Effect of Al2O3 particle size on preparation and properties of ZTA ceramics formed by gelcasting

Zirconia-toughened alumina (ZTA) ceramics were prepared using three different kinds of Al₂O₃ powders (marked PW-A average particle size: 7.53 μm, marked PW-B average particle size: 1.76 μm, marked PW-C average particle size: 0.61 μm) by gelcasting. Effect of Al₂O₃ particle size on zeta potential, dispersant dosage and solid volume fractions of ZTA suspensions as well as the mechanical properties of ZTA green bodies and ceramics were investigated. The optimum dosages of dispersant for ZTA suspensions prepared by PW-A, PW-B and PW-C are 0.4 wt%, 0.5 wt% and 0.7 wt%, respectively. The highest solid volume fractions of ZTA suspensions can reach 62 vol% (SP-A), 60 vol% (SP-B) and 52 vol% (SP-C), respectively. The green bodies show a bending strength as high as 20 MPa, which can meet the requirement of machining. The Al₂O₃ powder with fine particle size is beneficial to the improvement of mechanical properties. The ZTA ceramics prepared by PW-B Al₂O₃ powder show the highest bending strength (680 MPa) and toughness (7.49 MPa m^1/2).     

Properties of BaTiO3 synthesized from barium titanyl oxalate

In order to enhance the tetragonality of BaTiO₃ derived from barium titanyl oxalate (BTO), various treatments were carried out by considering the thermal decomposition mechanism of BTO in air. A multi-step heat treatment process and the addition of carbon black, as a particle growth inhibitor, were effective in increasing the tetragonality, whilst maintaining a particle size smaller than 200 nm. The synthesized BaTiO₃ powder with a mean particle size of 177 nm showed a tetragonality and K-factor of 1.0064 and approximately 3, respectively.     

Agglomeration of α-Al2O3 powders prepared by gel combustion

Ultrafine α-Al₂O₃ powders were prepared by a gel combustion method and the agglomeration characteristic of the resultant powders was studied. A variety of fine crystallite α-Al₂O₃ powders with different agglomeration structures could be obtained by altering the citrate-to-nitrate ratio γ and calcining the precursors at 1050 °C for 2 h. All the powders were of nearly equivalent crystallite size (60–80 nm) except for the P1 powder (113 nm) from the gel with γ = 0.033. The primary crystallites of the obtained α-Al₂O₃ powders were formed into large secondary particles with different degree of agglomeration. Except for the powder P1, the mean particle sizes from specific surface area and particle size distribution measurement increase with increasing citrate-to-nitrate ratio in the fuel-lean condition and decrease in the fuel-rich condition. Densities of alumina ceramics from powders P4 and P5 sintered at different temperatures were relatively low due to the wide particle size distribution.     

Characterization of high tap density Li[Ni1/3Co1/3Mn1/3]O2 cathode material synthesized via hydroxide co-precipitation

Li[Ni_1/3Co_1/3Mn_1/3]O₂ cathode material for lithium ion batteries was prepared by mixing metal hydroxide, (Ni_1/3Co_1/3Mn_1/3)(OH)₂, with 6% excess LiOH followed by calcinations. The (Ni_1/3Co_1/3Mn_1/3)(OH)₂ with secondary particle of about 12 μm was prepared by hydroxide co-precipitation. The tap density of the obtained Li[Ni_1/3Co_1/3Mn_1/3]O₂ powder was 2.56 ± 0.21 g cm⁻³. The powder was characterized by X-ray diffraction (XRD), scanning electron microscope (SEM), particle size distribution (PSD) and galvanostatic charge-discharge cycling. The XRD pattern of Li[Ni_1/3Co_1/3Mn_1/3]O₂ revealed a well ordered hexagonal layered structure with low cation mixing. Secondary particles with size of 13-14 μm and primary particles with size of about 1 μm can be identified from the SEM observations. In the voltage range of 2.8-4.3 V, the initial discharge capacity of the Li[Ni_1/3Co_1/3Mn_1/3]O₂ electrode was 166.6 mAh g⁻¹, and 96.5% of the initial capacity was retained after 50 charge-discharge cycling.     

