Preparation of α-cordierite through mechanochemical activation of MgO–Al2O3–SiO2 ternary system

Samples of the ternary system MgO–Al₂O₃–SiO₂ with stoichiometric composition in relation to α-cordierite (Mg₂A_l4Si₅O₁₈), consisting of 22.2 mol% MgO, 22.2 mol% Al₂O₃, and 55.6 mol% SiO₂, were activated in a low energy mill with a constant speed of 100 rpm, in an aqueous medium. The precursors used were corundum (Al₂O₃), silica gel HF254 type 60 (SiO₂), and periclase (MgO). The objective of the present study was to evaluate the effect of mechanochemical activation on the solid-state synthesis of α-cordierite, using a low energy ball mill. Another objective was to shed light on the effect of mechanochemical activation on the steps of α-cordierite formation. For this end several grinding conditions were evaluated, varying the time and mass ratio of precursors/grinding elements, as well as calcination at different temperatures between 950 °C and 1350 °C for 2 h. The samples were analyzed for the determination of the formed phases by Infrared (IR) and X-ray Diffraction (XRD). The phases identified in uncalcined samples were brucite (Mg(OH)₂), forsterite (Mg₂SiO₄), enstatite (MgSiO₃), spinel (MgAl₂O₃), amorphous silica (SiO₂), corundum (α-Al₂O₃), and zirconia (monoclinic and tetragonal ZrO₂). The lowest temperature corresponding to the formation of α-cordierite (α-Mg₂Al₄Si₅O₁₈) was 1150 °C and a considerable amount of this phase (16.2%) was observed at this temperature, for the sample with the higher mechanochemical activation. In a solid-state reaction, α-cordierite is normally obtained at around 1400 °C, therefore, the formation of this phase at 1150 °C confirms that the mechanochemical activation method, using a low-cost ball mill, is efficient in reducing the solid-state reaction temperature.     

Femtosecond Ti: Sa ultra short-pulse laser irradiation effects on the properties and morphology of the zirconia surface after ageing

Femtosecond pulses from a Ti:Sapphire laser were used to irradiate specimens of yttria-stabilised (35% mol) tetragonal zirconia (Y-TZP) with the purpose of studying the effects of the irradiations on their surface properties and morphology after ageing. Zirconia disks were divided into eight groups (n = 32) according to their surface treatment and subsequent ageing: Control: no treatment; sandblasting: Al₂O₃ sandblasting 50 μm; and ultrashort laser pulses irradiation with 25 μJ pulses, considering two different scanning steps based on the width between two grooves. These groups were duplicated and submitted to ageing. The surfaces were analysed using scanning electron microscopy (SEM), and X-ray diffraction. A finite element analysis, a biaxial flexure test, as well as fractographic and Weibull analyses, were performed. The strengths of the disks were statistically different for the treatment factor, and the principal stresses seemed to be concentrated at the centre of the specimens, as predicted by the computer simulations. Ageing decreased the strengths for all groups and increased the Weibull modulus for the laser group with the 40 μm-width between two grooves. The sandblasting group presented the highest monoclinic phase peak. Although the most significant strength was found within the sandblasting group, the phase transformation was favourable to the laser groups. The Weibull modulus was higher for the laser group with the 60 μm-width between two grooves, confirming the highest homogeneity of its failure distribution. Regardless of the surface treatment, strength was decreased with ageing in all groups. The femtosecond Ti:Sa ultra-short pulse laser irradiation can be suggested as an alternative to the gold standard sandblasting in long-term Y-TZP zirconia rehabilitations, such as crowns and veneers.     

A thermal perspective of flash sintering: The effect of AC current ramp rate on microstructure evolution

In flash sintering experiments, the thermal history of the sample is key to understanding the mechanisms underlying densification rate and final properties. By combining robust temperature measurements with current-ramp-rate control, this study examined the effects of the thermal profile on the flash sintering of yttria-stabilized zirconia, with experiments ranging from a few seconds to several hours. The final density was maximized at slower heating rates, although processes slower than a certain threshold led to grain growth. The amount of grain growth observed was comparable to a similar conventional thermal process. The bulk electrical conductivity correlated with the maximum temperature and cooling rate. The only property that exhibited behavior that could not be attributed to solely the thermal profile was the grain boundary conductivity, which was consistently higher than conventional in flash sintered samples. These results suggest that, during flash sintering, athermal electric field effects are relegated to the grain boundary.     

