Fabrication of Al2O3–ZrO2 ceramics with high porosity and strength

This study describes the synthesis of ceramics, in which a micrometre-sized Al₂O₃–ZrO₂ nanopowder was used as an oxide base for the hardening of the materials. To a suspension of this mixed metal oxide, the pore-forming crystallisation additives camphor and carbamide were added to produce ceramics with thin permeable pores. Camphor crystallised in the oxide suspension in the form of single pentagonal stars and сarbamide crystallised in the form of thin elongated needles. The use of the different crystallisation additives allowed the formation of ceramics after sintering that have both permeable and complex pore morphologies, where anisotropic properties were observed using carbamide as an additive but not when camphor was used. The total porosity of the resulting ceramics was 51.3%, with a compressive strength in the range of 17.3–92.3 MPa.     

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.     

Effects of light crude oil contamination on the physical and mechanical properties of geopolymer cement mortar

Fly ash and oil contaminated sand are considered as the two waste materials that may affect environment. This paper investigated the suitability of producing geopolymer cement mortar using oil contaminated sand. A comparison between physical and mechanical properties of mortar produced using geopolymer and Ordinary Portland Cement (OPC), in terms of porosity, hydration and compressive strength, was conducted. The results showed that heat curing can increase the compressive strength of geopolymer mortar up to 54% compared to ambient curing situation. The geopolymer mortar with 1% of light crude oil contamination yielded a 20% higher compressive strength than OPC mortar containing sand with a saturated surface dry condition. Furthermore, the formation of efflorescence decreased as the level of oil contamination decreased. Moreover, the heat curing method increased the kinetic energy and degree of reaction for geopolymer cement mortar, which cause an increment of the density of the pore system and improving the mechanical properties of the resulting composites. From the results of this study, it was demonstrated that geopolymer mortar has the potential of utilizing oil contaminated sand, and reducing its environmental impacts.     

Fluidisation characteristics of granular activated carbon in drinking water treatment applications

Granular activated carbon (GAC) filtration is an important unit operation in drinking water treatment. GAC filtration is widely used for its filtration and adsorption capabilities as a barrier for undesired organic macro- and micro-pollutants. GAC filtration consists of two successive phases: adsorption and filtration, capturing the impurities from the water in conjunction with a backwash procedure in which the suspended particles are flushed out of the system. Available literature predominantly focusses on adsorption. A less frequently discussed but nevertheless equally crucial aspect of this operation is the backwash procedure of GAC beds. To prevent accumulation of suspended particles and to avoid additional operation costs, optimal backwashing is required. Another factor is sustainability: water utilities are showing increasing interest in exploring new sustainable GAC media. As these have different bed expansion tendencies due to different GAC characteristics with varying geometries, operational developments are needed for prediction models to estimate the expansion degree during backwashing. The prediction of the bed expansion of GAC is complex as the particles are non-spherical, porous and polydisperse. Through a combination of advanced particle laboratory and fluidisation experiments, we demonstrate a new approach which leads to an improved expansion prediction model for the backwashing of GAC filters.     

The effects of porosity,asphalt content and fiberglass incorporation on the tensile strength and resilient modulus of asphalt concrete blends

Asphalt concrete is the prevailing material used for road surface construction. Its adequate characteristics in providing stability, durability and driving safety are controlled by complex interactions between its components. Thus, it is important to estimate the sensitivity of asphalt concrete mechanical properties as a function of its volumetrics. For this study, different combinations between asphalt content (3.5, 5 and 7.5%) and porosity values (above 4%) were used in order to disassociate these properties. The influence of mixing in fiberglass (0.5%) was also analyzed. It was found that porosity is significantly more relevant than the asphalt content in the prediction of tensile strength and resilient modulus of fiber-free asphalt concretes. In fiber-reinforced mixtures, the mechanical properties are improved by increasing the asphalt content, which suggests a better bonding between fibers and aggregates. For both cases, decreasing porosity is beneficial. By grouping both sets of results, it was possible to create a unique theoretical curve for both the tensile strength (q_t) and the resilient modulus (RM). The RM/q_t ratio was 5800 for the fiber-free group, and 3900 for the fiber-reinforced group - suggesting a better fatigue life indicator for asphalt concretes when fibers are added.     

Porous mullite ceramics with enhanced compressive strength from fly ash-based ceramic microspheres: Facile synthesis,structure, and performance

Porous mullite ceramics are widely used in heat insulation owing to their high temperature and corrosion resistant properties. Reducing the thermal conductivity by increasing porosity, while ensuring a high compressive strength, is vital for the synthesis of high-strength and lightweight porous mullite ceramics. In this study, ceramic microspheres are initially prepared from pre-treated high-alumina fly ash by spray drying, and then used to successfully prepare porous mullite ceramics with enhanced compressive strength via a simple direct stacking and sintering approach. The influence of sintering temperature and time on the microstructure and properties of porous mullite ceramics was evaluated, and the corresponding formation mechanism was elucidated. Results show that the porous mullite ceramics, calcined at 1550 °C for 3 h, possess a porosity of 47%, compressive strength of 31.4 MPa, and thermal conductivity of 0.775 W/(m?K) (at 25 °C), similar to mullite ceramics prepared from pure raw materials. The uniform pore size distribution and sintered neck between the microspheres contribute to the high compressive strength of mullite ceramics, while maintaining high porosity.     

