Microwave and conventional treatment of low-cement high-alumina castables with different water-to-cement ratio; Part II. Dehydration

Modern refractory castables contain between 3.5 and 5?wt.-% water that is necessary for sufficient flow during emplacement and for the formation of hydrate phases, necessary for the green strength of the material. Prior to the high temperature use of this material, it must be dried very carefully to avoid explosive spalling.This paper will demonstrate that beside conventional drying of pre-shaped materials in resistance furnaces microwave radiation is an energy saving and rapid method to remove pore water as well as hydrate bond water from the castable. In comparison to resistance furnaces, the use of microwave radiation does not affect the castable properties as there are mechanical strength (MOR, CCS), open porosity and pore size distribution. This study proved microwave radiation as valuable alternative with a series of tabular alumina based low cement castables (LLC) in which the water-to-cement-ratio (wcr = 0.64, 0.75, 0.82 and 1.13) was systematically altered by changing the cement concentration at constant mixing water concentration of 4.5%.     

Liquid phase sintering and characterization of SiC ceramics

The present study focuses on the sintering of silicon carbide-based ceramics (SiC) by liquid phase sintering (LPS) followed by characterization of the produced ceramics. AlN/Re₂O₃ mixtures were used as additives in the LPS process. In the first step, the LPS-SiC materials were produced in a graphite resistance furnace in the form of discs at different temperatures. The conditions with the best results regarding real density and relative density were taken as reference for sintering in the form of prismatic bars. In the second step, these samples were evaluated regarding fracture toughness (K_IC), by the Single Edge V Notch Beam – SEVNB – method, and flexural strength. K_IC behavior was evaluated according to the depth and curvature radius of the notches. Reliable K_IC values were presented when the ceramic displayed a small curvature radius at the notch tip. When the radius was large, it did not maintain the square root singularity of the notch tip. Tests were carried out to determine K_IC values in atmospheric air and water. K_IC results were lower in water than air, with a decrease ranging between 2.56% and 11.26%. The observations indicated a direct grain size correlation between K_IC values and fracture strength of the SiC ceramics.     

Fabrication and piezoelectric properties of BaTiO3/BaTiO3-Bi(Mg1/2Ti1/2)O3-BiFeO3 composites

We fabricated xBaTiO₃ (BT)/(1-x)[BaTiO₃-Bi(Mg_1/2Ti_1/2)O₃-BiFeO₃] (BT-BMT-BF)?+?0.1?wt%MnCO₃ composites by spark plasma sintering and investigated the effect of BT content x, BT powder size, and BT-BMT-BF composition on piezoelectric properties. For xBT/(1-x)(0.3BT-0.1BMT-0.6BF) +?0.1?wt%MnCO₃ (x?=?0–0.75) composites with a 0.5-µm BT powder, the dielectric constant was increased with x, and the relative density was decreased at x?=?0.67 and 0.75, creating optimum BT content of x?=?0.50 with a piezoelectric constant d₃₃ of 107?pC/N. When a larger 1.5-µm BT powder was utilized for the composite with x?=?0.50, the d₃₃ value increased to 150?pC/N due to the grain size effect of the BT grains. To compensate for a compositional change from the optimum 0.3BT-0.1BMT-0.6BF due to partial diffusion between the BT and 0.3BT-0.1BMT-0.6BF grains, a 0.5BT/0.5(0.275BT-0.1BMT-0.625BF)?+?0.1?wt%MnCO₃ composite with the 1.5-µm BT powder was fabricated. We obtained an increased d₃₃ value of 166?pC/N. These results provided a useful composite design to enhance the piezoelectric properties.     

