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).     

Plasma-assisted CO2 reforming of methane over Ni-based catalysts: Promoting role of Ag and Sn secondary metals

Carbon dioxide (CO₂) and methane (CH₄) are the primary greenhouse gases (GHGs) that drive global climate change. CO₂ reforming of CH₄ or dry reforming of CH₄ (DRM) is used for the simultaneous conversion of CO₂ and CH₄ into syngas and higher hydrocarbons. In this study, DRM was investigated using Ag–Ni/Al₂O₃ packing and Sn–Ni/Al₂O₃ packing in a parallel plate dielectric barrier discharge (DBD) reactor. The performance of the DBD reactor was significantly enhanced when applying Ag–Ni/Al₂O₃ and Sn–Ni/Al₂O₃ due to the relatively high electrical conductivity of Ag and Sn as well as their anti-coke performances. Using Ag–Ni/Al₂O₃ consisting of 1.5 wt% Ag and 5 wt% Ni/Al₂O₃ as the catalyst in the DBD reactor, 19% CH₄ conversion, 21% CO₂ conversion, 60% H₂ selectivity, 81% CO selectivity, energy efficiency of 7.9% and 0.74% (by mole) coke formation were achieved. In addition, using Sn–Ni/Al₂O₃, consisting of 0.5 wt% Sn and 5 wt% Ni/Al₂O₃, 15% CH₄ conversion, 19% CO₂ conversion, 64% H₂ selectivity, 70% CO selectivity, energy efficiency of 6.0%, and 2.1% (by mole) coke formation were achieved. Sn enhanced the reactant conversions and energy efficiency, and resulted in a reduction in coke formation; these results are comparable to that achieved when using the noble metal Ag. The decrease in the formation of coke could be correlated to the increase in the CO selectivity of the catalyst. Good dispersion of the secondary metals on Ni was found to be an important factor for the observed increases in the catalyst surface area and catalytic activities. Furthermore, the stability of the catalytic reactions was investigated for 1800 min over the 0.5 wt% Ag-5 wt% Ni/Al₂O₃ and 0.5 wt% Sn-5 wt% Ni/Al₂O₃ catalysts. The results showed an increase in the reactant conversions with an increase in the reaction time.     

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.     

Triggering the aqueous interparticle association of γ‒Al2O3 hierarchical assemblies using divalent cations and cellulose nanofibers

Understanding aqueous dispersion, rheological properties and colloidal stabilisation mechanisms of hierarchically assembled ceramic powders is important for progress in the fields of catalysis, separation and/or adsorption. The present study was designed to evaluate the rheological and sedimentation behaviour of highly loaded aqueous suspensions (up to φ_A = 0.126) containing AlN-powder-hydrolysis-derived, micron-sized, mesoporous, gamma alumina (MA) particulates with a high surface area (～180 m²/g) dispersed with sodium polyacrylate (NaPAA). The as-prepared suspensions were prone to sedimentation and segregation. However, when divalent cations (Mg²⁺, Ca²⁺) or cellulose nanofibers were added, the formation of interparticle association networks in the aqueous suspensions containing MA particles was triggered, facilitating their long-term resistance to sedimentation lasting more than 12 weeks.     

Optical properties of transparent polycrystalline ruby (Cr:Al2O3) fabricated by high-pressure spark plasma sintering

Doped transparent ceramics with high optical quality can serve as materials for photonic applications such as laser gain media. In that regard, transparent polycrystalline alumina has potential for high-power applications due to its excellent physical and chemical properties, combined with unique doping possibilities. However, optical birefringence of Al₂O₃ crystals make achieving sufficiently high optical transmittance a processing challenge. In the present study, we demonstrated fabrication of highly transparent 0.5 at.% Cr:Al₂O₃ ceramics by high-pressure spark plasma sintering (HPSPS). The optical properties of these polycrystalline ruby ceramics were analyzed in order to assess possible laser operation (at 694.3 nm). The obtained ceramics exhibit high in-line transmittance (～72.5 % at 700 nm), equivalent to a scattering coefficient of 2.15 cm^?1, and characteristic ruby photoluminescence. The theoretically estimated lasing threshold and percentage of absorbed pump power indicate that such ruby ceramic lasers could operate at reasonable thresholds of 80?225 mW with short lengths of 0.5?5 mm. Thus, HPSPS is a promising method for producing laser-quality doped transparent ceramics for compact laser systems.     

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.     

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.     

Microstructure and mechanical properties of Al2O3/ZrO2 composites by two-step sintering

Composites of Al₂O₃/ZrO₂ (containing 25, 50, and 75 vol% ZrO₂) were prepared by mixing Al₂O₃ and ZrO₂ suspensions. The microstructural control via two-step sintering (TSS) was the main objective of this work. For this purpose, different sintering curves were constructed, aiming to achieve the best temperature combination for the sintering steps that provides higher density and finer microstructure. The results were compared with single-step sintering (SSS). Furthermore, microhardness and fracture toughness were measured for the best TSS specimens under each composition. The results showed that the high densities were obtained, and the reduction of grain size was greater than 40% for two-step sintered specimens, compared to SSS ones. Consequently, microhardness values increased. However, fracture toughness values remained unchanged.     

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.     

非相变固体蓄热材料的蓄放热特性

搭建了低谷电蓄能蒸汽发生换热测试系统，采用数据记录仪、Hot Disk热常数分析仪等仪器检测了刚玉球等非相变固体蓄热材料的热物性。通过实验与模拟相结合的方式，研究了粉煤灰、氧化镁、刚玉砂、刚玉球等材料的蓄放热特性。分析了蓄热材料种类和粒径大小对蓄放热特性的影响，得到了不同材料的蓄热密度和综合换热系数等关键参数。结合FLUENT非稳态模拟方法，模拟了蓄热体在不同材料粒径下的蓄热和放热温度场变化规律。结果表明：刚玉球能够提供充足连续的热量，可以作为一种性能良好的蓄热材料进行应用；随着刚玉砂粒径的增大，其蓄热密度和综合换热系数会增大，有效放热时间也会延长。