Permeability differences based on three-dimensional geometrical information of void spaces

In this study,the permeabilities of Berea and Otway sandstones were measured under different confining pressures,and porosity was investigated through mercury intrusion porosimetry(MIP).The total porosities of the Berea and Otway sandstones were approximately 17.4%and 25%,respectively.Pore size distributions of each sandstone were almost the same,but the pores in the Otway sandstone were slightly narrower.However,the permeability of the Otway sandstone was smaller than that of the Berea sandstone by one order of magnitude.Three-dimensional(3D)void geometry and geometrical properties of the void spaces relevant to flow were compared to obtain the relation between the permeability differences and porosities of the two sandstones.The 3D geometrical analysis using microfocus X-ray computed tomography(CT)was performed,and the pore geometries of both sandstones were compared using the 3D medial axis(3DMA)method.Pore and throat radii,pore coordination number,tortuosity,number of connecting paths,connecting path volume,and other factors were determined using 3DMA.The Otway sandstone was characterized by a small effective throat/pore radius ratio.Based on the fluid flow mechanism,the lower effective throat/pore radius ratio results in a lower permeability induced by the fluid energy loss,which means that the 3D geometrical shape of void spaces affects the permeability value.     

Recent progress of the gas diffusion layer in proton exchange membrane fuel cells: Material and structure designs of microporous layer

Proton exchange membrane fuel cells (PEMFCs) have become the most attractive power supply units for stationary and mobile applications. The operation, design characteristics, as well as performance of PEMFCs, are closely related to the multiphase transport of mass, heat, and electricity in the cell, a critical of which is the gas diffusion layer (GDL). It is very important to guarantee the transmission of water and gasses under high current density, and which is the weakness of PEMFCs at present. Microporous layer (MPL) is considered to be the key variable for mass transfer, so varieties of works focus on modification of MPL materials and its structure design. However, there is still a lack of special review to summarize and prospect the progress of MPL in recent years. This review article therefore focuses on the insights and comprehensive understanding of four critical issues of the MPL, the porosity, pore size distribution, wettability, structural design and the durability of MPL. At last, the conclusion and recommendations section summarized the future prospects and recommendations for possible research opportunities.     

Petrographic and petrophysical characterization of some Paleozoic rocks,Um Bogma area,Southwest Sinai,Egypt

Sixty-two samples were collected from the five formations at Um Bogma area, (Southwest Sinai, Egypt). Nine samples were collected from Sarabit El Khedim Formation, ten samples were collected from Abu Hamata Formation, eighteen samples were collected from Adedia Formation, eight samples were collected from Um Bogma Formation and eighteen samples were collected from Abu Thora Formation.The Paleozoic rocks at Um Bogma area, consist mainly of sandstones, siltstones, shales, limestone and dolostones, which are unconformably overlie igneous and metamorphic rocks (granite, diorite and gneiss) of Precambrian age.The petrographic studies were applied to identify different rock units, different facies and its diagenetic history and to reveal its effect on the storage capacity properties. Different types of porosity (oversized, intergranular, fracture and vuggy porosities) have been identified based on the petrographic investigation of the studied thin sections.The Paleozoic sandstone rock samples are characterized by porosity average about 19% for Facies 1 (quartz wack) and about 18%for Facies 2 (quartz arenite) and permeability average 420?mD for Facies 1 (quartz wack) and 690?mD for Facies 2 (quartz arenite), so these rocks can be considered as good reservoir rocks. The Paleozoic carbonate rock samples (Facies 3) are characterized by poor porosity (less than 7%) and very low permeability (less than 0.5?mD), which caused by matrix and diagenetic processes and refer to bad reservoir rocks.Porosity can be linked to the two derived electrical properties (formation resistivity factor and electrical tortuosity) of the studied Paleozoic rocks at Um Bogma area. The electrical tortuosity has significant effects on both permeability and formation resistivity factor. The permeability decreases with increasing electrical tortuosity and the relation between both of them is inverse relationship with good coefficient of correlation. The permeability decreases with increasing electrical tortuosity and the relations between both of them are inverse relationships with high coefficient of correlation. The formation resistivity factor increases with increasing electrical tortuosity and the relations between both of them are positive relationships with a fair to very high coefficient of correlation.     

Online monitoring of laser remelting of plasma sprayed coatings to study the effect of cooling rate on residual stress and mechanical properties

This investigation deals with laser remelting of plasma sprayed alumina and chromia coatings. The time-temperature history of the laser remelted zone was recorded using an infrared pyrometer during the remelting operation. Cooling rates, under varying scanning speed, were determined from the time temperature curve. Surface morphology, microstructure, and phases of the laser treated and as-sprayed coatings were characterized using scanning electron microscopy, optical microscopy, X-ray diffraction, respectively. X-ray diffraction was also employed to measure the surface residual stress of the coatings. Inherent features of plasma sprayed coatings like porosity and inter-lamellar boundary were obliterated upon laser remelting. A columnar grain growth perpendicular to the laser scanning direction was observed. The range of roughness of the as-sprayed coatings reduced from 6 to 8?µm to 1–2?µm in the remelted layers. For both coatings, more than 90% reduction in porosity was found upon laser remelting. Surface residual stress of the as-sprayed alumina and chromia coatings was found to be tensile and compressive, respectively. Within the limits of the testing condition the tensile residual stress of the remelted layers increased by up to around 500% in the alumina coatings. In the chromia coating a decrease of compressive stress by up to around 80% was recorded. In the remelted layer the tensile nature of the stress showed a tendency to increase with an increase in the cooling rate. However, the state of stress of the as-sprayed layer, i.e., tensile or compressive, was retained in the remelted layer. The residual stress was found to decrease in the remelted layer with an increase in the degree of overlap of the remelted tracks.