Reconstruction and hydration of hydrotalcite response to thermal activation temperature: Enhancement of properties for magnesia castables

Optimization binding system for refractory castables is significant to enhance the service performance. Hydrotalcite has been considered a promoter for high-temperature performance of basic castables, however, its binding property remains to be improved before practical application. In this work, the thermal activated Mg–Al hydrotalcites were incorporated in magnesia castables, and the mutual influence of pre-calcination temperature on the hydration, microstructure, and strength of castables was investigated. The obtained results indicated that the reconstruction of calcined hydrotalcite took place in the hydration process and effectively motivated the hydrolysis. Hydrate was thus promoted and a relatively dense microstructure of magnesia castables was confirmed by X-ray computed tomography analysis. Hydrotalcite pre-calcinated at 300 °C contributed to the highest early strength for castable, and the high-temperature properties also performed better than that of other pre-calcinated hydrotalcite-adding. The enhancement mechanisms of calcined hydrotalcite were attributed to the two following reasons: (ⅰ) the modified microstructure of magnesia castables from the early stage by hydration process, (ⅱ) the further enhanced sinterability inspired by the appropriate thermal activation effect.     

Effect of particle grading on fracture behavior and thermal shock resistance of MgO-C refractories

Two types of MgO-C refractories with tight particle grading and non-tight particle grading were prepared according to Andreasen's continuous packing theory. Fracture behaviors were investigated using wedge splitting tests combined with digital image correlation method and acoustic emission techniques. The results indicated that MgO-C refractory with non-tight particle grading treated at 1400 ℃ had more in situ phases (e.g., AlN and MgAl₂O₄) and exhibited less brittleness than specimens with tight particle grading even though they had similar nominal tensile strengths. In contrast, specimens with non-tight particle grading had greater horizontal strain under various loading stages, reflecting their better ability to resist rupture deformation. In addition, more microcracks were initiated earlier in the pre-peak region, and more energy was consumed. The decrease in coarse particles and corresponding increase in fine powder content increased the interface between particles, benefiting for reducing the local stress concentration and improving the thermal shock resistance of refractories.     

基于IMCT理论的CaO-SiO2-MgO-Al2O3-Na2O渣系的脱硫热力学模型

 为了精确表征含Na2O渣系的脱硫能力，改善脱硫效果，基于熔渣离子与分子共存理论（IMCT）建立了CaO-SiO2-MgO-Al2O3-Na2O渣系结构单元的作用浓度计算模型和1 753 K时该渣系的脱硫热力学模型。并对渣系的总硫分配比及各自硫分配比的影响因素进行了讨论分析。理论结果表明，除LS， MgS外，随着Al2O3质量分数的增加，该渣系的脱硫能力明显下降，而MgO和Na2O质量分数的增加，对提高渣系的脱硫能力具有明显的促进作用。此外，少量的Na2O即可表现出很强的脱硫效果，这为含有Na2O的冶金二次资源在铁水脱硫过程中的应用以及铁水脱硫渣系的优化提供了必要的理论依据。     

In situ synthesis of Al2O3–SiC powders via molten-salt-assisted aluminum/carbothermal reduction method

Al₂O₃–SiC composite powder (ASCP) was successfully synthesized using a novel molten-salt-assisted aluminum/carbothermal reduction (MS-ACTR) method with silica fume, aluminum powder, and carbon black as raw materials; NaCl–KCl was used as the molten salt medium. The effects of the synthesis temperature and salt-reactant ratio on the phase composition and microstructure were investigated. The results showed that the Al₂O₃–SiC content increased with an increase in molten salt temperature, and the salt–reactant ratio in the range of 1.5:1–2.5:1 had an impact on the fabrication of ASCP. The optimum condition for synthesizing ASCP from NaCl–KCl molten salt consisted of maintaining the temperature at 1573 K for 4 h. The chemical reaction thermodynamics and growth mechanism indicate that the molten salt plays an important role in the formation of SiC whiskers by following the vapor-solid growth mode in the MS-ACTR treatment. This study demonstrates that the addition of molten salt as a reaction medium is a promising approach for synthesizing high-melting-point composite powders at low temperatures.     

