Preparation and thermophysical properties of LaMgAl11O19–Yb3Al5O12 ceramic composites

LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites were prepared by pressureless sintering process at 1700 °C for 10 h in air. The microstructure and thermophysical properties of the composites were characterized by X-ray diffraction, scanning electron microscopy, high-temperature dilatometer and laser flash diffusivity measurements. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites are composed of magnetoplumbite and garnet structures. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites exhibit typical linear increase in thermal expansion with the increase of temperature. The measured thermal diffusivity gradually decreases with increasing temperature. Thermal conductivity of LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites is in the range of 2.6–3.9 W·m⁻¹·K⁻¹ from room temperature to 1200 °C.     

Mechanical properties of graphene platelet-reinforced alumina ceramic composites

Alumina (Al₂O₃) ceramic composites reinforced with graphene platelets (GPLs) were prepared using Spark Plasma Sintering. The effects of GPLs on the microstructure and mechanical properties of the Al₂O₃ based ceramic composites were investigated. The results show that GPLs are well dispersed in the ceramic matrix. However, overlapping of GPLs and porosity within ceramics are observed. The flexural strength and fracture toughness of the GPL-reinforced Al₂O₃ ceramic composites are significantly higher than that of monolithic Al₂O₃ samples. A 30.75% increase in flexural strength and a 27.20% increase in fracture toughness for the Al₂O₃ceramic composites have been achieved by adding GPLs. The toughening mechanisms, such as pull-out and crack deflection induced by GPLs are observed and discussed.     

Hot pressed and spark plasma sintered zirconia/carbon nanofiber composites

Zirconia/carbon nanofiber composites were prepared by hot pressing and spark plasma sintering with 2.0 and 3.3 vol.% of carbon nanofibers (CNFs). The effects of the sintering route and the carbon nanofiber additions on the microstructure, fracture/mechanical and electrical properties of the CNF/3Y-TZP composites were investigated. The microstructure of the ZrO₂ and ZrO₂–CNF composites consisted of a small grain sized matrix (approximately 120 nm), with relatively well dispersed carbon nanofibers in the composite. All of the composites showed significantly higher electrical conductivity (from 391 to 985 S/m) compared to the monolithic zirconia (approximately 1 × 10⁻¹⁰ S/m). The spark plasma sintered composites exhibited higher densities, hardness and indentation toughness but lower electrical conductivity compared to the hot pressed composites. The improved electrical conductivity of the composites is caused by CNFs network and by thin disordered graphite layers at the ZrO₂/ZrO₂ boundaries.     

Effect of nanoparticles on the performance of thermally conductive epoxy adhesives

Microsized or nanosized α‐alumina (Al₂O₃) and boron nitride (BN) were effectively treated by silanes or diisocyanate, and then filled into the epoxy to prepare thermally conductive adhesives. The effects of surface modification and particle size on the performance of thermally conductive epoxy adhesives were investigated. It was revealed that epoxy adhesives filled with nanosized particles performed higher thermal conductivity, electrical insulation, and mechanical strength than those filled with microsized ones. It was also indicated that surface modification of the particles was beneficial for improving thermal conductivity of the epoxy composites, which was due to the decrease of thermal contact resistance of the filler‐matrix through the improvement of the interface between filler and matrix by surface treatment. A synergic effect was found when epoxy adhesives were filled with combination of Al₂O₃ nanoparticles and microsized BN platelets, that is, the thermal conductivity was higher than that of any sole particles filled epoxy composites at a constant loading content. The heat conductive mechanism was proposed that conductive networks easily formed among nano‐Al₂O₃ particles and micro‐BN platelets and the thermal resistance decreased due to the contact between the nano‐Al₂O₃ and BN, which resulted in improving the thermal conductivity. POLYM. ENG. SCI., 50:1809–1819, 2010. © 2010 Society of Plastics Engineers     

In situ synthesis,mechanical and cyclic oxidation properties of Ti3AlC2/Al2O3 composites

