. Influence of the Knudsen number is investigated, and temperature and Mach number variations are presented. In addition, the influence of the expansion ratio is studied with three (1.7:1, 3.4:1, and 6.8:1) different configurations. The results are compared with each other and an experimental data in the literature.