Preparation and characterization of ultrafine ZrB2–SiC composite powders by a combined sol–gel and microwave boro/carbothermal reduction method

A combined sol–gel and microwave boro/carbothermal reduction technique was investigated and used to synthesize ultrafine ZrB₂–SiC composite powders from raw starting materials of zirconium oxychloride, boric acid, tetraethoxysilane and glucose. The effects of reaction temperature, molar ratios of n(B)/n(Zr) and n(C)/n(Zr+Si) on the synthesis of ultrafine ZrB₂–SiC composite powders were studied. The results showed that the optimum molar ratios of n(B)/n(Zr) and n(C)/n(Zr+Si) for the preparation of phase pure ultrafine ZrB₂–SiC composite powders were 2.5 and 8.0, respectively, and the firing temperature required was 1300 °C. This temperature was 200 °C lower than that require by using the conventional boro/carbothermal reduction method. Microstructures and phase morphologies of as-prepared ultrafine ZrB₂–SiC composite powders were examined by field emission-scanning electron microscopy (FE-SEM) and transmission electron microscope (TEM), showing that SiC grains were formed evenly among the ZrB₂ grains, and the grain sizes of ZrB₂ in the samples prepared at 1300 °C for 3 h were about 1–2 μm. The average crystalline sizes of these two phases in the as-prepared samples were calculated by using the Scherrer equation as about 58 and 27 nm, respectively.     

Synthesis of Ti(C,N) ultrafine powders by carbothermal reduction of TiO2 derived from sol–gel process

Experimental results demonstrate that TiC_1−XN_X ultrafine powders can be synthesized by the sol–gel process. The factors influencing the powder synthesizing process, such as temperature, C/Ti ratio in raw materials, holding time and flow rate of nitrogen gas, are discussed. TiC_0.5N_0.5 powders with particle sizes less than 100 nm were produced at 1550°C. The microhardness of hot-pressed TiC_0.5N_0.5 samples at 1750°C was 19.6 GPa and the relative density was 98.9%.     

Preparation of alumina ultrafine powders through acrylamide,starch and glutaric dialdehyde mediated sol–gel method

Ultrafine alumina powders were synthesized through acrylamide (AM), starch and glutaric dialdehyde mediated aqueous sol–gel process, respectively. Sol and gel formed gradually during drying of the solution due to polymerization reaction between functional groups. The used AM, starch and glutaric dialdehyde could be applied to form perfect matrix for the entrapment of metal ions, giving rise to ultrafine crystalline alumina particles during heating treatment. Al₂O₃ nanoparticles with γ crystalline phase were obtained via heating treatment of the dried precursor in air. Then the γ phase transforms to α phase and pure α-Al₂O₃ powders could be obtained when the heating temperature was 1473 K. Our results provide a new way of aqueous sol–gel process.     

Preparation and characterisation of TiN by microwave-assisted carbothermic reduction–nitridation in air atmosphere

Titanium nitride (TiN) is prepared from ilmenite (FeTiO₃) powders by microwave-assisted carbothermic reduction–nitridation in air atmosphere followed by acid leaching treatment. The thermal analysis of the reduction–nitridation of FeTiO₃ powders is conducted by thermogravimetry/differential scanning calorimeter. The phase transition sequence of microwave carbothermal synthesis of TiN–Fe composite is: FeTiO₃?→?Fe?+?TiO₂?→?Fe?+?TiN. There is no any other oxygen-deficient titanium oxides detected. Particularly, FeTiO₃ can be transformed into TiN–Fe composite completely at 900°C for 60?min by microwave heating. The increase in both the reaction temperature and dwelling time is in favour of the transformation of FeTiO₃. The product morphologies are spherical about 2–5?μm in size. Then TiN is obtained with the removal of Fe and their oxides from TiN–Fe composite by acid leaching treatment. This method not only reduces the reaction temperature significantly through microwave heating but also can simplify the operation process effectively.     