ABSTRACT

Ti₃AlC₂/Al₂O₃ composite materials were successfully fabricated from TiO₂/TiC/Ti/Al powders by the in situ reactive hot pressed technique. The microstructure, mechanical and oxidation properties of the composites were investigated in the paper. Vickers hardness increased with the Al₂O₃ content. The relative density of Ti₃AlC₂/Al₂O₃ composites exhibits a declining tendency with Al₂O₃ content especially exceeds 10 vol.?%. The Ti₃AlC₂/Al₂O₃ composites show excellent electrical conductivity. The flexural strength and fracture toughness of Ti₃AlC₂/10 vol. % Al₂O₃ are 461 ± 20?MPa and 6.2?±?0.2?MPa m^1/2, respectively. The cyclic oxidation behaviour of resistance of Ti₃AlC₂/10 vol. % Al₂O₃ composites at 800–1000°C generally obeys a parabolic law. The oxide scale of sample consists of a mass of α-Al₂O₃ and TiO₂, forming a dense and adhesive protect layer. The result indicates that the Al₂O₃ can greatly improve the oxidation resistance of Ti₃AlC₂.     

A new Al2O3 porous ceramic prepared by addition of hollow spheres

A method for making porous ceramic prepared by adding hollow spheres was developed, and the resulting porous ceramic was named as hollow spheres ceramic. Water soluble epoxy resin was used as a gel former in the gelcasting process of the Al₂O₃ hollow sphere and Al₂O₃ powder, the porous ceramic porosity varies from 22.3 to 60.1 %. The influence of amount of Al₂O₃ hollow sphere and sintering temperature on the microstructure, compressive strength and thermal conductivity were investigated. With an increasing amount of hollow sphere in the matrix, the porosity increases, which leads to decreased bulk density, compressive strength and thermal conductivity. The compressive strength of the porous ceramics has a power law relation with the porosity, and the calculated power law index is 4.5. The equations of the relationship between porosity and thermal conductivity of porous ceramics are proposed. The thermal conductivity of samples with 60.1 % porosity is as low as 2.1 W/m k at room temperature.     

Thermal conductivity studies on ceramic floor tiles

Thermal diffusivity, thermal conductivity and specific heat of several materials used as floor tiles have been measured using the laser flash method. Natural stones, particularly granite, porcelain stoneware and red stoneware materials of low water absorption, are more effective thermal conductors than white stoneware and vinyl, which have thermal conductivities below 1 W m⁻¹ K⁻¹. Therefore, last two should not be recommended for radiant floor heating applications. Enhancement of thermal conductivity of red and porcelain stoneware has been achieved by adding Al₂O₃ of certain characteristics to the ceramic paste. In this way, thermal diffusivity increases of up to 50% have been obtained by adding 20 wt.% of Al₂O₃ particles.     

Fabrication of novel multilayer Al2O3-(m-ZrO2)/t-ZrO2 fibrous ceramics composites

A novel layered microstructure in the Al₂O₃/ZrO₂ composites system was fabricated by the multipass extrusion method. The microstructure consisted with very fine alternate lamina of Al₂O₃-(m-ZrO₂) and t-ZrO₂. The composites were designed in such a way that a small group of 7 cylindrical alternate layers of Al₂O₃-(m-ZrO₂) and t-ZrO₂ made a concentric microgroup around 40 μm in diameter, with a common boundary layer between the adjacent groups. The thickness of both layers was around 2-3 μm. The microstructure was unidirectionally aligned throughout the composites. The composite microstructure was fibrous due to the unidirectional orientation of these microgroups. Detailed microstructure of the fabricated composites was characterized by SEM. The effect of the concentric layered microstructure on mechanical behavior was discussed. Material properties such as density, bending strength, Vickers hardness and fracture toughness were measured and evaluated depending on different sintering temperatures.     

Processing and physical properties of Al2O3/aluminum alloy composites

Porous aluminum oxide (Al₂O₃) preforms were formed by sintering in air at 1200 °C for 2 h. A356, 6061, and 1050 aluminum alloys were infiltrated into the preforms by squeeze casting in order to fabricate Al₂O₃/A356, Al₂O₃/6061, and Al₂O₃/1050 composites, respectively, with different volumes of aluminum alloy content. The content of aluminum alloy in the composites was 10–40% by volume. The resistivity of Al₂O₃/A356, Al₂O₃/6061, and Al₂O₃/1050 composites decreased dramatically from 6.41 × 10¹² to 9.77 × 10⁻⁴, 7.28 × 10⁻⁴, and 6.24 × 10⁻⁴ Ω m, respectively, the four-points bending strength increased from 397 to 443, 435.1, 407.2 MPa, respectively, and the deviations were smaller than 2%. From SEM microstructural analysis and TEM bright field images, the pore volume fraction and the relative density of the composites were the most important factors that affected the physical and mechanical properties. The ceramic phase and alloy phase in Al₂O₃/aluminum alloy composites were found to be homogenized and uniformly distributed using electrical and mechanical properties analysis, microstructure analysis, and image analysis.     

