Novel glass ceramic foams materials based on red mud

Glass ceramic foams were prepared using red mud and fly ash with added CaCO₃ as foaming agents. The aim of the present work was to investigate the possibility of adding red mud, an alkaline leaching waste, in the raw material for the preparation of glass ceramic foams. The results of mineralogical analyses as well as the microscopic examination showed that the use of the red mud affect the mineralogical characteristics and structures of the as produced foams. The influence of amount of red mud on the bulk density and compressive strength of samples was further evaluated. The experimental results showed that relatively low bulk density foams (0.33–0.41 g/cm³) could be obtained by using low sintering temperature (760–840 °C) when the red mud/fly ash ratio does not exceed 40:60. The reduction of sintering temperature or, above all, the reduction of the holding time, was found to limit the coalescence and significantly improve the compressive strength of the foams (0.33–2.74 MPa).     

Microstructure and mechanical properties of hydroxyapatite obtained by gel-casting process

In the present work, well-shaped HAp green bodies were obtained by the gel-casting process with 50 vol.% slurry. After drying, the microstructure and pore distribution of the green body were investigated. The density, compressive strength and flexural strength of the green body were 1.621 g/cm³, 32.6 ± 3.2 MPa and 13.8 ± 1.0 MPa, respectively. After pressureless sintering at the range of 1100–1300 °C for 2 h, the relative density of the final product ranges from 71.8 to 97.1% th. The maximum value of flexural strength, elastic modulus, hardness and fracture toughness were 84.6 ± 12.6 MPa, 138 ± 7 GPa, 4.45 ± 0.18 GPa and 0.95 ± 0.13 MPa m^1/2, respectively. SEM images show a compact and uniform microstructure; the average grain size was found by using the linear intercept method. XRD and FTIR determined the phase and the radical preserved after sintering.     

Effects of microwave sintering on the properties of porous hydroxyapatite scaffolds

Microwave sintering was used to process porous hydroxyapatite scaffolds fabricated by the extrusion deposition technique. The effects of microwave sintering on the microstructure, phase composition, degradation, compressive strength and biological properties of the scaffolds were investigated. After rapid sintering, scaffolds with controlled structure, high densification and fine grains were obtained. A significant increase in mechanical strength was observed relative to conventional sintering. The scaffolds (55–60% porosity) microwave sintered at 1200 °C for 30 min exhibited the highest average compressive strength (45.57 MPa). The degradation was determined by immersing the scaffolds in physiological saline and monitoring the Ca²⁺concentration. The results indicated that the microwave-sintered scaffolds possessed higher solubility than conventionally sintered scaffolds, as it released more Ca²⁺ at the same temperature. Furthermore, an in vitro MC3T3-E1 cell culturing study showed significant cell adhesion, distribution, and proliferation in the microwave-sintered scaffolds. These results confirm that microwave sintering has a positive effect on the properties of porous hydroxyapatite scaffolds for bone tissue engineering applications.     

Densification behavior and related phenomena of spark plasma sintered boron carbide

In this work, boron carbide ceramics were sintered in the temperature range of 1400–1600 °C by spark plasma sintering (SPS). The influence of sintering temperature, heating rate, and holding time on the microstructure, densification process and physical property was studied. The heating rate was found to have greater influence than that of the holding time on the microstructure and the densification of boron carbide. The optimal sintering temperature was 1600 °C under the heating rate higher than 100 °C/min. The relative density, flexural strength, Vickers hardness and fracture toughness of the sample synthesized at 1600 °C were 98.33%, 828 MPa, 31 GPa and 2.66±0.29 MPa m^1/2, respectively. The densification mechanism was also investigated.     

