Sintering,microstructure, and mechanical properties of vitrified bond diamond composite

The demand for high-performance grinding wheels is gradually increasing due to rapid industrial development. Vitrified bond diamond composite is a versatile material for grinding wheels used in the backside grinding step of Si wafer production. However, the properties of the vitrified bond diamond composite are controlled by the characteristics of the diamond particles, the vitrified bond, and pores and are very complicated. The main objective of this study was to investigate the effects of SiO₂–Na₂O–B₂O₃–Al₂O₃–Li₂O–K₂O–CaO–MgO–ZrO₂–TiO₂–Bi₂O₃ glass powder on the sintering, microstructure, and mechanical properties of the vitrified bond diamond composite. The elemental distributions of the composite were analyzed using electron probe micro-analysis (EPMA) to clarify the diffusion behaviors of various elements during sintering.The results showed that the relative density and transverse rupture strength of the composite sintered at 620 °C were 91.7% and 126 MPa, respectively. After sintering at 680 °C, the glass powder used in this study exhibited a superior forming ability without an additional pore foaming agent. The relative density and transverse rupture strength of the composite decreased to 48.2% and 49 MPa, respectively. Moreover, the low sintering temperature of this glass powder protected the diamond particles from graphitization during sintering, as determined by X-ray diffraction and Raman spectrum. Furthermore, the EPMA results indicate that Na diffused and segregated at the interface between the diamond particles and vitrified bond, contributing to the improved bonding. The diamond particles can remain effectively bonded by the vitrified bond even after fracture.     

Preparation of a CeO2–ZrO2 based nano-composite with enhanced thermal stability by a novel chelating precipitation method

In this study, a chelating agent is introduced to prepare CeO₂–ZrO₂ nano-composite through a precipitation process. The physicochemical properties of the oxide precursors, nano composite materials are strongly dependent on the preparation method and whether a chelating agent is used. Adding an appropriate quantity of chelating agent SO₄²⁻ can facilitate thermal stability and phase structure uniformity of CeO₂–ZrO₂ mixed oxides. The calculation results showed that the Gibbs free energy of chelating complex of [ZrSO₄]²⁺ (ΔG = −127.2469 kJ/mol) is higher than the [Ce(III)SO₄]⁺ (ΔG = -29.8279 kJ/mol). The precipitation chemical potential of Zr⁴⁺ moves close to the precipitation chemical potential of Ce³⁺. The novel and low-cost chelating precipitation method can modify the homogeneity of the compounds at the atomic scale, which can offer a powerful opportunity for, and provide direction in, the design of materials with exceptional properties.     

Sol-gel auto-combustion synthesis of Ba–Sr hexaferrite ceramic powders

We report the mechanism involved in sol-gel auto-combustion synthesis of Ba–Sr-hexaferrite (Ba_1-xSr_xFe₁₂O₁₉; x = 0, 0.25, 0.5, 0.75 and 1, BSFO) ceramic powders through the analysis of the phases evolved during annealing of the as-synthesized powders, along with their structure and morphological studies. The XRD patterns of the as-synthesized samples indicate the formation of barium/strontium monoferrite ((Ba/Sr)Fe₂O₄) and maghemite (γ-Fe₂O₃) phases along with a minute amount of hematite (α-Fe₂O₃) phase. Annealing of these samples facilitates formation of BSFO phase through the solid state reaction between BaFe₂O₄ and γ-Fe₂O₃ phase. Interestingly, after annealing the samples with x = 0, 0.5 and 1, at 1000 °C for 2 h, we observed that phase pure Ba–Sr hexaferrite structure forms, but for samples with x = 0.25 and 0.75, high amount of hematite (α-Fe₂O₃) phase is observed, especially for x = 0.75. The reason associated with this could be the large difference between the ionic radii of Ba²⁺ and Sr²⁺ ions occupying the oxygen site. Furthermore, our study on annealing dependent phase evolution confirms that, this difference in ionic radii forbids the formation of a single phase Ba–Sr hexaferrite. The growth of clear hexagonal-shaped plate-like particles with varied particle sizes was observed for all the samples. The particle size variation may be due to the influence of the ionic radii difference on the sinterability of the samples. Our study provides a better understanding of synthesis mechanism of Ba–Sr hexaferrite samples.     

