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.     

Effect of suspension characteristics on the performance of thermal barrier coatings deposited by suspension plasma spray

This paper investigates the influence of suspension characteristics on microstructure and performance of suspensions plasma sprayed (SPS) thermal barrier coatings (TBCs). Five suspensions were produced using various suspension characteristics, namely, type of solvent and solid load content, and the resultant suspensions were utilized to deposit five different TBCs under identical processing conditions. The produced TBCs were evaluated for their performance i.e. thermal conductivity, thermal cyclic fatigue (TCF) and thermal shock (TS) lifetime. This experimental study revealed that the differences in the microstructure of SPS TBCs produced using varied suspensions resulted in a wide-ranging overall TBC performance. All TBCs exhibited thermal conductivity lower than 1 W/(m. K) except water-ethanol mixed suspension produced TBC. The TS lifetime was also affected to a large extent where 10 wt % solid loaded ethanol and 25 wt % solid loaded water suspensions produced TBCs exhibited the highest and the lowest lifetime, respectively. On the contrary, TCF lifetime was not as significantly affected as thermal conductivity and TS lifetime, and all ethanol suspensions showed marginally better TCF lifetime than water and ethanol-water mixed suspensions deposited TBCs.     

Thermal shock response behaviour of carbon fibre reinforced silicon carbide matrix composites prepared by chemical vapour infiltration at different heating rates

The present work investigated the effects of thermal cycles in air on the tensile properties of a two-dimensional carbon fibre reinforced silicon carbide composite (2D C/SiC) prepared by chemical vapour infiltration at different heating rates. The composite was exposed to different cycles of thermal shock between 20 °C and 1300 °C in air. The damage mechanisms were investigated by AE online monitoring and fractured morphology offline analysis. The tensile strength of 2D-C/SiC decreases with increasing thermal cycles. However, the modulus only decrease within 40 cycles. Due to oxidation, with the decrease in heating rate, the residual properties of the material decrease more obviously. Meanwhile, the results of AE online monitoring and fracture analysis show that the matrix damage is more serious at higher heating rate and that more delamination occours in tensile fractures. The above results indicate that for the thermal shock of 2D C/SiC composites in air, oxidative damage plays a key role in the residual properties.     

Catalytic combustion synthesis of CNTs/MgO composite powders and the influences on the thermal shock resistance of low-carbon Al2O3–C refractories

Using MgC₂O₄, Mg powders as raw materials and Ni(NO₃)₂?6H₂O as a catalyst, CNTs/MgO composite powders were prepared by a catalytic combustion synthesis method. The CNTs/MgO composite powders were characterized by XRD, Raman spectroscopy, FESEM/EDS and HRTEM. The effects of catalyst content on the degree of graphitization and aspect ratio of the CNTs in composite powders were investigated. Moreover, the thermal shock resistance of low-carbon Al₂O₃–C refractories after adding the composite powder was investigated. The results indicated that the CNTs prepared with 1 wt% Ni(NO₃)₂?6H₂O addition had a higher degree of graphitization and aspect ratio. In particular, the aspect ratio could reach approximately 200. The growth mechanism of hollow bamboo-like CNTs in the composite powders was proven to be a V-L-S mechanism. The thermal shock resistance of Al₂O₃–C samples could be improved significantly after adding CNTs/MgO composite powders. In particular, compared with CM0, the residual strength ratio of Al₂O₃–C samples with added 2.5 wt% composite powders could be increased 63.9%.     

Characterization of anisotropic gas permeability and thermomechanical properties of highly textured porous alumina

Porous alumina with a highly textured microstructure was fabricated by pulse electric current sintering (PECS) using alumina platelets. Highly oriented porous alumina with a porosity of 3%–50% was obtained by a pressure-controlled method of PECS. The properties of the highly textured porous alumina were measured in two directions. The nitrogen gas permeance and thermal conductivity at room temperature were higher in the direction along the platelet length due to the higher continuity of pores and the connectivity of alumina platelets, respectively. The anisotropy of the thermal conductivity at room temperature was investigated and explained by the effect of grain size of platelets as well as morphology and orientation of pores. The bending strength was higher with the loading direction along the platelet thickness. The thermal shock strength was clearly different in the two directions. The difference in the thermal shock strength was investigated by the measurement of properties and thermal stress analysis.     

Application of Cr3C2/C composite powders synthesized via molten-salt method in low-carbon MgO–C refractories

High-performance and low-carbon MgO–C refractories are important refractories for smelting ultra-low carbon steel and clean steel. Based on this, Cr₃C₂/C composite powders were synthesized by the molten-salt method, and used as an additive to prepare low-carbon MgO–C refractories under nitrogen atmosphere. The phase, morphology and oxidation kinetics of Cr₃C₂/C composite powders were studied. In addition, the effect of Cr₃C₂/C composite powders on the morphology, mechanical properties, thermal shock resistance, and corrosion resistance of MgO–C refractories was investigated. The results indicated that the Cr₃C₂/C composite powders exhibited superior oxidation resistance than flake graphite. Moreover, the Cr₃C₂/C composite powders were introduced into the MgO–C refractories. Compared with the sample without Cr₃C₂/C composite powders, the introduction of 1 wt% Cr₃C₂/C composite powders significantly improved the thermomechanical properties and corrosion resistance of the material, its CMOR, CCS before and CCS after thermal shock were 9.06 MPa, 50.40 MPa and 32.60 MPa, respectively, and the corrosion index was significantly reduced from 44.6% to 26.5%.     

Cyclic thermal shock resistance of h-BN composite ceramics with La2O3–Al2O3–SiO2 addition

The effects of La₂O₃–Al₂O₃–SiO₂ addition on the thermal conductivity, coefficient of thermal expansion (CTE), Young's modulus and cyclic thermal shock resistance of hot-pressed h-BN composite ceramics were investigated. The samples were heated to 1000 °C and then quenched to room temperature with 1–50 cycles, and the residual flexural strength was used to evaluate cyclic thermal shock resistance. h-BN composite ceramics containing 10 vol% La₂O₃–Al₂O₃ and 20 vol% SiO₂ addition exhibited the highest flexural strength, thermal conductivity and relatively low CTE, which were beneficial to the excellent thermal shock resistance. In addition, the viscous amorphous phase of ternary La₂O₃–Al₂O₃–SiO₂ system could accommodate and relax thermal stress contributing to the high thermal shock resistance. Therefore, the residual flexural strength still maintained the value of 234.3 MPa (86.9% of initial strength) after 50 cycles of thermal shock.     

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 ionic conductivity and thermal shock resistance of MgO stabilized ZrO2 doped with Y2O3

The present work focused on the effect of Y₂O₃ co-doping on the phase composition, microstructure, ionic conductivity and thermal shock resistance of 8 mol% MgO stabilized ZrO₂ (Mg-PSZ) electrolyte ceramics for high temperature applications. The addition of Y₂O₃ could promote the process of monoclinic-to-cubic/tetragonal phase transformation and became the metastable phase at room temperature. Meanwhile, the grain size of Mg-PSZ decreased. It was demonstrated that an appreciable increase in the ionic conductivity and compressive strength occurred on substituting MgO with Y₂O₃ in the Mg-PSZ electrolyte ceramics across the measured temperature range. Moreover, the Y₂O₃ addition could restrain the adverse effect of the cyclic thermal shock on the ionic conductivity and compressive strength of Mg-PSZ. The main reason was that the increase of the amount of monoclinic phase caused by cubic/tetragonal-to-monoclinic phase transformation by the cyclic thermal shock was restrained after the Y₂O₃ addition.