Mechanical properties and thermal shock in thin ZrO2–Y2O3–Al2O3 films obtained by the sol-gel method

Thin multilayer coatings of ZrO₂–Y₂O₃–Al₂O₃ were prepared using the sol-gel method and dip-coating technique in order to advance in the study of what influence the incorporation of Al₂O₃ has on films of Y₂O₃-doped ZrO₂, investigating its role in the synthesis of the solutions and in the characteristics and properties of the coatings. After the characterization of the solutions used in the process, the microstructure of the films was studied and their mechanical behaviour and resistance to thermal shock were determined so as to optimize the characteristics and functionality of these coatings. With increased alumina content, 3YSZ-Al₂O₃ (20 mol%), the cubic phase of the zirconia disappeared completely at the sintering temperature used (700 °C), resulting in the tetragonal phase with Al in solution. There was also a decrease in the coatings' hardness and Young's modulus, and an increase in toughness and resistance to thermal shock. These results allow guidelines to be established for the design of multilayer structures that are, tougher, more resistant, and have improved surface properties.     

Joining zirconia with nickel-based superalloys for extreme applications by using a pressure-free high-temperature resistant adhesive

In order to meet the high demand for joining ceramic/superalloy composite structure in extreme environments, a novel high-temperature resistant adhesion technique was developed for joining ZrO₂ and Inconel 625 by applying an aluminum phosphate emulsion/zirconium sol based adhesive. With increasing temperature, a series of reactions occurred in adhesive, and its high-temperature bonding was attributed to the formation of a composite structure containing various ceramics and intermetallics. The adhesive after RT curing could find direct applications in extreme environments, and provide bonding strength no less than 2.5 MPa in the temperature range of RT-1100 °C. The bonding strength was higher than 4 MPa in the temperature range of 800–1000 °C, which was further attributed to the formation of an effective CTE-gradient relationship among ZrO₂, adhesive and Inconel 625, as well as the interfacial reactions between the two substrates. The work broadened the application of adhesion technique and brought new ideas for joining dissimilar engineering materials.     

Chemical looping glycerol reforming for hydrogen production by Ni@ZrO2 nanocomposite oxygen carriers

The research describes the synthesis of nanocomposite Ni@ZrO₂ oxygen carriers (OCs) and lanthanide doping effect on maintaining the platelet-structure of the nanocomposite OCs. The prepared OCs were tested in chemical looping reforming of glycerol (CLR) process and sorption enhanced chemical looping reforming of glycerol (SE-CLR) process. A series of characterization techniques including N₂ adsorption-desorption, X-ray diffraction (XRD), inductively coupled plasma optical emission spectrometry (ICP-OES), high resolution transmission electron microscopy (HRTEM), H₂ temperature-programmed reduction (H₂-TPR), H₂ pulse chemisorption and O₂ temperature-programmed desorption (O₂-TPD) were used to investigate the physical properties of the fresh and used OCs. The results show that the platelet-stack structure of nanocomposite OCs could significantly improve the metal support interaction (MSI), thus enhancing the sintering resistance. The effect of lanthanide promotion on maintaining this platelet-stack structure increased with the lanthanide radius, namely, La³⁺ > Ce³⁺ > Pr³⁺ > Yb³⁺. Additionally, the oxygen mobility was also enhanced because of the coordination of oxygen transfer channel size by doping small radius lanthanide ions. The CeNi@ZrO₂ showed a moderate ‘dead time’ of 220 s, a high H₂ selectivity of 94% and a nearly complete glycerol conversion throughout a 50-cycle CLR test. In a 50-cycle SE-CLR stability test, the CeNi@ZrO₂CaO showed high H₂ purity of 96.3%, and an average CaCO₃ decomposition percentage of 53% without external heating was achieved.     