Microstructure, growth mechanism and mechanical property of Al2O3-based eutectic ceramic in situ composites

Directionally solidified Al₂O₃-based eutectic ceramic in situ composites with inherently high melting point, low density, excellent microstructure stability, outstanding resistance to creep, corrosion and oxidation at elevated temperature, have attracted significant interest as promising candidate for high-temperature application. This paper reviews the recent research progress on Al₂O₃-based eutectic ceramic in situ composites in State Key Laboratory of Solidification Processing. Al₂O₃/YAG binary eutectic and Al₂O₃/YAG/ZrO₂ ternary eutectic ceramics are prepared by laser zone melting, electron beam floating zone melting and laser direct forming, respectively. The processing control, solidification characteristic, microstructure evolution, eutectic growth mechanism, phase interface structure, mechanical property and toughening mechanism are investigated. The high thermal gradient and cooling rate during solidification lead to the refined microstructure with minimum eutectic spacing of 100 nm. Besides the typical faceted/faceted eutectic growth manner, the faceted to non-faceted growth transition is found. The room-temperature hardness H_V and fracture toughness K_IC are measured with micro-indentation method. For Al₂O₃/YAG/ZrO₂, K_IC = 8.0 ± 2.0 MPa m^1/2 while for Al₂O₃/YAG, K_IC = 3.6 ± 0.4 MPa m^1/2. It is expectable that directionally solidified Al₂O₃-based eutectic ceramics are approaching practical application with the advancement of processing theory, technique and apparatus.     

Effect of the addition of silica sol on layered extrusion forming of Al2O3-based cores

Layered extrusion forming of ceramic cores with a nanoceramic suspension as a binder was conducted to explore a novel method to produce complex-shaped ceramic cores. Green bodies were prepared using Al₂O₃ particles as precursor materials and silica sol combined with aqueous polyvinyl alcohol solution as a binder. Increasing the silica sol content increased the viscosity of the slurry, enhanced the green bending strength, and decreased the green linear shrinkage. The green microstructure showed the nanosized silica particles were deposited on the surface of the Al₂O₃ particles and among the pores formed by Al₂O₃ particles irregular packing. In addition, increasing the silica sol content increased the bending strength, however, decreased linear shrinkage and open porosity of the sintered bodies. During sintering, the nanosized silica particles converted to the melting phase and reacted with Al₂O₃ and the microstructure of sintered bodies indicated the existence of sintering neck with silica sol addition.     

Thermal,morphological, and mechanical characterization of novel carbon nanofiber‐filled bismaleimide composites

Novel carbon nanofiber (CNF) ‐filled bismalemide composites were fabricated by a thermokinetic mixing method. The thermal and mechanical properties of composites containing 1 wt % and 2 wt % CNFs were investigated. Thermogravimetric analysis demonstrated that minimal improvement in thermal stability of the nanocomposites was obtained by the addition of CNFs. Dynamic mechanical analysis showed an increase in storage modulus (E′) and glass transition temperature (T_g) upon incorporation of nanofibers. Limiting oxygen index (LOI) has also been found to increase with incorporation of CNFs. Morphological studies of fractured surfaces of the composites has been carried out by scanning electron microscopy to determine the effect of fiber content and dispersion on the failure mechanism. In general, good dispersion was observed, along with agglomeration at some points and some fiber matrix interfacial debonding. A decrease in mechanical strength has been observed and debonding was found as the main failure mechanism. Further research outlook is also presented. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

High-temperature creep of carbon nanofiber-reinforced and graphene oxide-reinforced alumina composites sintered by spark plasma sintering

Alumina (Al₂O₃) ceramic composites reinforced with either graphene oxide (GO) or carbon nanofibers (CNFs) were prepared using Spark Plasma Sintering. The effects of GO and CNFs on the microstructure and in consequence on their mechanical properties were investigated. The microstructure of the sintered materials have been characterized quantitatively prior to and after the creep experiments in order to discover the deformation mechanism. Graphene-oxide reinforced alumina composites were found to be more creep resistant than carbon nanofibers-reinforced alumina ones or monolithic alumina with the same grain size distribution. In all the cases, grain boundary sliding was identified as the deformation mechanism.     