One-step hydrothermal routine for pure-phased orthorhombic LiMnO2 for Li ion battery application

This paper reports a simple one-step hydrothermal routine to prepare orthorhombic LiMnO₂ powder for Li ion battery application. Employing Mn₂O₃ and LiOH as the starting materials, hydrothermal reaction operated under 160 °C for 12 h generated pure-phased o-LiMnO₂ powder. The morphological change and reduction in grain size between the reagent and the resultant were revealed by SEM observation, which indicated that LiOH played two important roles in the process, one as the Li ion source to form orthorhombic LiMnO₂ by intercalation and the other as the corrosive medium to control the morphology and reduce the particle size. Detailed investigation showed that the LiOH concentration and the hydrothermal temperature were two key factors influencing phase purity of the final product. Pure-phased o-LiMnO₂ prepared under optimized hydrothermal conditions showed higher capacity and better cyclical performance than the commonly prepared o-LiMnO₂ powder, and therefore promised potential application for lithium ion secondary batteries.     

Mechanochemical synthesis of MgTa2O6 ceramic

MgTa₂O₆ powders were prepared by mechanochemical synthesis from MgO and Ta₂O₅ in a planetary ball mill in air atmosphere using steel vial and steel balls. High-energy ball milling gave nearly single-phase MgTa₂O₆ after 8 h of milling time. Annealing of high-energy milled powder at various temperatures (700–1200 °C) indicated that high-energy milling speed up the formation and crystallization of MgTa₂O₆ from the amorphous mixture. The powder derived from 8 h of mechanical activation gave a particle size of around 28 nm. Although at low-annealing temperatures the grain size was almost the same as-milled powder, the grain size increased with annealing temperature reaching to around 1–2 μm after annealing at 1200 °C for 8 h.     

Size-controlled high magnetization CoFe2O4 nanospheres and nanocubes using rapid one-pot sonochemical technique

Highly crystalline single phase spherical and monodisperse cobalt ferrite (CoFe₂O₄) nanoparticles (NPs) with uniform shape and size distribution have been synthesized by one pot-rapid sonochemical method. The effect of different solvents, such as aqueous, alcoholic, and a mix of water/ethanol in 1:1 volume ratio on the shape, size, and crystalline structure of CoFe₂O₄ NPs were studied using X-ray diffraction, transmission electron microscopy, energy dispersive spectroscopy and Fourier transform infrared spectroscopy. The size of CoFe₂O₄ nanoparticle was controlled in the range from 20 to 110 nm based on the solvent medium used in the synthesis process. Furthermore, the evolution from spherical to cubic morphology of cobalt ferrite NPs is achieved by simply changing the solvent medium from aqueous to alcoholic medium. The magnetic properties of all the synthesized CoFe₂O₄ NPs were studied by vibrating sample magnetometer (VSM) at room temperature. The magnetization value was found to be particle size dependent, and high magnetization (Ms) of 92.5 emu/g was obtained for the CoFe₂O₄ NPs sample synthesized in a mixed solution of water and ethanol. A possible reaction mechanism for the formation of cobalt ferrite NPs by the sonochemical technique was discussed. The facile method adopted in our study appears to be a promising route for synthesis of highly crystalline nanoparticles within short times and without the need for using any calcination process.     

Crystalline morphology and photoluminescent properties of YInGe2O7:Eu phosphors prepared from microwave and conventional sintering

This paper describes an investigation of the crystalline morphology and photoluminescent properties of YInGe₂O₇:Eu³⁺ powders using microwave assisted sintering. For comparison, the properties of YInGe₂O₇:Eu³⁺ powders sintered at 1200 °C in conventional furnace for 10 h were also investigated. X-ray powder diffraction analysis confirmed the formation of monoclinic YInGe₂O₇ without second phase or phases of starting materials as YInGe₂O₇:50 mol% Eu powders sintered at 1200 °C in microwave furnace for 1 h. Scanning electron microscopy showed smaller particle size and more uniform grain size distributions are obtained by microwave assisted sintering. In the PL studies, both microwave sintered and conventionally sintered powders emitted a maximum luminescence centered at 620 nm under excitation of 393 nm with similar luminescent intensity. The results show that microwave processing has the potential to reduce the time and required energy input for the production of YInGe₂O₇:Eu³⁺ phosphors without sacrificing the photoluminescence.     