High-temperature stability of Mg(Al,Cr)2O4 spinel co-existing with calcium aluminates in air

Cr₂O₃ is a well-known corrosion resistant oxide used in refractory applications. However, it can oxidize into toxic and water-soluble Cr(VI) compounds upon reaction with calcium aluminate cement phases in the presence of oxygen, which subsequently causes disposal problems after use. This study describes the extent to which chromium in the spinel Mg(Al,Cr)₂O₄ phase can be oxidized to Cr(VI) when it reacts with the calcium aluminate cement phases C₁₂A₇, CA, CA₂ and free CaO at 1300 °C in air, using XRD, XPS and leaching tests (TRGS 613 standard) as analytical tools. On reaction with CaO, the Mg(Al,Cr^III)₂O₄ spinel mainly transformed into hauyne (Ca₄Al₆Cr^VIO₁₆) and Ca₅Cr₃O₁₂ which contains both Cr(IV) and Cr(VI). The reaction of C₁₂A₇ and CA with the spinel phase also resulted in the formation of Ca₄Al₆CrO₁₆. Conversely, the reaction of Mg(Al,Cr^III)₂O₄ spinel with CA₂ resulted in the formation of only a trace amount of Cr(VI). Water-soluble Cr(VI) leached in large quantities (>100 mg/L) from samples where the Mg(Al,Cr^III)₂O₄ reacted with either C₁₂A₇ or CA. Almost no Cr(VI) leached from the sample when Mg(Al,Cr^III)₂O₄ reacted with CaO, using the standard TRGS 613 leach test, but a significant amount of Cr(VI) was released into solution when leached with a HCl solution for 12 h. Both Cr(IV) and Cr(VI) present in the Ca₅Cr₃O₁₂ dissolved into acidic solution. Only a small amount of Cr(VI) leached from the sample that resulted when spinel was reacted with CA₂, even after a prolonged HCl leach. Cr(III) in spinel Mg(Al,Cr)₂O₄ is very stable and does not leach in either distilled water or acidic solution.     

Construction of MnO2 nanosheets@graphenated carbon nanotube networks core-shell heterostructure on 316L stainless steel as binder-free supercapacitor electrodes

Carbon nanotubes are regarded as typical and promising electrode materials in supercapacitors. However, small specific capacitance of carbon nanotubes restricts the practical application in high energy density devices. Herein, MnO₂ nanosheets@graphenated carbon nanotube networks are synthesized directly on 316L stainless steel as binder-free electrodes for high-performance supercapacitors. Graphenated carbon nanotube networks are grown in-situ on stainless steel by chemical vapor deposition method followed by annealing treatment. Subsequently, MnO₂ nanosheets are uniformly deposited on graphenated carbon nanotube networks to construct core-shell heterostructure based on the facile hydrothermal reaction using KMnO₄ as the precursor. Core carbon nanotube networks can offer a stable structural backbone and shell MnO₂ nanosheets can shorten diffusion paths of ions. The MnO₂ nanosheets@graphenated carbon nanotube networks exhibit a high specific capacitance of 575.4 F g⁻¹ (areal capacitance of 274 mF cm⁻²) at the current density of 0.5 mA cm⁻² and good cycling stability (93% of capacity retention after 6000 cycles), due to the synergistic effects between pseudocapacitive MnO₂ nanosheets and conductive carbon nanotube networks. The developed synthetic strategy offers design guidelines for the construction of advanced binder-free electrodes for high-performance supercapacitors.     

Formation mechanism of Ti(C,N) solid solution in Al-brown fused alumina refractory at 1973 K in flowing N2

Brown fused alumina is a cost-effective alumina material, and the state of Ti in alumina has a great influence on its high-temperature performance. In this paper, the Ti-containing phases in brown fused alumina particles and Al-brown fused alumina refractory were successfully transformed into Ti(C,N) at 1973 K in flowing N₂. The evolution of the Ti-containing phases in brown fused alumina under high temperature and nitrogen conditions was investigated by XRD, SEM and EDS. The results show that the Ti-containing phases in brown fused alumina include Ti₂O₃, Ti(C,N,O), TiFeSi₂, Ca_0·95Mg_0·9Al_10·1(Ti)O₁₇ and a low-melting point Ca₃Al₂Si₃(Mg,Ti)O₁₂ phase. Under high temperature and nitrogen conditions, the TiO_2[liquid], MgO_[liquid] and SiO_2[liquid] in the low-melting point phase are transformed into Ti(C,N), Mg(g) and SiO(g), while they are supplemented from Ti₂O₃, Ti(C,N,O) and Ca_0·95Mg_0·9Al_10·1(Ti)O₁₇. After heat treatment at 1973 K for 3 h, Ti₂O₃ and Ti(C,N,O) disappear, Ca_0·95Mg_0·9Al_10·1(Ti)O₁₇ is transformed into plate-like Ca_0·55Al₁₁O_17.05, and Ti(C,N) is formed on the surface of the corundum particles. The formation of Ti(C,N) reduces the porosity of the brown fused alumina particles and increases their strength.     