Microwave assisted synthesis of Dy2Ti2O7 ultrafine powders by sol–gel method

Dy₂Ti₂O₇ ultrafine powders ranging from 100 to 300 nm were successfully synthesized by sol–gel method. Particularly, the dried gel precursor was treated at different temperatures (700–1000 °C) via microwave-heating, which contributed to decreasing the grain size and reaction time. The phase composition and structural evolution of the final products were examined by X-ray diffraction (XRD), scanning electron microscope (SEM) and transmission electron microscope (TEM). Furthermore, the resultant powders were selected to fabricate ceramics and rubber based absobers. Their sinterability, mechanical properties and neutron absorption ability were also studied. Results showed that the highest flexural strength of 99.0 MPa were obtained for Dy₂Ti₂O₇ samples when sintered at 1600 °C for 2 h in air atmosphere. Meanwhile, the neutron absorption rate of Dy₂Ti₂O₇ ceramics and rubber based absorbers could reach 97.39% and 80.00% respectively when the thickness of samples was set as 5.0 mm.     

Preparation of nano-AlN powder by sol–gel foaming and its sintering properties

Uniformly dispersed nano-sized aluminum nitride powders were prepared by the sol–gel foaming method using aluminum nitrate as the aluminum source, sucrose as the carbon source, and ammonium chloride as the foaming agent. The effects of ammonium chloride content on the particle size and the sintering properties of aluminum nitride were investigated. The results showed that when the molar ratio of ammonium chloride to aluminum nitrate was .5, the colloidal foams were uniform, large, and fluffy, and amorphous alumina precursors with uniform particles could be prepared. Aluminum nitride powder with a particle size of 22–27 nm can be obtained by calcining these precursors in nitrogen atmosphere at 1400°C for 2 h. At the same time, aluminum nitride bulk material with a relative density of 95% can be obtained by sintering the compact samples in nitrogen atmosphere at 1700°C for 2 h.     

Ca-α SiAlON hollow spheres prepared by carbothermal reduction–nitridation from different SiO2 powders

The formation process of hollow spheres composed of nanosized Ca-α SiAlON particles was investigated using SiO₂ starting powders with different characteristics in particle size, shape and crystalline state. TEM observations showed Ca-α SiAlON hollow spheres composed of a large number of nanosized particles in the products prepared at 1450 °C for 120 min in nitrogen. In all systems, the Ca-α SiAlON hollow spheres were always produced through an intermediate Si–Al–Ca–O liquid phase in the same mechanism, regardless of the characteristics of SiO₂ starting powders used. Spherical solid particles consisted of amorphous phase containing Si, Al, Ca, O and a small amount of N were generated at the initial stage of carbothermal reduction–nitridation. These spherical solid particles changed into hollow particles with the progression of the reaction from the liquid phase to the crystalline Ca-α SiAlON with increasing temperature.     

Preparation and dielectric properties of dense and amorphous alumina film by sol–gel technology

Dense and crack-free aluminum oxide films were fabricated by sol–gel spin-coating technology. Aluminum nitrate (Al(NO₃)₃.9H₂O) was used as the precursor material. X-ray diffraction shows that the fabricated films are amorphous. X-ray photoelectron spectroscopy confirms that the thin films are alumina (Al₂O₃). Field-emission scanning electron microscopy images of the films reveal that the films are compact with a dense cross section. Dielectric measurements were carried out on samples with a metal–insulator–metal structure. The electrical characteristics of the films were affected by the thermal sintering temperature of the films. The leakage current density of the films decreases with the increase in the sintering temperature and increases with the increase in the measuring temperature. The leakage current shows a linear dependence on the voltage in the low-electric field-regime. The current density ascends to higher values due to the effect of space charges in the high-electric-field regime. The ionization energy of the top-electrode metals (Au, Pt or Ti–Au) has a strong effect on the leakage current.     