Assembly of 8YSZ nanoparticles into gas-tight 1-2 μm thick 8YSZ electrolyte layers using wet coating methods

The application of a thin film electrolyte layer with a thickness in the micrometer range could greatly improve current solid oxide fuel cells (SOFCs) in terms of operating temperature and power output. Since the achievable minimal layer thickness with conventional powder coating methods is limited to ∼5 μm, a variety of thin film methods have been studied, but results on regular large-scale anode substrates are still lacking in the literature. In this paper, a wet coating process is presented for fabricating gas-tight 1-2 μm thick 8YSZ electrolyte layers on a regular NiO/8YSZ substrate, with a rough surface, a high porosity and a large pore size. These layers were deposited in a similar way as conventional suspension based layers, but the essential difference includes the use of coating liquids (nano-dispersion, sol) with a considerably smaller particle size (85 nm, 60 nm, 35 nm, 6 nm). Successful deposition of such layers was accomplished by means of an innovative coating process, which involves the preparation of a hybrid polyvinyl alcohol/8YSZ membrane by dip-coating or spin-coating and subsequently burning out the polymer part at 500 °C. Results from He leak tests confirmed that the sintered layers posses a very low number of defects and with values in the range 10⁻⁴-10⁻⁶ (hPa dm³)/(s cm²) the gas-tightness of the thin film layers is satisfactory for fuel cell operation. Moreover, preliminary results have also indicated a potential reduction of the sintering temperature from 1400 °C to the range 1200-1300 °C, using the presented coating process.     

Microwave-assisted preparation of submicron-sized FeTiO3 powders

FeTiO₃ powders were prepared from (Fe+Ti) mixed carbonate precursor by the microwave-assisted calcination method. The thermal analysis of the precursor was conducted by TG/DSC. It is demonstrated that the calcination process can be divided into three different stages: the removal of water, the decomposition of precursor and the formation of FeTiO₃. A variety of techniques, such as XRD, FT-IR, SEM and EDS were utilized to characterize the samples. The results indicated that FeTiO₃ powders can be prepared by microwave-assisted calcination for 20 min at 450 °C, while those cannot be obtained by conventional one until reaction time exceeds 120 min at 600 °C. The FeTiO₃ powders prepared by microwave-assisted calcination are nearly spherical with limited aggregation and have a mean particle size of 400–500 nm.     

Molten salt synthesis of spherical LiNi0.5Mn1.5O4 cathode materials

This paper describes a novel simple redox process for synthesizing monodispersed MnO₂ powders and preparation of spherical LiNi_0.5Mn_1.5O₄ cathode materials by molten salt synthesis (MSS) method. Monodispersed MnO₂ powders have been synthesized by using potassium permanganate and manganese sulfate as the starting materials. By using this redox method, it was found that monodispersed MnO₂ powders with average particle size ∼5 μm can be easily obtained. Resultant MnO₂ and LiOH, Ni(OH)₂ was then used to synthesis LiNi_0.5Mn_1.5O₄ cathode materials with retention of spherical particle shape by MSS method. The discharge capacity was 129 mAh g⁻¹ in the first cycle and 127 mAh g⁻¹ after 50 cycles under an optimal synthesis condition for 12 h at 800 °C.     

Low-temperature solution combustion synthesis of high performance LiNi0.5Mn1.5O4

High-voltage LiNi_0.5Mn_1.5O₄ spinels were synthesized by a low temperature solution combustion method at 400 °C, 600 °C and 800 °C for 3 h. The phase composition, structural disordering, micro-morphologies and electrochemical properties of the products were investigated by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscope (SEM) and constant current charge–discharge test. XRD analysis indicated that single phase LiNi_0.5Mn_1.5O₄ powders with disordered Fd-3m structures were obtained by the method at 400 °C, 600 °C and 800 °C. The crystallinity increased with increasing preparation temperatures. XRD and FTIR data indicated that the degree of structural disordering in the product prepared at 800 °C was the largest and in the product prepared at 600 °C was the least. SEM investigation demonstrated that the particle size and the crystal perfection of the products were increased with increasing temperatures. The particles of the product prepared at 600 °C with ~200 nm in size are well developed and homogeneously distributed. Charge/discharge curves and cycling performance tests at different current density indicated that the product prepared at 600 °C had the largest specific capacity and the best cycling performance, due to its high purity, high crystallinity, small particle size as well as moderate amount of Mn³⁺ ions.     