Structure and electrical properties of Ca2+-doped (Na0.47Bi0.47Ba0.06)TiO3 lead-free piezoelectric ceramics

The lead-free piezoelectric ceramics (Na_.47Bi_.47Ba_.06)_1-xCa_xTiO₃ (x?=?0, 0.01, 0.02, 0.03, 0.05, and 0.08, abbreviated as BNBTC/0, BNBTC/1, BNBTC/2, BNBTC/3, BNBTC/5, and BNBTC/8, respectively) were obtained using the solid-state reaction method. The structure, electric conductivity, and dielectric, ferroelectric, and piezoelectric properties of the Ca²⁺-doped (Na_.47Bi_.47Ba_.06)TiO₃ ceramics were thoroughly investigated. The ceramics sintered at 1200?°C exhibit dense microstructures, having relative densities higher than 96%. The X-ray diffraction results demonstrate that all ceramics have a pure perovskite structure. The mean grain sizes of the ceramics are related to the Ca²⁺ quantity. A small quantity of Ca²⁺ ions (x?≤?0.03) improves the piezoelectric and ferroelectric properties of the samples. The dielectric behavior of the samples is sensitive to the Ca²⁺ content and electric poling. The results demonstrate that the electrical properties of the (Na_.47Bi_.47Ba_.06)TiO₃ lead-free ceramics can be well tuned by varying the Ca²⁺ quantity.     

Methodology for dependence-based integrated constitutive modelling: An illustrative application to SiCp/Al composites

In industrial forming and machining process, the large plastic deformation of material takes place in wide loading ranges of strain-rate and forming temperature. A satisfactory modelling of quasi-static and dynamic material behaviors is of great importance for understanding physical process and processes optimization. A dependence-based integrated methodology, together with an improved weighted multi-objective parameter identification strategy is presented for the development of phenomenological constitutive model and the parameter identification using experimental data from quasi-static and dynamic tests with instantaneous strain rate variations and plastic strain-related temperature changes. The improved multi-objective parameter identification model is reformulated by introducing three weighting factors for valuing different measure errors and fit standard errors in individual objective function corresponding to each test, considering the sampling point number and active material parameter number under different loading conditions, and balancing optimization opportunity of quasi-static and dynamic sub-objective functions. The methodology is verified for feasibility through illustrative constitutive identification for SiC_p/Al composites. This may provide a methodology of constitutive modelling for predicting material behaviors in quasi-static and dynamic modes equally well.     

Ultrasonic vibration-assisted laser engineering net shaping of ZrO2-Al2O3 bulk parts: Effects on crack suppression,microstructure, and mechanical properties

Laser additive manufactured zirconia-alumina ceramic (ZrO₂-Al₂O₃) parts demonstrate severe problems resulting from cracking and inhomogeneous material dispersion. To reduce these problems, we propose a novel ultrasonic vibration-assisted laser engineered net shaping (LENS) process for fabrication of bulk ZrO₂-Al₂O₃ parts. Results showed that the initiation of cracks and the crack propagation were suppressed in the parts fabricated by LENS process with ultrasonic vibration. For the parts fabricated without ultrasonic vibration, the sizes of cracks decreased with the increase of laser power. Scanning electron microscope analyses proved that the introduction of ultrasonic vibration was beneficial for grain refinement and uniform material dispersion. Due to the suppressed cracking, refined grains, and homogenized material dispersion, the parts fabricated with ultrasonic vibration demonstrated better mechanical properties (including higher microhardness, higher wear resistance, and better compressive properties), compared with the parts fabricated without ultrasonic vibration.     

Catalytic graphene formation in coal tar pitch- derived carbon structure in the presence of SiO2 nanoparticles

A simple and effective way to manufacture graphene from a coal tar pitch (CTP) is demonstrated. Silica (SiO₂) nanoparticles were used to modify the CTP as carbon precursor. A silica nanofiller introduced into the CTP matrix underwent carboreduction during heat treatment to 2000 °C, resulting in the formation of silicon carbide. Surfaces of SiC grains were sites for graphene formation. The influence of SiO₂ on the structure and microstructure of CTP- based carbon matrix, after annealing up to 2800 °C, was studied. Carbon samples were analyzed using X- ray Diffraction (XRD), Transmission Electron Microscopy (TEM) and Raman Spectroscopy. Crystallite sizes (L_a, L_c) and interplanar distance (d₀₀₂) were determined. The presence of SiO₂ in CTP carbon precursor favored the crystallites’ growth in the ‘a′ crystallographic graphite direction, and inhibited their growth on the ‘c′ axis. The crystallites composing of graphene layers, were characterized by an elongated dimension in the ‘a′ axis direction. Above 2000 °C silicon carbide decomposed, followed by the sublimation of silicon from the carbon matrix.     