Preparation of scratch resistant superhydrophobic hybrid coatings by sol–gel process

Organic–inorganic hybrid coatings on glass substrates with superhydrophobic properties and with improved scratch resistance were obtained by means of applying a multilayer approach including multiple sol–gel processes. The coatings exhibited a water contact angle (WCA) higher than 150°. Ultraviolet (UV)-curable vinyl ester resins and vinyltriethoxysilane (VTEOS) as coupling agent were employed to increase the adhesion between substrate and the inorganic layers. The surfaces were characterized by means of dynamic contact angle and roughness measurements. Indeed, the occurrence of superhydrophobic behavior was observed. The scratch resistance of the hybrid coatings was tested to evaluate the adhesion of the coatings to the glass substrate. The proposed preparation method for scratch resistant, mechanically stable, superhydrophobic coatings is simple and can be applied on large areas of different kinds of substrates.     

Preparation of nanocrystalline SrTiO3 powder by sol–gel combustion method

In this research a sol–gel combustion route has been presented to synthesize strontium titanate (SrTiO₃:ST) nanocrystalline, using citric acid as fuel. The synthesis procedure was optimized by systematically varying the molar ratios of total metal nitrate to citric acid (MN:CA) from 1:1 to 1:3. The effect was investigated through XRD, SEM and TEM analysis. Analysis of XRD spectrum shows the complete of SrTiO₃ nanocrystalline, however, a minor phase of SrCO₃ impurity was found. Hence, an acid treatment process, with 1 mol/l HNO₃ solution and deionized water, was applied to remove the impurity. The results show that the appropriate condition to prepare the single phase nanocrystalline SrTiO₃ powders is MN:CA molar ratio of 1:3, coupled with an acid treatment process and at the lower calcination temperature of 500 °C. The particle size of powders was in nanometer ranges. The average crystallite size calculated from FWHM was about 23 nm. Morphology of powders was identified by SEM analysis. However, TEM estimated the average particle size about 7.5 nm after applying an acid treatment technique at 600 °C.     

Synthesis of TiC–TiB2 composite powders via carbothermal reduction and its reaction mechanism

Titanium carbide–titanium diboride (TiC–TiB₂) composite powders were synthesised through a carbothermal reduction method by using titanium dioxide, boric acid, and different carbon sources (namely, carbon black, sucrose, and glucose) as starting materials. The thermal decomposition behaviour of the precursors was studied by thermogravimetry–differential thermal analyser. Phase compositions and morphologies of the synthesised products were characterised by X-ray diffractometer and scanning electron microscope. When n(Ti):n(B):n(C)?=?1.0:2.5:5.0, the blended stock mainly formed TiB₂ with sucrose or glucose as a carbon source, whereas the stock produced TiC when carbon black was the source. At an optimum reaction temperature, the particles of the powders synthesised from carbon black as a carbon source were the smallest at approximately 100?nm. With increasing amount of boric acid in the precursor, the morphologies of the samples changed into less spherical particles, and more flaky grains and small particles with irregular structures were observed.     

Raman scattering and X-ray diffraction investigations of sol–gel derived SBN powders

Sol–gel derived Sr_xBa_1-xNb₂O₆ (SBN) powders were prepared at an annealing temperature of 1200°C. Their structural changes were characterized by Raman spectroscopy and X-ray diffractometry. Changes in the peak position and the relative intensity of the Raman spectra and X-ray patterns were examined for different values of x. Our results suggest that the SBN powders consist of a mixture of orthorhombic phase BaNb₂O₆ (BN) and tetragonal tungsten-bronze phase (TTB) SBN powders for x<0·5, and orthorhombic phase SrNb₂O₆ (SN) and TTB phase SBN powders for x>0·5. Pure TTB type SBN powders with x≠0·5, however, were obtained at higher annealing temperatures. A possible formation route of the sol–gel derived SBN powder is discussed.     