Preparation and characterization of foam glass from waste container glasses and water glass for application in thermal insulations

Glass foams are modern developed building materials which are now favorably competing with conventional materials for applications in thermal insulation. In this study, glass foams are synthesized solely from waste container glasses of mixed colors using sodium silicate (water glass) as foaming agent. Several glass foams of 150 × 150 × 30 mm were prepared from waste glasses of 75 μm, 150 μm and 250 μm size with addition of 15 wt % sodium silicate respectively and pressed uniaxially under a pressure of 10 MPa. The prepared glass foams were then sintered at temperatures of 800 °C and 850 °C respectively. Tests such as bulk density, estimated porosity, flexural strength, compressive strength and microstructure evaluation were used to assess the performance of the developed glass foams. The results showed that with increasing temperature and grain sizes, the percent porosity of the developed foams increased while the bulk density decreased. The microstructure evaluation showed that the finer the grain sizes used, the more homogenized are the pores formed and the higher the temperature, the larger the pores but are mostly closed. Both compressive and flexural strength were found to decrease with grain sizes and higher temperatures. The thermal conductivities of all the developed foam glasses satisfy the standard requirement to be used as an insulating material as their thermal conductivities did not exceed 0.25 W/m.K.     

Effect of uniaxial load on the sintering behaviour of 45S5 Bioglass powder compacts

The effect of a uniaxial compressive load on the sintering behaviour of 45S5 Bioglass^® powder compacts was investigated by means of sinter-forging. In comparison to free sintering, densification kinetics was enhanced and the degree of crystallization was reduced. Significantly lower sintering temperatures, i.e. 610 °C instead of 1050 °C, can be employed to obtain dense Bioglass^® parts when sintering is performed under uniaxial load. The effect of mechanical loading on microstructure (pore density, shape and orientation) is discussed. The results of the investigation are relevant in connection with the development of sintered Bioglass^® substrates for bone replacement devices, where both porosity and crystallinity of the part require careful control and low densification temperatures are sought.     

Formation of rod-like Si3N4 grains in porous SRBSN bodies using 6Y2O3–2MgO sintering additives

The porous reaction-bonded silicon nitride (RBSN) bodies using (6 wt.% Y₂O₃–2 wt.% MgO) 6Y2M were fabricated by nitridation process at 1350 °C for 8 h. The porous gas pressure sintered (GPSed)-RBSN bodies post-sintered at 1550–1850 °C for 6 h show a microstructure with low aspect ratios having high porosity. The compressive strength of samples sintered at 1650 °C, 1750 °C and 1850 °C were about 146 MPa, 251 MPa and 285 MPa, respectively. The duration time for sintering had a significant effect on the microstructure and grain morphology of the GPSed-RBSN bodies. Even though the GPSed-RBSN was carried out at the comparatively low temperature (1550 °C) for 9 h, high aspect ratio of rod-like Si₃N₄ grains with about 9 was observed. The material properties of samples such as porosity, phase ratio (β/(α + β)) and compressive strength of sample sintered at 9 h were about 43.2%, 99% and 141 MPa, respectively.     

Effect of sintering temperature on compressive strength of porous yttria-stabilized zirconia ceramics

Porous yttria-stabilized zirconia (YSZ) ceramics were fabricated by tert-butyl alcohol (TBA)-based gel-casting method for potential applications in heat-insulation materials. The effect of sintering temperature on compressive strength of porous YSZ ceramics was investigated on the basis of measurements linear shrinkage, porosity and pore size. As the sintering temperature increased from 1350 to 1550 °C, a decrease of porosity from 77 to 65%, a decrease of average pore size from and an increase of linear shrinkage from 15.4 to 31.8% were observed. The compressive strength increased remarkably from 3 to 27 MPa with increasing sintering temperature from 1350 to 1550 °C, which was related to the corresponding change of linear shrinkage, porosity, pore size and microstructure. A remarkable decrease of compressive strength with increasing porosity was observed. The compressive strength decreased also with increasing pore size.     

Preparation of phenolic-based carbon foam with controllable pore structure and high compressive strength

Phenolic-based carbon foams with controllable pore structure and high compressive strength were prepared by foaming of resin solution under the pressure of 4 MPa and then carbonizing. Results showed that the average pore size of carbon foam ranging from 20 to 180 nm can be controlled by changing the resin concentration. The nanometer pore structure resulted in significant improvement of compressive strength and thermal insulation properties of the carbon foams. Carbon foam with bulk density of 0.73 g/cm³, average pore size of 20 nm, compressive strength of 98.3 MPa and thermal conductivity of 0.24 W/mK was obtained.     