Effect of amine functionalization of CNF on electrical, thermal, and mechanical properties of epoxy/CNF composites

This paper presents experimental results of the effect of amine functionalization of carbon nanofibers (CNF) on the electrical, thermal, and mechanical properties of CNF/epoxy composites. The functionalized and non-functionalized CNFs (up to 3 wt%) were dispersed into epoxy using twin screw extruder. The specimens were characterized for electrical resistivities, thermal conductivity (K), UTS, and Vicker’s microhardness. The properties of the nanocomposites were compared with that of neat epoxy. The volume conductivity of the specimens increased by E12 S/cm and E09 S/cm in f-CNF/epoxy and CNF/epoxy, respectively, at 3 wt% filler loading. The increase in K for former was 106% at 150 °C, while for the latter it was only 64%. Similarly, UTS increased by 61% vs. 45% and hardness 65% vs. 43%. T _g increased with increase in filler content. SEM examinations showed that functionalization resulted in better dispersion of the nanofibers and hence greater improvement in the studied properties of the nanocomposites.     

Significantly enhanced electromagnetic interference shielding in Al2O3 ceramic composites incorporated with highly aligned non-woven carbon fibers

Macroscopic parallel aligned non-woven carbon fibers were incorporated into Al₂O₃ composites in this study to evaluate the contribution of multiple reflections to the total electric magnetic interference (EMI) shielding. Results indicate that parallel aligned non-woven carbon fiber layers contribute significantly to the total EMI shielding effectiveness (SE_T) of Al₂O₃ composites by largely enhancing the EMI absorption, and seven parallel aligned thin non-woven carbon fiber layers finally make the almost microwave-transparent Al₂O₃ an excellent EMI shielding material with an EMI SE_T as high as 29–32 dB in the X-band frequency range. The volume fraction of carbon fibers in Al₂O₃ composites with seven carbon fiber layers is calculated to be only 0.5%, and therefore the EMI SE enhancement efficiency by parallel aligned large non-woven carbon fiber layers is much higher than other highly conducting nano fillers. It validates the significance of multiple reflections in achieving high EMI shielding properties in ceramic composites and provides an instructive approach to design efficient EMI shielding ceramic composites.     

Highly dispersed and electrically conductive polycarbonate/oxidized carbon nanofiber composites for electrostatic dissipation applications

The influence of low cost, commercially oxidized carbon nanofibers (ox-CNFs) on the morphological, thermal, mechanical and electrical properties of polycarbonate (PC) composites was examined. Using a simple solution mixing process leads to good dispersion and high packing density of CNFs in the resultant composites. The composite materials exhibit a dramatic improvement in the DC conductivity; for example, increasing from 2.36 × 10⁻¹⁴ S/m for PC to ca. 10⁻² S/m for the composite at only 3.0 wt.% of CNFs, and exhibits a very fast static charge dissipation rate. Dynamic mechanical analysis showed a remarkable increase in storage modulus (282%) at 165 °C, compared to pure PC. Thermogravimetric analysis showed that thermal stability of the composites increased by 54 °C compared to the pure PC. To our knowledge, the measured electrical conductivity and thermal properties for PC/CNF are the highest values yet reported for PC/CNF composites at comparable loadings. The AC/DC conductivity is shown to play an important role to predict the state of dispersion.     

