Cyclic cold isostatic pressing and improved particle packing of coarse grained oxide ceramics for refractory applications

This study investigated the cold isostatic pressing of coarse grained alumina refractories applying either a cyclic pressure increase or a cycling at maximum pressure. Additionally the effects of the maximum pressure and the particle size distribution on physical, mechanical and thermomechanical properties were analyzed. The cyclic pressure increase resulted in a slightly higher apparent density and lower apparent porosity. A cycling at maximum pressure decreased the median pore size to some extent. Remarkably, an optimized particle size distribution resulted in a lower apparent porosity, lower median pore size and in a higher Young's modulus before and after thermal shock together with a slightly lower relative decrease of the Young's modulus. A higher pressing pressure which decreased the apparent porosity did not affect the Young's modulus. Thus, apparently the optimized particle size distribution improved the particle packing which was associated with a smaller median pore size. This smaller pore size increased the number of pores relative to the total porosity, which then acted as points of crack initiation and crack deflection limiting the length of propagating cracks in case of thermal shock. Thus, tailoring the pore size distribution is a promising starting point to improve the thermomechanical properties of refractories.     

Interface reactions between rutile coatings and molten aluminium or AlSi7Mg0.6 alloy

Rutile coatings deposited on corundum substrates are considered as promising functional elements improving the efficiency of the filtration of oxide inclusions out of aluminium melts. This contribution describes the reactions between rutile and two kinds of the aluminium melts and discusses the consequences of these reactions for the filtration process. It was found that the contact of rutile coatings with molten aluminium leads to the formation of a corundum layer at the solid/liquid interface. The exposure of the rutile coatings to molten AlSi7Mg0.6 alloy produces an interface layer of MgTiO₃. The interface layers possess defined orientation relationship to rutile which is characteristic for locally heteroepitaxial growth. The density functional theory calculations revealed that the TiO₂/α-Al₂O₃ and TiO₂/MgTiO₃ interfaces with the orientation relationships observed experimentally have low interface energies. The mechanisms of the interface layer formation and the impact of these layers on the degradation of the rutile coatings are discussed.     

CMC jackets for metallic pipes – A novel approach to prevent the creep deformation of thermo-mechanically loaded metals

Steel materials suffer extensive creep by the application at temperatures of about 700?°C and pressures about 350?bar in a power plant environment. The presented concept overwraps a steel pipe with a ceramic matrix composite (CMC) jacket in order to support the steel pipe and provide high temperature strength. Finite Element simulations show the influence of the wall thickness of CMC jacket and the coefficient of thermal expansion (CTE) on circumferential stresses within the hybrid metal ceramic pipe. Suitable fiber and matrix materials were studied, composites fabricated and mechanical properties determined. Finally, a prototype was designed in order to confirm the feasibility of the concept. The lifetime of a pure steel pipe was increased by more than four-fold by the additional CMC jacket.     

Bioraffinerien auf Basis schwach verholzter Biomasse

Weakly lignified biomass, like brewers' spent grain and grass silage, is good feedstock for biorefineries. The biomass can be separated and converted into valuable products in different ways. In this study, brewers' spent grain is used to investigate solid state fermentations with Cellulomonas uda. Additionally, hydrothermal pretreatment and subsequent enzymatic saccharification, as well as formation of inhibitory compounds, is demonstrated. Hydrothermal pretreatment combined with simultaneous saccharification and fermentation is shown as an example for the utilization of grass silage.     

Co-doping effects of (Al,Ti, Mg) on the microstructure and electrical behavior of ZnO-based ceramics

Co-doped ZnO-based ceramics using Al, Ti, and Mg ions in different ratios were synthesized with the objective to investigate the doping effects on the crystalline features, microstructure and the electrical behavior. For Al and Ti doping, a coexistence of crystalline phases was shown with a major wurtzite ZnO structure and secondary spinel phases (ZnAl₂O₄, Zn₂TiO₄, or Zn_aTi_bAl_cO_d), while Mg doping did not alter significantly the structural features of the wurtzite ZnO phase. The electrical behavior induced by Al, Ti, and Mg co-doping in different ratios was investigated using Raman, electron paramagnetic resonance (EPR) and ²⁷Al and ⁶⁷Zn solid-state nuclear magnetic resonance (NMR). Al doping induces a high electrical conductivity compared to other doping elements. In particular, shallow donors from Zn_i-Al_Zn defect structures are inferred from the characteristic NMR signal at about 185 ppm; that is, quite far from the usual oxygen coordinated Al. The Knight shift effect emanating from a highly conducting Al-doped ZnO ceramics was considered as the origin of this observation. Oppositely, as Ti doping leads to the formation of secondary spinel phases, EPR analysis shows a high concentration of Ti³⁺ ions which limit the electrical conductivity. The correlation between the structural features at the local order, the involved defects and the electrical behavior as function of the doping process are discussed.     

Analytical Model to Characterize the Efficiency of Disk Stack Separators

Up to now the prediction of separation efficiency for disk stack separators is largely based on the concept of equivalent clarification area, short Σ-theory, firstly published in 1949. An improved analytical model with a closed-form solution is presented in which the assumptions of uniform flow and unhindered solids transport are dropped. The contributions of distributor and solids holding space to the total separation efficiency are considered. The model is validated by comprehensive experiments with different geometry parameters and particle systems. The results are presented in a universal form for a combination of dimensionless numbers.     

Local analysis of Marangoni effects during and after droplet formation

The influence on the mass transfer in liquid-liquid extraction was investigated during droplet formation in a quiescent aqueous continuous phase for the two transition components, acetone and acetonitrile, in toluene. Both transition components have similar characteristics. However, an approximately eight times slower mass transfer of a droplet hanging on a capillary in relation to a rising droplet could be observed. The droplet formation time and the initial solute concentration are decisive for the mass transfer behaviour. A lower volumetric flow leads to slower droplet formation and a higher specific mass transfer area enhancing mass transfer, which is visualized via laser induced fluorescence (LIF). Additionally, as expected, higher initial solute concentrations promote Marangoni turbulences and thus mass transfer, which is measured via confocal Raman spectroscopy inside a fixed hanging droplet.