A new direct coagulation casting process for alumina slurries prepared using poly(acrylate) dispersant

Direct coagulation casting (DCC) of concentrated aqueous alumina slurries prepared using ammonium poly(acrylate) dispersant has been studied using MgO as coagulating agent. Addition of small amounts of MgO increased the viscosity of the concentrated alumina slurries with time and finally transformed it in to a stiff gel. Sufficient working time for degassing and casting could be achieved by cooling the slurries to a temperature of ∼5 °C after proper homogenization after the addition of MgO. The DCC slip with alumina loading in the range of 50–55 vol% showed relatively low viscosity (0.12–0.36 Pa s at shear rate of 93 s⁻¹) and yield stress (1.96–10.56 Pa) values. The wet coagulated bodies prepared from slurries of alumina loading in the range of 50–55 vol% had enough compressive strength (45–211 kPa) for handling during mould removal and further drying. The coagulated bodies prepared from slurries of alumina loading in the range of 50–55 vol% showed linear shrinkage in the range of 4.8–2.3 during drying and 17.1–16.2 during sintering respectively. Near-net-shape alumina components with density >98% TD could be prepared by the DCC process.     

Effect of sintering temperature electrical properties of ZNR doped with Pr–Co–Cr–La

The microstructure, electrical properties, and dielectric characteristics of the ZNR (zinc oxide-based nonlinear resistors), which are composed of zinc oxide-based ceramics doped with Pr–Co–Cr–La, were investigated at different sintering temperatures (1240, 1245, 1250, 1255, 1260, and 1300 °C). The increase of sintering temperature led to more densified ceramics, whereas it decreased the nonlinear properties and breakdown voltage. The highest nonlinearity was obtained from 1240 °C, with 79.3 in nonlinear coefficient and 0.3 μA in leakage current. As the sintering temperature increased, the donor density increased from 0.90 × 10¹⁸ to 2.59 × 10¹⁸/cm³, and the barrier height decreased from 1.90 to 0.67 eV, and the dielectric dissipation factor increased from 0.0874 to 0.2839.     

Constrained sintering kinetics of 3YSZ films

3YSZ green layers approximately 10 μm thick were screen-printed onto 3YSZ substrates and their constrained sintering kinetics were measured at 1100-1350 °C using an optical dilatometer. The densification rates of the same powder in the form of pellets and free-standing films were also measured. The constrained densification rate was greatly retarded compared with the free densification rate at a given temperature and density. The retardation increased with increasing density and temperature and could not be properly accounted for by existing theories of constrained sintering. As a result the apparent activation energy is much lower for constrained sintering (135 ± 20 kJ mol⁻¹) than for free sintering (660 ± 30 kJ mol⁻¹). It is proposed that this is because the constrained microstructure exhibits larger and more widely separated pores at the higher temperatures.     

Filamentous alumina–chitosan porous structures produced by gelcasting

Porous filamentous macroelements with tunable properties were developed using alumina–chitosan fibers produced by gelcasting extrusion. The initial suspension was prepared as a dilute aqueous acetic acid solution containing 13 vol% of alumina particles and 1.3 vol% of dissolved chitosan. After extrusion, coagulation in an NaOH bath and drying, 300 μm diameter continuous fibers (9 vol% of chitosan) were compacted and sintered at different temperatures (1100–1500 °C) to produce 40×40 mm² cylindrical macroelements. The effects of the thermal treatment temperature on the porosity, specific surface area, mechanical strength and microstructure of the macroelements were evaluated. It was verified that these properties can be controllably modified in a wide range, depending on the sintering conditions.     