Submicro-zirconia crystal-intergrown zircon opaque glaze

Zircon opaque glaze is widely used in sanitary and building ceramic products due to its high-temperature stability. Massive amounts of zircon are consumed by the ceramic industry yearly. In this work, a method to reduce zircon consumption and enhance opaque effect was proposed by intergrowth of submicro zirconia. Alumina was added to a K–Na–Ca–Al–Si–Zr system glaze to prepare a 5 wt % content highly opaque glaze, where zirconia coexisted with zircon. The crystallization behavior, opacification properties, and Vickers hardness of the glaze were investigated. Back-scattered electron images showed that when Al₂O₃ addition increased into more than 13 wt %, abundant of submicro zirconia crystals would intergrow with zircon crystals. The glaze containing 13 wt % Al₂O₃ had an L* value of 96.76 ± 0.27 after being fired at 1220 ℃.     

Microwave assisted synthesis and antimicrobial activity of Fe3O4-doped ZrO2 nanoparticles

Composites play important role in dental filling by controlling shrinkage along with correction in teeth's shape and position. Rehabilitation of severely worn dentition can be achieved using mechanically strong composites. This study aims to synthesize zirconia-based composites to be used as dental fillers. Effect of microwave powers (100–900?W) along with Fe₃O₄ doping are studied on the structural, mechanical and magnetic properties of stabilized zirconia. SEM and TEM reveal formation of spherical nanoparticles with diameter of ～30?nm. XRD results shows phase pure tetragonal zirconia (t-ZrO₂) at microwave power of 500?W without any post heat treatment. Crystallite size calculated from XRD data (～23?nm) matches well with the previously reported value for stabilization of t-ZrO₂. Microwave energy dissipation results in stresses causing volume shrinkage leading to monoclinic to tetragonal phase transformation with higher X-ray density and hardness of ～1347HV. VSM results show ferromagnetic response with low coercivity (600Oe) value and saturation magnetization (～2emu/g). It is worth mentioning here that this is one of its kind study reporting synthesis of room temperature stabilized Fe₃O₄ doped zirconia composites at microwave power of 500?W. Antibacterial studies reveal inhibition zone of ～32?mm against bacillus bacteria suggesting their potential use as dental filler.     

Microcrack healing in zirconia ceramics under a DC electric field/current

Flash event caused by a DC electric field/current was applied to the crack healing in 8 mol % Y₂O₃ stabilized cubic ZrO₂ polycrystals (8Y-CSZ). The flash event, which occurred by applying the DC power higher than a critical value of 100 mW/mm³, successfully healed the microcrack within several minutes without any healing agents at a furnace temperature of 800 °C. As compared to the healing treatment under static annealing, the healing phenomena were accelerated about 2 times under the flash treatment even at the same temperatures, suggesting that the enhanced healing phenomena cannot be explained only by the temperature effect. Since the rate of grain growth was accelerated under the flash treatment, the flash healing would be accelerated through the current-enhanced diffusional processes. This study shows for the first time that the flash event has a potential to apply to the crack healing process in the ceramic materials and composites.     

Additive manufacturing of zirconia ceramics by material jetting

The possibility of additive manufacturing of ceramics has been reported widely in scientific literature. This study investigates the potential of direct inkjet printing or material jetting of 3Y-TZP ceramics by assessing the microstructure and mechanical properties of the sintered printed parts. The technique allows to print in layers of 10.5 μm, with an as-printed green density of 58 % and nearly fully sintered density of 6.03 ± 0.1 g/cm³ (99.7 % TD). The dimensions of the green and sintered parts were highly accurate but showed an anisotropic roughness in function of the building direction, mainly due to the support structures. The biaxial bending and 4-point bending strength of the sintered material was found to be substantially higher in the XY direction than in the building (Z) direction. SEM and X-Ray computed tomography revealed the presence of delamination cracks, agglomerates and spherical pores, which were identified as fracture origins on fractured surfaces.