Fabrication strategies and application fields of novel 2D Ti3C2Tx (MXene) composite hydrogels: A mini-review

Ti₃C₂T_x (MXene), a new kind of 2D ceramic nanosheets, is receiving more and more attention in the fields of medicine, biology, energy, electronics, etc. However, the preparation and application of MXene in hydrogel is still in its infancy period. Here, we review the latest progress (after 2018) related to MXene hydrogels in time. Aiming at the key issue of the dispersion stability of MXene in hydrogel systems, the preparation strategy, mechanism, advantages and disadvantages of MXene hydrogels are sorted out in detail, and the potential application prospects of MXene composite hydrogel are introduced. Finally, future viewpoints are put forward for the dispersion stability challenges that need solving in the design of MXene hydrogel.     

Achieving thermally stable and anti-hydrolytic Sr2Si5N8:Eu2+ phosphor via a nanoscale carbon deposition strategy

Chemical stability of phosphors is critical to the efficiency and lifetime of the white light-emitting diodes. Therefore, many strategies have been adopted to improve the stability of phosphors. However, it is still lack of report on the improvement of thermal stability and hydrolysis resistance of phosphors by a single layer coating. Due to the high transmittance and high chemical inertness of graphene, it was coated on the surface of Sr₂Si₅N₈:Eu²⁺ phosphor by chemical vapor deposition, aiming to improve its thermal stability and hydrolysis resistance. The chemical composition and microstructure of the coating were characterized and analyzed. A nanoscale carbon layer was attached on the surface of Sr₂Si₅N₈:Eu²⁺ phosphor particles in an amorphous state. In coated Sr₂Si₅N₈:Eu²⁺ phosphor, the oxidation degree of Eu²⁺ to Eu³⁺ was significantly suppressed. At the same time, the surface of Sr₂Si₅N₈:Eu²⁺ particle turned from hydrophilic to hydrophobic after carbon coating, and consequently the hydrolysis resistance of Sr₂Si₅N₈:Eu²⁺ phosphor was greatly improved. After tests at 85 °C and 85% humidity for 200 h, the carbon coated Sr₂Si₅N₈:Eu²⁺ phosphor still maintained about 95% of its initial luminous intensity as compared with 35% of the uncoated. By observing the in-situ microstructure evolution of coated phosphor in air-water vapor environment, remained presence of the carbon layer even at 500 °C explained the excellent chemical stability of carbon coated Sr₂Si₅N₈:Eu²⁺ phosphor in complex environment. These results indicate that a nanoscale carbon layer can be used to provide superior thermal stability and hydrolysis resistance of (oxy) nitrides phosphors.     

Simulation of thermal barrier coating spallation induced by the initiation/growth/coalescence of internal crack and interfacial crack based on a real image model

In the furnace cycle test, the growth of oxide film leads to the propagation and coalescence of multiple cracks near the interface, which should be responsible for the spallation of thermal barrier coatings (TBCs). A TBC model with real interface morphology is created, and the near-interface large pore is retained. The purpose of this work is to clarify the mechanism of TBC spallation caused by successive initiation, propagation, and linkage of cracks near the interface during thermal cycle. The dynamic growth of thermally grown oxide (TGO) is carried out by applying a stress-free strain. The crack nucleation and arbitrary path propagation in YSZ and TGO are simulated by the extended finite element method (XFEM). The debonding along the YSZ/TGO/BC interface is evaluated using a surface-based cohesive behavior. The large-scale pore in YSZ near the interface can initiate a new crack. The ceramic crack can propagate to the YSZ/TGO interface, which will accelerate the interfacial damage and debonding. For the TGO/BC interface, the normal compressive stress and small shear stress at the valley hinder the further crack propagation. The growth of YSZ crack and the formation of through-TGO crack are the main causes of TBC delamination. The accelerated BC oxidation increases the lateral growth strain of TGO, which will promote crack propagation and coalescence. The optimization design proposed in this work can provide another option for developing TBC with high durability.     

Review on development of metal/ceramic interpenetrating phase composites and critical analysis of their properties

Metal/ceramic composites are in high demand in several industries because of their superior thermo-mechanical properties. Among various composite types, the interpenetrating phase composites (IPCs) with percolating metallic and ceramic phases offer manifold benefits, such as a good combination of strength, toughness, and stiffness, very good thermal properties, excellent wear resistance, as well as the flexibility of microstructure and processing route selection, etc. The fabrication of metal/ceramic IPCs typically involves two steps - i) processing of an open porous ceramic body, and ii) infiltration of metallic melt in the pores to fabricate the IPC. Although significant progress has been made in recent years for developing both porous ceramics and melt infiltration methods, to the best of the knowledge of the authors, no review article summarizing all the aspects of processing and properties of IPCs has been published till date. This review article is aimed at filling this gap. Starting with a brief introduction about the current status and applications of IPCs, the various processing routes for fabricating open porous ceramic preforms and melt infiltration techniques have been discussed. Subsequently, the data available for various important physical, mechanical, and thermal properties for IPCs have been critically analyzed to thoroughly understand their dependence on various structural and processing parameters. To compare the properties of IPCs with other relevant materials, seven different Ashby material property maps have been used, and the domains for IPCs have been created in them. For each map, the concept of material indices has been employed to critically discuss how IPCs perform in relation to other material classes for various optimum design conditions. Finally, a detailed future outlook for further research on IPCs has been provided.     