Polyvinylpyrrolidone-assisted synthesis of microscale C-LiFePO4 with high tap density as positive electrode materials for lithium batteries

Carbon-coated LiFePO₄ (C-LiFePO₄) with micron particle size (6 μm) and high tap density (1.6 g cm⁻³) was prepared from spherical FePO₄·2H₂O powder via the co-precipitation method. The C-LiFePO₄ powder was calcined at temperatures between 650 and 800 °C. The 6 μm C-LiFePO₄ prepared at 800 °C exhibited an excellent rate capability, delivering 150 mAh g⁻¹ on discharge at the 0.1 C-rate and 108 mAh g⁻¹ at the 5 C-rate. The volumetric capacity of the 6 μm C-LiFePO₄ corresponded to 225 mAh cm⁻³, since the large secondary particles (6 μm) C-LiFePO₄ sufficiently allowed tight packing of the particles. The 6 μm C-LiFePO₄ powder with high tap density makes an attractive positive electrode candidate for lithium-ion batteries designed for high energy density.     

Magnetite/maghemite mixture prepared in benzyl alcohol for the preparation of α″-Fe16N2 with α-Fe

Fine powder of iron oxide has been required in the preparation of ferromagnetic α″-Fe₁₆N₂ powder in low temperature nitridation. Magnetite and maghemite mixture was obtained by the reaction of iron acetylacetonate Fe(acac)₃ in benzyl alcohol. It was reduced to α-Fe in hydrogen at 400 °C. Particle size of the α-Fe was 300 nm in the reduction of iron oxides obtained from 2 g of Fe(acac)₃. It decreased to 100 nm in the preparation using 8 g of Fe(acac)₃. After the successive nitridation under ammonia flow at 160 °C, the highest yield of α″-Fe₁₆N₂ in 66 wt.% was observed on the nitrided product from the latter α-Fe, because of the smallest α-Fe particle size after the reduction in the present study. The yield and reproducibility of α″-Fe₁₆N₂ formation in low temperature nitridation was improved using the iron oxide prepared in non-aqueous benzyl alcohol compared to the use of magnetite obtained from aqueous solution.     

Synthesis of ZnNb2O6 powder with rod-like particle morphologies

A ZnNb₂O₆ powder was synthesized through the molten salt method. The XRD and SEM results indicated that the crystal ZnNb₂O₆ powder with rod-like particle morphologies could be obtained via this method at temperature of 600 °C, which is significantly lower than that required by solid-state reaction, where a calcining temperature of 800 °C was needed and the obtained ZnNb₂O₆ particles were equiaxial. The heat treatment temperature scarcely affected the ZnNb₂O₆ particle morphologies in the molten salt synthesis process.     

Processing of different alumina–zirconia composites by slip casting

Two Al₂O₃–ZrO₂ mixture preparation routes: classical powder mixing and addition of a Zr (IV) precursor solution to a well dispersed Al₂O₃ suspension, were used to produce alumina (Al₂O₃)–zirconia (ZrO₂) slip cast composites. For the conventional powder mixing route, two commercial 3 mol% yttria-partially stabilized zirconia powders, 0.3 wt% Al₂O₃-doped (Al-doped Y-PSZ) and without Al₂O₃ (Y-PSZ), were employed. The influence of the zirconia content and the solid loading on the rheological properties of concentrated aqueous Al₂O₃–ZrO₂ slips were investigated. The density of green samples was studied and related to the degree of slip dispersion. In addition, the influence of the processing conditions on the density and microstructure development of sintered samples were investigated. By using the Zr (IV) precursor route, nano-sized ZrO₂ (ZN) particles homogeneously distributed on the Al₂O₃ particle surfaces were obtained; however, it let to aggregates of some Al₂O₃ particles with very fine ZrO₂ uniformly distributed. The viscosity and yield stress values of Al₂O₃–ZN suspensions were markedly higher than those of Al₂O₃–Al-doped Y-PSZ and Al₂O₃–Y-PSZ ones, for all the compositions and solid loading studied and resulted in a less dense packing of cast samples. However, for the composite with 10.5 vol% ZN a high sintered density and a smaller ZrO₂ grain size distribution compared with the conventional powder mixing route could be obtained.     

