A numerical model to predict the powder–binder separation during micro-powder injection molding

The micro-powder injection molding (micro-PIM) process has the potential to bridge the gap between the design and manufacturing of micro-components that are often used in small and handy devices. Numerical modeling helps to analyze and overcome various difficulties of micro-PIM. In the present work, a numerical model is developed to predict the powder–binder separation (a common defect in PIM and especially severe in micro-PIM) during the injection of an alumina feedstock. A powder–binder separation criterion is proposed dealing with applied injection pressure and friction force between the powder and binder. An indirect comparison of feedstock travel time between two locations is used to validate the model. The predicted segregation from the simulated result is supported by a qualitative experimental measurement. The developed model can be used to optimize injection parameters to get a defect-free product.     

Highly oriented α-Al2O3 transparent ceramics shaped by shear force

Alumina platelets were arranged horizontally in submicron alumina particles by shear force in the flow of slurries during casting. The obtained alumina green bodies with platelets were pressureless-sintered in vacuum, producing ceramics with thoroughly oriented grains and high transmittance. The effects of sintering parameters on the densification, microstructure evolution, and orientation degree of alumina ceramics were investigated and discussed. The results showed that the densification, grain size, orientation degree, and in-line transmittance were increased with increasing sintering temperature. The enhancement of orientation degree was mainly coherent with grain growth. The grain-oriented samples exhibited a much higher in-line transmittance (at 600 nm) of 61 % than that of the grain random sample (29 %). Moreover, the transmission remained a high level in the ultraviolet range (<300 nm).     

Degradation mechanism of high alumina refractory bricks by reaction with deposits in a rotary kiln for fluxed iron ore pellets production

The formed deposits wear out of refractory wall linings in the rotary kiln and may cause production disturbances. This study describes the chemical composition and mineralogical phase components at the deposit/refractory interface in the rotary kiln for fluxed iron ore pellets production. The main phases of refractory bricks are corundum and mullite, while the deposits mainly contain hematite and silicates. The main phases in the deposit/refractory brick contact zone are hematite, anorthite (CaAl₂Si₂O₈), mullite, corundum, and silicates. Moreover, the hematite phases in the deposit/brick interface averagely contain 6.98 wt% Al and 1.38 wt% Ti. The silicates in the contact zone contain higher aluminium content and lower iron content than the silicates in the deposits. Finally, the thermodynamic analysis indicates that the main phases in the deposits can react with the refractory to form Al₂Fe₂O₆, CaAl₂Si₂O₈, feldspar, and liquid phases lead to the degradation of bricks in the kiln during the iron ore pellets production.     

Tailoring Cu/Al2O3 catalysts for the catalytic pyrolysis of tomato waste

In this study, pyrolysis of tomato waste has been performed in fixed bed tubular reactor at 500 °C, both in absence and presence of Cu/Al₂O₃ catalyst. The influences of heating rate, catalyst preparation method and catalyst loading on bio-oil yields and properties were examined. According to pyrolysis experiments, the highest bio-oil yield was obtained as 30.31% with a heating rate of 100 °C/min, 5% Cu/Al₂O₃ catalyst loading ratio and co-precipitation method. Results showed that the catalysts have strong positive effect on bio-oil yields. Bio-oil quality obtained from fast catalytic pyrolysis was more favorable than that obtained from non-catalytic and slow catalytic pyrolysis.     

High-temperature behavior of oxide dispersion strengthening CoNiCrAlY

To fabricate oxide dispersion strengthened bond coatings, commercial Co–30wt-%Ni–20Cr–8Al–0?4Y powder was milled with 2% additions of Al₂O₃, Y₂O₃ or Y₂O₃ + HfO₂. Low-pressure plasma sprayed, free-standing specimens were oxidised in air + 10%H2O at 1100 °C both isothermally (100 h) and in 500, 1?h cycles. Dry air cyclic testing conducted at both ORNL and FZJ showed remarkably similar results. In general, the water vapour addition caused more scale spallation. Two LPPS specimens without oxide additions were tested for comparison. The specimens with 2%Al₂O₃ addition exhibited the best behaviour as the powder already contained 0?4%Y. Additions of 2%Y₂O₃ and especially 1%Y₂O₃ + 1%HfO₂ resulted in over-doping as evidenced by high mass gains and the formation of Y- and Hf-rich pegs. Scanning transmission electron microscopy of the isothermal specimens showed no Hf and/or Y segregation to the alumina scale grain boundaries in the over-doped specimens.     

Effect of heat treatment and zircon addition on the properties of low-cement castables based on recycled alumina grog

In this investigation, low-cement castables were prepared using 70% alumina grog aggregates obtained from crushed alumina brick waste. The aggregates were thermally treated at 1550 °C for 3 h. Four types of low-cement castables were prepared with various types of aggregates (alumina grog with or without thermal treatment) and fillers (with or without zircon addition), and they were evaluated in terms of their physical, thermal, and chemical properties. Microstructural analysis via scanning electron microscopy (SEM) was performed on the castables before and after slag attack. Compared to the other fabricated castables, the thermally treated alumina grog castables with zircon showed better physical properties, such as a higher bulk density, cold crushing strength, and modulus of rupture and a lower apparent porosity and water absorption. In addition, they had a higher positive linear thermal expansion, refractoriness under load, permanent linear change, and hot modulus of rupture. The results of the SEM with energy dispersive X-ray analysis of the prepared castables confirmed that the mullite and anorthite phases were predominant when zircon was not added and the zircon–mullite phase additionally appeared upon the incorporation of zircon. A quantitative elemental analysis via X-ray fluorescence spectroscopy was employed to determine the composition of the castables. X-ray diffraction analysis showed that the alumina grog castables had a high mullite and low anorthite content, and the thermally treated alumina grog had a high anorthite, low mullite, and high zircon content. The improvement in the mechanical and thermo-mechanical properties of the castables with thermally treated alumina grog and added zircon can be attributed to the formation of the zircon–mullite phase with a low mullite phase content.     

Effect of moisture and filler content on the structural,thermal and dielectric properties of polyamide‐6/boehmite alumina nanocomposites

Polyamide‐6 (PA‐6)/boehmite alumina (BA) nanocomposites were prepared via direct melt compounding. Structural, thermal and dielectric properties of ‘as‐received’ (including moisture) and ‘dried’ (thermally treated) specimens were examined. The BA nanofiller was homogeneously dispersed in the PA‐6 matrix. XRD and FTIR revealed that crystallization of PA‐6 in the γ phase was favoured over α phase with increasing BA content. The crystallinity index (CI) and the percentage of α and γ phases were also evaluated. Dried specimens exhibited a lower CI than as‐received specimens while the CI decreased with the addition of filler. Broadband dielectric spectroscopy revealed the presence of γ, β and α relaxations, the Maxwell–Wagner–Sillars effect and the contribution of conductivity relaxation in the as‐received samples. The drying procedure unmasked a double feature of both β and α modes. The results of the complementary techniques were analysed and the effects of moisture and/or the incorporation of BA nanofiller on the microstructure of the PA‐6 matrix are disclosed. © 2019 Society of Chemical Industry