Electrochemically deposited Fe2O3 nanorods on carbon nanofibers for free-standing anodes of lithium-ion batteries

Fe₂O₃ nanorod/carbon nanofiber (CNF) composites were prepared by the electrochemical deposition of Fe₂O₃ on a web of CNFs, which was then used as a free-standing anode. The conductive, three-dimensional structure of the CNF web allowed for the electrodeposition of the Fe₂O₃ nanorods, while its high conductivity made it possible to use the composite as a free-standing electrode in lithium-ion batteries. In addition, it was easy and cheap to fabricate by a simplification of a process of cell preparation. The nanorod-like Fe₂O₃ structures could only be electrodeposited on the CNFs; flake-like Fe₂O₃ was formed on flat conductive glass substrates. It can be attributed to the different growth mechanism of Fe₂O₃ on the CNFs because of the large number of reaction sites on the CNFs, differences in the precursor concentration and diffusivity within the CNF web. The formation of aggregates of the Fe₂O₃ particles on thicker CNFs also indicated that the CNFs had determined the Fe₂O₃ growth mechanism. The synthesised Fe₂O₃/CNF composite electrode exhibited stable rate capacities at different current densities. This suggested that CNF-based composite did not exhibit the intrinsic disadvantages of Fe₂O₃. Finally, carbon coatings were deposited on the Fe₂O₃/CNF composites to further improve their electronic conductivity and rate capability.     

Synthesis and electrochemical performance of carbon nanofiber-cobalt oxide composites

Carbon nanofiber (CNF) supported cobalt oxide composites as high-capacity anode materials were prepared through a facile, effective method for potential use in rechargeable lithium-ion batteries. The effects of the calcining temperature on the crystallinity, grain size, specific surface area of Co₃O₄ and phase transformation from Co₃O₄ to CoO were studied in detail. Both the specific surface area and CNF content in CNF-cobalt oxide composites strongly affect the electrochemical performance of these series composites. The CNF-Co₃O₄ composite with 24.3% CNF pyrolyzed at 500 °C in Ar shows an excellent cycling performance, retaining a specific capacity of 881 mAh g⁻¹ beyond 100 cycles. Homogeneous deposition and distribution of nanosized Co₃O₄ particles on the surface of CNF can stabilize the electronic and ionic conductivity as well as the morphology of Co₃O₄ phase, which may be the main reason for the markedly improved electrochemical performance.     

Indirect selective laser sintering of epoxy resin-Al2O3 ceramic powders combined with cold isostatic pressing

To fabricate Al₂O₃ ceramic components with complex shape, selective laser sintering (SLS) combined with cold isostatic pressing (CIP) process was used to consolidate Al₂O₃ powder with additive of epoxy resin E06 (ER06) and polyvinyl alcohol (PVA). The starting material preparation combined spray drying with mechanical mixing to formulate compound powder consisting of PVA (1.5 wt%), ER06 (8 wt%) and Al₂O₃ and provide a good fluidity for SLS. Experimental investigations were carried the shrinkage, relative density, bending strength of Al₂O₃-ER06 SLS specimens in order to optimize the laser sintering parameters. It was found that Al₂O₃-ER06 SLS specimens represented acceptable shrinkage, high density and bending strength when laser power, scanning speed, scanning space and layer thickness were, respectively, 21 W, 1600 mm/s, 100 μm and 150 μm. Following that, the SLS specimens were processed through CIP to eliminate the pores in green ceramics. Finally, the optimized SLS/CIP Al₂O₃ specimens were debinded, sintered to produce crack-free Al₂O₃ bodies. The final Al₂O₃ components achieved a relative high density of more than 92% after furnace sintering. The study shows a novel and promising approach to fabricate complex ceramic matrix and ceramic components via indirect SLS and CIP process.     

Large-scale fine structural alumina matrix ceramic guideway materials improved by diopside and Fe2O3

Diopside and Fe₂O₃ were introduced in alumina matrix ceramic materials. Large-scale fine structural alumina matrix ceramic guideway materials were fabricated by the technology of pressureless sintering, during which liquid phase sintering took place and new phases such as 3Al₂O₃·2SiO₂, CaO·Al₂O₃·2SiO₂ and CaO·6Al₂O₃ were produced by the chemical reactions taking place among alumina and the additives. The hardness, the fracture toughness and the bending strength of the guideway products were tested. The influences of diopside and Fe₂O₃ additions were studied by microstructural observations and mechanical properties evaluations. Meanwhile, the expected improvement of mechanical properties compared with pure alumina was indeed observed. The fracture mechanism and porosity of large-scale fine structural alumina matrix ceramic guideway materials were analyzed.