Copper-alumina nanocomposite coating on copper substrate through solution combustion

The main objective of the present research is to investigate the production of Cu-Al₂O₃ nanocomposite coating on a copper substrate using solution combustion synthesis. Solution combustion synthesis is mainly used to produce nanocomposite powders; however, in this study it is applied to produce nanocomposite coat. For this purpose, both copper and aluminum nitrates (Cu (NO₃)₂·3H₂O and Al (NO₃)₃·9H₂O) are used as oxidizers. Also, urea and graphite are respectively used as fuel to synthesize the Cu-Al₂O₃ nanocomposite and as inhibitor to prevent the oxidation of the synthesized copper. The microstructure and morphology of the nanocomposite coating, which includes 25 wt% alumina as the reinforcing phase, was studied using X-ray diffraction, scanning electron microscopy, and transmission electron microscopy at different fuel/oxidizer ratios ranging from 0.9 to 2. The temperature variation during the process was measured as a function of time using a precise thermocouple. Finally, micro-hardness and wear tests were conducted on the nanocomposite coating. The results verified the formation of Cu-Al₂O₃ nanocomposite coating. Time-temperature curve illustrated that the highest temperature was achieved at the fuel/oxidizer ratio of 1.25. The results of the microhardness and wear resistance test showed that these properties depend heavily on the fuel/oxidizer ratio, with the best condition attained at the ratio of 1.25.     

Synthesis and two-step sintering behavior of solution derived corundum abrasives with plate-like grains

Corundum abrasives with plate-like grains were fabricated by a two-step sintering technique using the solution-based process with the addition of the ternary compound additive Na₃AlF₆-CaO-SiO₂. The two-step sintering method showed obvious advantages over conventional sintering methods in promoting sample densification, suppressing grain growth, and homogenizing the microstructure of the corundum abrasives. The sample doped with 2.5?wt% Na₃AlF₆ and 4?wt% CaO + SiO₂ in the molar ratio of 1:1 possessed a relative density of 99.3%, average grain size of 0.54?µm, and single-particle compressive strength of 49?N. The introduction of seeds reduced the temperature of θ- to α-Al₂O₃ phase transformation. The relationship between the microstructure and the mechanical properties of the abrasives was also discussed.     

Influence of calcium concentration on formation of tetravalent chromium doped Y3Al5O12 ceramics

Yttrium Aluminium Garnet (YAG) ceramics doped with chromium were prepared by solid-state reactive sintering in a vacuum. The influence of the charge compensator Ca²⁺ concentration on microstructure, optical properties and efficacy of Cr³⁺ oxidation to Cr⁴⁺ under air annealing was investigated. A non-monotonic dependence of these features on the amount of CaO as an additive was found. The changes in ceramic transparency and microstructure were explained considering the interaction between CaO and Cr₂O₃ at the ceramic grain boundaries, which leads to a different pore evolution in distinct samples during sintering. The efficacy of the oxidation of Cr³⁺ to Cr⁴⁺ strongly depends on the concentration of Ca dissolved in the YAG. The calcium solubility decreases due to the higher oxygen partial pressure of the extra phases on the grain boundaries that decreases the amount of generated Cr⁴⁺ ions. Such phenomenon explains the lower concentration of Cr⁴⁺ ions in the sample with 0.8% of Ca against the one with 0.5%. The experiment shows that the ceramic with 0.5% of Ca has a better in-line transmission and a higher concentration of Cr⁴⁺ ions in comparison with samples with a different Ca concentration.