Producing fully-lamellar microstructure for wrought beta-gamma TiAl alloys without single α-phase field

Fine-grained fully-lamellar (FL) microstructure is desired for TiAl components to serve as compressor/turbine blades and turbocharger turbine wheels. This study deals with the process and phase transformation to produce FL microstructure for Mo stabilized beta-gamma TiAl alloys without single α-phase field. Unlike the α + γ two-phased TiAl or beta-gamma TiAl with single α-phase field, the wrought multi-phase TiAl–4/6Nb–2Mo–B/Y alloys exhibit special annealing process to obtain FL microstructure. Short-term annealing at temperatures slightly above β-transus is recommended to produce the desired FL microstructure. The related mechanism is to guarantee the sufficient diffusion homogenization of β stabilizers during single β-phase annealing, and further avoid α decomposition by α → γ + β when cooling through α + β + γ phase field. The colony boundary β phase contributes to fine-grained nearly FL microstructure, by retarding the coarsening of the α phase grains.     

Effects of SDBS and ZrO2 additives on the microstructure and properties of silicon-bonded SiC porous ceramics

Porous silicon-bonded silicon carbide (SBSC) ceramics were prepared under argon atmosphere, with silicon as pore former and bonding material, simultaneously, sodium dodecyl benzene sulfonate (SDBS) and ZrO₂ as sintering additives, the effects of SDBS and ZrO₂ on the porosity, pore size, mechanical, physical and thermal properties and microstructures were investigated. The results suggested that suitable content of SDBS and ZrO₂ could not only effectively lower the sintering temperature to 1450 °C due to the sticky flow of molten silicon, but also increase the pore structure and improve the bending strength. The reason for this is that SDBS decomposed into Na₂O which reacted with ZrO₂ and impurity SiO₂, which was the native oxide film on the surface of SiC particles, to form a bonding phase between SiC particles to improve the bending strength; meanwhile, the disappearances of impurity SiO₂ would benefit the bond of molten silicon and silicon carbide particles, and silicon melt leaving pores in its original position to increase the pore structure. The optimal apparent porosity, bending strength, average pore size, gas permeance and residual bending strength after thermal shock cycles of SBSC porous ceramic sintered at 1450 °C with 5 wt% SDBS and 6 wt% ZrO₂ were 38.33%, 55.4 MPa, 11.3 μm, 106.4 m³/m²·h·kPa and 28.2 MPa, respectively.     

Enhanced dielectric and piezoelectric properties in Na0.5Bi4.5Ti4O15 ceramics with Pr-doping

The bismuth layer-structured Na_0.5Bi_4.5-xPr_xTi₄O₁₅ (x?=?0, 0.1, 0.2, 0.3, 0.4, and 0.5) (NBT-xPr³⁺) ceramics were fabricated using the traditional solid reaction process. The effect of different Pr³⁺ contents on dielectric, ferroelectric and piezoelectric properties of Na_0.5Bi_4.5Ti₄O₁₅ ceramics were investigated. The grain size of Pr³⁺-doping ceramics was found to be smaller than that of pure one, the maximum dielectric constant and Curie temperature T_c gradually decreased with increasing Pr³⁺ contents, and the dielectric loss decreased at high temperature by Pr³⁺-doping. Moreover, the activation energy (E_a), resistivity (Z’), remanent polarization (2P_r) and piezoelectric constant (d₃₃) increased by Pr³⁺-doping. The NBT-xPr³⁺ ceramics with x?=?0.3 achieved the optimal properties with the maximum dielectric constant of 1109.18, minimum loss of 0.00822 (250?kHz), E_a of 1.122?eV, Z’ of 7.9?kΩ?cm (725 ºC), d₃₃ of 18 pC/N, 2P_r of 12.04 μC/cm². The enhancement was due to the addition of Pr³⁺ which suppressed the decreasing of resistivity at high temperature and made it possible for NBT-xPr³⁺ ceramics to be poled in perpendicular direction, implying that it is a great improvement for Na_0.5Bi_4.5Ti₄O₁₅ ceramics in electrical properties.