Preparation and characterization of phosphine oxide containing organosilica hybrid coatings by photopolymerization and sol–gel process

A series of UV-cured organic–inorganic hybrid coating materials containing up to 20 wt.% silica were prepared by sol–gel method from tetraethoxy silane (TEOS) which is used as the primary inorganic precursor, and diallylphenylphosphine oxide monomer (DAPPO), aliphatic urethane diacrylate resin (Ebecryl 210) are employed as the source of the organic components. In addition, methacryloxypropyltrimethoxy silane (MAPTMS) was used as both a secondary inorganic source and a silane-coupling agent to improve the compatibility of the organic and inorganic phases. The DAPPO content in all the coating formulations were from 0 to 20 wt.%. The physical and mechanical properties such as gel content, hardness, adhesion, gloss, contact angle as well as tensile strength were measured. These measurements revealed that all the properties of the hybrid coatings improved effectively, in case of adding the sol–gel precursor and DAPPO monomer content in the hybrid systems. The photo-calorimetric-DSC studies showed that the double bond conversion of the hybrid coatings was faster than the coating materials without silica. The thermal stabilities of the UV-cured hybrid materials were investigated by thermogravimetric analysis. The results showed that the addition of sol–gel precursor and DAPPO into the organic network also improves the thermal-oxidative stability of the hybrid coating materials. The surface morphology was also characterized by scanning electron microscopy (SEM). SEM studies indicated that inorganic particles were dispersed homogenously throughout the organic matrix.     

Synthesis of SiC precursors by a two-step sol–gel process and their conversion to SiC powders

A two-step sol–gel processing was developed to synthesize phenolic resin–SiO₂ hybrid gels as SiC precursors, with tetraethoxysilane (TEOS) and novolac phenolic resin being the starting materials, and oxalic acid (OA) and hexamethylenetetramine (HMTA) being the catalysts. At the first step TEOS was prehydrolyzed under the catalysis of OA. At the second step HMTA was added to facilitate gelation. The influences of the molar ratio of OA/TEOS and prehydrolysis time on the sol–gel reaction were investigated. There existed an optimum OA/TEOS ratio where prehydrolysis time needed to form transparent gels was the shortest. The increase of temperature could accelerate sol–gel reaction. The dried hybrid gels were yellowish transparent glassy solids, with uniform microstructure composed of nanometer-sized particles. The conversion of the gels to silicon carbide powders was complete when heated at 1650°C for 30 min in vacuum. The oxygen and free carbon were 0.43 and 0.50 wt%, respectively, in the powder produced from the gel prepared with starting resin/TEOS being 0.143 g/ml.     

Preparation of hollow mesoporous silica spheres by a sol–gel/emulsion approach

Hollow mesoporous silica spheres were synthesized by a sol–gel/emulsion (oil-in-water/ethanol) approach, in which cetyltrimethylammonium bromide (CTAB) surfactant was employed to stabilize and direct the hydrolysis of oil droplets of tetraethoxysilane (TEOS). The diameters of the hollow spheres can be tuned in the range from 210 to 720 nm by varying the ratio of ethanol-to-water and their shell thickness can be mediated by changing the concentration of CTAB used in the system. BET surface areas of the hollow silica spheres are determined to be in the range of 924–1766 m² g^?1 and their pore sizes are around 3.10 nm as determined by BJH method.     

Synthesis and microwave dielectric properties of CaSiO3 nanopowder by the sol–gel process

The synthesis and microwave dielectric properties of CaSiO₃ nanopowder by sol–gel method have been investigated in this paper. CaSiO₃ nanoparticles with an average grain size of 50–60 nm were obtained by calcining the CaO–SiO₂ xerogel that was prepared from Calcium nitrate tetrahydrate (Ca(NO₃)₂·4H₂O) and tetraethylortho silicate (TEOS). Calcining the CaO–SiO₂ xerogel at 1150 °C, the pseudowollastonite-CaSiO₃ phase was completely formed. However, the main phase is not CaSiO₃ or CaSi₂O₄ but SiO₂ when calcining the mixture of SiO₂ and CaCO₃ at 1150 °C. Comparing with CaO–SiO₂ ceramics prepared by solid-state process, the CaSiO₃ ceramics made from nanopowders calcined at 1000 °C achieved more compact structure at the sintering temperature of 1320 °C, and then had excellent microwave dielectric properties: ?_r = 6.69, Qf = 25398 GHz.     