Gelcasting of alumina using the hexamethylenediamine–paraformaldehyde monomer system

A new aqueous alumina gelcasting system using hexamethylenediamine (HMDA) and paraformaldehyde monomers has been studied. The 500 vol% aqueous alumina slurries ‘A’ and ‘B’ containing paraformaldehyde and HMDA, respectively, undergo gelation after thorough mixing of the two due to the polymerization of HMDA and formaldehyde. The gelation time of the slurries cast in a mold is in the range of 7–2.4 min at HMDA to formaldehyde mole ratio in the range of 1.1–1.5. The faster reaction between HMDA and formaldehyde prevents the formaldehyde emission during the processing. The minimum HMDA to formaldehyde mole ratio required for the formation of a mechanically stable gel is 1.1. The compressive strengths and Young's modulus of the wet and dry alumina bodies increased with an increase in HMDA to formaldehyde mole ratio. Though the wet gelcast alumina bodies had low compressive strength (11.2–88.7 kPa) and Young's modulus (0.17–5.9 MPa) the dried ones showed high strength (6–11.7 MPa) and Young's modulus (209–364 MPa). The binder removal by slow heating to a temperature below 500 °C followed by sintering at 1600 °C produced alumina ceramics with ~97% of theoretical density.     

Low temperature production of glass ceramics in the anorthite–diopside system via sintering and crystallization of glass powder compacts

The production of glass ceramics (GCs) with theoretical anorthite–diopside (An–Di) weight ratios of 60/40, 50/50 and 45/55 via sintering and crystallization of glass powder compacts was investigated at different temperatures between 800 and 950 °C. The investigated compositions are located in the cross-section of the ternary fluorapatite–An–Di system close to An–Di binary joint, with constant fluorapatite content of 4.8 wt.%. Two different groups of glass powders, with mean particle size of 2 and 10 μm, were used. The experimental results showed that sintering is almost complete at 800 °C, preceding crystallization, which takes place via surface crystallization mechanism. The properties values of the produced GCs, which are the best for the composition close to An–Di eutectic line, are discussed with respect to the evolution of crystalline phases and the microstructure over increasing firing temperature. Under the technology perspective, the investigated processing route is significantly superior in comparison to the attempts reported in earlier studies.     

Fabrication of CaSiO3 bioceramics with open and unidirectional macro-channels using an ice/fiber-templated method

Porous CaSiO₃ bioceramics with open and unidirectional macro-channels of pore size more than 200 μm are of particular interest for biomedical applications. An ice/fiber-templated method was employed for the fabrication of CaSiO₃ bioceramics with interconnected lamellar pores and macro-channels of pore size more than 200 μm. The pores formed by ice crystals transformed from cellular to lamellar, while the pores formed by fibers were aligned macro-channels, which were also in alignment with the lamellar pores. Keeping the initial slurry concentration constant and increasing the packing density of fibers, the volume fraction of macro-channels and open porosity increased, and the compressive strength decreased. Maintaining the packing density of fibers and increasing the initial slurry concentration, the pore sizes of lamellar pores and open porosity decreased, and the compressive strength increased. The results indicated that it was possible to manufacture porous CaSiO₃ bioceramics with the macro-channels of 250–350 μm, lamellae spacing of 50–100 μm, open porosity of 71.12–83.94% and compressive strength of 0.87–3.59 MPa, indicating the suitability for tissue engineering.     

Preparation,characterization, and physicomechanical properties of glass-ceramic foams based on alkali-activation and sintering of zeolite-poor rock and eggshell