Fabrication and characterization of porous silver powder prepared by spray drying and calcining technology

High porosity porous silver powder with about 100 µm average size and 5 µm pore size was fabricated by spray drying and calcining technology. Effects of calcining temperature and process of spray-dried powder on the phases, grain size, particle morphology and pore microstructure of silver powder were investigated. The results showed that porous silver with approximately spherical shape and via hole structure was obtained using 0.25 mol Ag₂CO₃ solution of ammonia water, which was spray-dried at 200 °C and calcined at 400 °C for 30 min with heat treatment technology curve of gradient temperature in air. And there were not Ag₂CO₃, Ag₂O and AgO phases existing in the porous silver. However, using 0.25 mol Ag₂CO₃ solution of ammonia water, the porous silver powder could not be fabricated by spray pyrolysis technology with a solution feed rate of 300 mL/h, flux of carrier gas of 0.30 MPa, and 640 °C furnace set temperature.     

Preparation and characterization of CeO2/TiO2 nanoparticles by flame spray pyrolysis

Nanocrystalline TiO₂, CeO₂ and CeO₂-doped TiO₂ have been successfully prepared by one-step flame spray pyrolysis (FSP). Resulting powders were characterized with X-ray diffraction (XRD), N₂-physisorption, Transmission Electron Microscopy (TEM) and UV-Vis spectrophotometry. The TiO₂ and CeO₂-doped TiO₂ nanopowders were composed of single-crystalline spherical particles with as-prepared primary particle size of 10-13 nm for Ce doping concentrations of 5-50 at%, while square-shape particles with average size around 9 nm were only observed from flame-made CeO₂. The adsorption edge of resulting powder was shifted from 388 to 467 nm as the Ce content increased from 0 to 30 at% and there was an optimal Ce content in association with the maximum absorbance. This effect is due to the insertion of Ce^3+/4+ in the TiO₂ matrix, which generated an n-type impurity band.     

Synthesis of mono-dispersed spherical Nd:Y2O3 powder for transparent ceramics

Transparent Nd:Y₂O₃ ceramic was obtained by sintering mono-sized spherical powder. The powder was prepared by homogeneous precipitation method in aqueous media using urea to regulate the pH. The structure and morphology of the powder were investigated by TG-DTA, XRD, SEM and IR spectrum. The effect of aging temperature, time, and the concentration of urea, [Y³⁺], and [Nd³⁺] were investigated. Results showed that the obtained precursor was R₂(OH)CO₃·H₂O (R = Y, Nd), and the least size of mono-sized spherical yttria particles was 72 nm by a microwave oven method after calcinations at 850 °C for 4 h. After dry press and CIP, the particles accumulated closely, and no defects can be detected in the green body.     

Hydrothermal synthesis and electrochemical behavior of orthorhombic LiMnO2

The most highlighted point of this work to emphasize is that it is the first trial to use Mn₃O₄ oxide as a precursor to synthesize orthorhombic LiMnO₂ by the hydrothermal method. A well-ordered orthorhombic LiMnO₂ phase was formed by the hydrothermal treatment of Mn₃O₄ with excess LiOH aqueous solution at 170 °C. According to TEM observation, the as-synthesized powder was single crystalline particle oxide. Comparing with other orthorhombic LiMnO₂ prepared by low temperature synthetic route and by high temperature calcination, the orthorhombic LiMnO₂ prepared by the hydrothermal route showed enhanced battery performance as a lithium battery cathode material. We believe that the new hydrothermal synthesis is expected as an excellent alternative of powder preparation method of high capacity cathode material to be used for Li-ion secondary battery.