Preparation and reaction mechanistic characterization of sol–gel indium/alumina catalysts developed for NO x reduction by propene in lean conditions

The impregnation and sol–gel preparation methods were investigated to develop high activity catalysts and understand the significance of the indium–aluminium interaction on aluminasupported indium catalysts in NO _x reduction with propene. Active In/alumina catalysts with a very high surface area (270 m²/g) and thermal stability were prepared in controlled conditions by sol–gel processing. When Al isopropoxide and In nitrate in ethyl glycol were used as precursors in aqua media, indium atoms were incorporated evenly distributed as a thermally stable form in the aluminium oxide lattice structure. In wet impregnation it was beneficial to use a certain excess of aqueous In solution (volumes of solution : pores = 2 : 1) to have the highest NO _x reduction activity. The catalyst containing dispersed Al on In oxide (58 wt% In, phaseequilibrium preparation method) showed activity at lower temperatures than any other In–Al oxide catalyst or pure In₂O₃. The adsorption of different reaction intermediates on alumina and stable In₂O₃ sites were detected by FTIR studies. In/alumina catalysts have active sites to oxidize NO to NO₂, partially oxidize HC, form the actual reductant which contains N–H or N–C bonding and react with NO to dinitrogen. The cooperation with indium and aluminium was evident even in the mechanical mixture of sol–gel prepared alumina (301 m²/g) and In₂O₃ powders (27 m²/g), where the probability for molecularscale intimate contact between indium and aluminium sites was very low (particle size 10–250 m). Shortlived gaseous intermediates and surface migration are the possible reasons for the high catalytic activities on the two physically separated active sites both necessary for the reaction sequence.     

Physical characteristics and sintering behavior of ultrafine zirconia–ceria powders

Ultrafine zirconia–12 mol% ceria powders have been prepared by the coprecipitation technique. The azeotropic distillation with n-butanol has been carried out to ensure complete elimination of the residual water in the precipitate. This procedure has proved to be quite effective in preventing the formation of agglomerates, which are responsible for inhomogeneities in the sintered microstructure, and for non-densification at low temperatures. The crystallization of the solid solution occurs at 430 °C as determined by thermal analyses. The specific surface of the calcined powder is 127.9 m² g⁻¹ and the pore size distribution exhibits only a maximum at approximately 9 nm. Total shrinkage of the compacted powder reached 30% at 1200 °C. Sintered specimens show six bands characteristics of the tetragonal phase in the Raman spectrum. Specimens with apparent densities >95% of the theoretical density and average grain size of 230–400 nm were obtained after sintering at 1200 °C.     

Preparation of multi-coating PZT thick films by sol–gel method onto stainless steel substrates

PbZr_0.45Ti_0.55O₃ ferroelectric films have been prepared by sol–gel method, using alkoxide precursor compounds and multi-layer technique. The gel films were deposited by spin-coating onto stainless steel substrates. In order to obtain crystallization in the perovskite phase, the samples were annealed at 600–700°C for 1 min. The dependence of the electric properties on the heat-treatment temperature is studied, and the coercive electric field as a function of the material thickness is determined. By SEM photography, the microstructure of the films could be shown to be homogeneous.     

Microwave sintering and fusion of low-fusing titanium body porcelain derived from sol–gel synthesis

The titanium body porcelain was synthesised through sol–gel using borate–silicate system. The porcelain was characterised by X-ray diffraction (XRD), scanning electron microscope and three-point flexure tests. The XRD and selected area electron diffraction (SAED) results showed that the porcelain was mainly amorphous. The SEM and TEM microphotographs showed that the shape of the porcelain particles was irregular and their sizes range from 5 to 25?μm, while there were no obvious pores on the porcelain surface. The flexure strength significantly increased from 18.9 to 70.6?MPa when the sintering temperature of the porcelain increased from 600 to 675°C and then slowly decreased to 49.1?MPa when the sintering temperature elevated to 700°C. The improvement of the strength was mainly due to the decrease of pores and increase of density. A closely bonded dense coating was fused on the Ti surface by microwave.