This study reports the fabrication of novel glass-ceramic foams for thermal insulation to minimize the energy consumption in the buildings. Different combinations of zeolite-poor rock/eggshell powders (with eggshell content varying from 0 to 20 wt%) have been used to produce the foams through alkali-activation and reactive sintering techniques. The produced glass-ceramic foams were characterized based on their structural, thermal, and mechanical characteristics. The heat treatment process and the foaming patterns are examined by a heating microscope, and the findings reveal an excellent foamability of the utilized alkali-activated mixture in the range of 800–950 °C. The microstructure and the pore size of the acquired foams are investigated using a scanning electron microscope (SEM) and computed tomography (CT) analysis. The crystallinity and phase composition of the prepared samples were investigated via X-ray diffraction (XRD). The experiment findings reveal that raising the eggshell content is favorable to gas production, but it affects the liquid phase creation resulting in inconsistent pore size distribution. The appropriate eggshell content is 4%, and the optimal heat treatment temperature is 900 °C. The produced ceramic foams possess a density ranging from 0.54 to 1 g/cm³, thermal conductivity around 0.07–0.4 W/mK, and compressive strength values between 1.2 and 6.7 MPa. The results indicate that the ceramic foams created could be a feasible choice for applications in constriction as thermal insulation materials.     

Dielectric relaxation behavior and energy storage properties in Ba0.4Sr0.6Zr0.15Ti0.85O3 ceramics with glass additives

Ba_0.4Sr_0.6Zr_0.15Ti_0.85O₃ ceramics with SrO–B₂O₃–SiO₂ glass additives were prepared via the solid state reaction route. The effects of glass contents on the sintering behavior, dielectric properties, microstructures, and energy storage properties of BSZT ceramics were investigated. Dielectric breakdown strength of 22.4 kV/mm was achieved for BSZT ceramics with 20 wt% glass addition. Dielectric relaxation behavior was observed in dielectric loss versus temperature plots. In order to investigate the mechanism of dielectric breakdown performance, the relationship between dielectric breakdown strength and grain boundary barrier was studied by the measurements of breakdown strength and activation energy. A discharged energy density of 0.45 J/cm³ with an energy efficiency of 88.2% was achieved for BSZT ceramics with 5 wt% glass addition.     

Effects of strain rate and temperature on compressive strength and fragment size of ZrB2–SiC–graphite composites

The quasi-static (strain rate of 10⁻⁴ s⁻¹) and dynamic compression experiments (strain rate of 200–1500 s⁻¹) of ZrB₂–SiC–graphite composites are conducted at 293 K and 1073 K. The initial compressive strength and Weibull modulus are calculated to handle the discrete quasi-static experimental data. Considering effects of strain rate and temperature, the compressions of ZrB₂–SiC–graphite composites are investigated. The results show that both compressive strength and fragment size are higher at 1073 K than those at room temperature. The compressive strengths increase with increasing strain rate at room temperature and 1073 K, whereas fragment sizes decrease. Moreover, a micromechanical model is utilized to characterize the effect of strain rate on the compressive strength. The predictions of this micromechanical model are good agreement with the experimental results. Meanwhile, the fragment sizes of dynamic compressive specimens are analyzed through analytical approaches.     

Generation and characterization of carbon nano-fiber-poly(arylene ether sulfone) nanocomposite foams

In this study, carbon nano-fibers (CNFs) were used to increase the compressive properties of poly(arylene ether sulfone) (PAES) foams. The polymer composite pellets were produced by melt blending the PAES resin with CNFs in a single screw extruder. The pellets were saturated and foamed with water and CO₂ in a one-step batch process method. Dynamic mechanical thermal analysis (DMTA) was used to determine the reduced glass transition temperature (T_g) of the CNF-PAES as a result of plasticization with water and CO₂. Sharp transitions were observed as peaks in the tan δ leading to accurate quantitative values for the T_g. By accurately determining the reduced T_g, the foaming temperature could be chosen to control the foam morphology. Foams were produced which ranged in density from 290 to 1100 kg/m³. The foams had cell nucleation densities between 10⁹ and 10¹⁰ cells/cm³, two orders of magnitude higher than unreinforced PAES foam, suggesting that the CNFs acted as heterogeneous nucleating agents. The CNF-PAES foam exhibited improved compressive properties compared to unreinforced PAES foam produced from a similar method. Both the specific compressive modulus and strength increased by over 1.5 times that of unreinforced PAES foam. The specific compressive strength of 59 MPa for the CNF-PAES foam is similar to that of commonly used high performance structural foam, poly(methacrylimide foam).