Structural characteristics and high-temperature oxidation behaviour of nano-HfO2-doped thermal barrier coatings

The uneven growth of thermally grown oxides (TGOs) in thermal barrier coating systems is an important cause of cracking failure at the coating interface in high-temperature environments. The doping of rare earth elements in the bonding layer can effectively inhibit the formation of spinel oxides in the TGO and improve the high-temperature oxidation resistance of the coating. However, a single rare earth element has a limited effect on inhibiting TGO failure. In this study, a NiCoCrAlYHf coating was prepared using a supersonic flame spraying (HVOF) technique. The effects of HfO₂ doping on the high-temperature oxidation behaviour of the coatings and diffusion behaviour of metallic elements in the coatings were investigated at 1100 °C. The results showed that the nano-sized HfO₂ filled the pores between the powder particles and improved the hardness of the coating. During the high-temperature oxidation process, the oxides formed by Hf and Y had a large size and low solubility, which effectively blocked the diffusion of Al. This slowed the generation of spinel oxides, effectively inhibited the growth of the TGO, it inhibits the initiation and propagation of cracks within the coating, reduces damage to the coating from tensile and compressive stresses at the interface, and improved the high-temperature oxidation resistance of the coating.     

Mechanical properties and wear behavior of Al5083 matrix composites reinforced with high amounts of SiC particles fabricated by combined stir casting and squeeze casting; A comparative study

Combined stir casting and squeeze casting processes were used to fabricate Al5083 matrix composites reinforced with 20, 25, and 30 wt% SiC_p. The microstructure, mechanical properties and wear behavior of the composites fabricated by combined stir casting and squeeze casting were compared with those fabricated by stir casting. The results revealed that the combined casting method improved the distribution of SiC particles through the reduction of the agglomeration of SiC particle and reduced the porosities of the samples from 2.32% to 1.29% in the sample containing 30 wt% SiC. These modifications led to the enhancement of mechanical properties i.e. increased the hardness to 85 BHN and the compressive strength to 350 MPa for the sample containing 30 wt% SiC fabricated by the combined casting method. In addition, the wear resistance of the samples fabricated by the combined casting method improved because of the reduced size of the wear debris as well as the smaller worn region. The dominant wear mechanism of all the composite samples fabricated by both methods was the delamination of the tribological layer while adhesion wear was dominant in the monolithic Al alloy.     

Ca2+ doping effects on the structural and electrical properties of Na0.5Bi4.5Ti4O15 piezoceramics

Bismuth layer structured Na_0.5Bi_4.5Ti₄O₁₅ (NBT) ferroelectric is one of the most promising materials for potential applications at high temperature. However, it is challenged to achieve a balance between high Curie temperature piezoelectric coefficient and excellent thermal stability for NBT piezoceramics. Here, through chemical modification at the A site of NBT with Ca²⁺, novel (Na_0.5Bi_0.5)_1-xCa_xBi₄Ti₄O₁₅ piezoceramics with excellent properties fabricated by solid state reaction were studied. After doping of Ca²⁺, the Curie temperature T_C increased from 648 °C to 662 °C while the piezoelectric coefficient d₃₃ increased from 14 pC/N to 22 pC/N which can be attributed to the intrinsic contribution of TiO₆ octahedral lattice distortion (tilting and rotation) and the extrinsic contribution of the increased density of domain walls. The composition of (Na_0.5Bi_0.5)_0.95Ca_0.05Bi₄Ti₄O₁₅ ceramics with x = 0.05 has the optimal performance with high T_C of 655 °C, large d₃₃ of 22 pC/N, high electrical resistivity ρ close to 10⁷ Ω cm at 500 °C and especially excellent thermal stability of d₃₃ only about 5% reduction after being annealed at 625 °C. The work effectively reveals the great potential of CNBT-5 ceramics for high-temperature piezoelectric applications.