Synthesis of Nanofiber‐like Mesoporous γ‐Al2O3 toward Its Adsorption Efficiency for Congo Red

Nanofiber‐like mesoporous γ‐Al₂O₃ was synthesized using freshly prepared boehmite sol in the presence of triblock copolymer, P123 following evaporation‐induced self‐assembly (EISA) process followed by calcinations at 400°C–1000°C. The samples were characterized by thermogravimetry (TG), differential thermal analysis (DTA), X‐ray diffraction (XRD), N₂ adsorption–desorption, and transmission electron microscopy (TEM). The adsorption efficiency of the samples with Congo red (CR) was studied by UV – vis spectroscopy. XRD results showed boehmite phase in the as‐prepared sample while γ‐Al₂O₃ phase obtained at 400°C was stable up to 900°C, a little transformation of θ‐Al₂O₃ resulted at 1000°C. The Brunauer‐Emmett‐Teller surface area of the 400°C‐treated sample was found to be 175.5 m²g ^{? 1}. The TEM micrograph showed nanofiber‐like morphology of γ‐Al₂O_3. The 400°C‐treated sample showed about 100% CR adsorption within 60 min.     

Preparation and Characterization of CIGSe Solar Cells by Ink Printing on Alumina Substrates with Self‐Synthesized Selenide Powders via an Environment‐Friendly and Cost‐Effective Dry Synthesis Route

CIGSe solar cells with an ink‐printing absorber layer were prepared on Mo‐coated alumina substrates. The use of alumina substrates can extend the process window to higher temperatures. The inks contained single‐phase CIGSe powder, which was formed by firing different selenide powders of Cu₂Se, In₂Se₃, and Ga₂Se₃ at 800°C. All these powders were synthesized with an environment‐friendly and cost‐effective powder process. The printed inks were sintered at 600–800°C. The solar cells had power conversion efficiency of 0.50%, an open‐circuit voltage of 27 mV, a short‐circuit current density of 37 mA/cm², and a fill factor of 0.50.     

Synthesis of mesoporous alumina with CO2 expanded carbonation and its catalytic oxidation of cyclohexanone

A CO₂ expanded carbonation technique is proposed for direct synthesis of alumina powders that does not require structure directing substances or templates. Mesoporous amorphous flower-like alumina was synthesized at relatively low volume expansions (lower ethanol to water volume ratio), whereas mesoporous crystalline honey-comb-like alumina was synthesized at high volume expansions. The alumina powders exhibited high surface area and pore size with small crystallite sizes. The alumina structures were stable from 400 to 800 °C. Experimental tests showed that the alumina powders could catalytically convert cyclohexanone to ɛ-caprolactone efficiently. The use of the calcined catalysts (at 400 and 800 °C; flower-like alumina) at equal ethanol to water volume ratio avoids the usual and inevitable hydrolysis of ɛ-caprolactone to ɛ-hydroxyhexanoic acid. The catalyst was recyclable and stable for up to five reaction cycles.     

Solvothermal Conversion of Nanofiber to Nanorod‐Like Mesoporous γ‐Al2O3 Powders,and Study Their Adsorption Efficiency for Congo Red

Mesoporous γ‐Al₂O₃ powders with nanofiber and nanorod‐like structures were synthesized using boehmite sols in the presence of triblock copolymer, P123 in ethanol by solvothermal process at different temparatures (100°C–165°C) followed by calcination at 400°C–1000°C. The powders were characterized by low‐ and wide‐angle X‐ray diffraction (XRD), N₂ adsorption–desorption, and transmission electron microscopy (TEM). The adsorption efficiency of the powders with Congo red (CR) was studied by UV–vis spectroscopy. The γ‐Al₂O₃ phase became stable up to 1000°C. The nanorods obtained at 165°C had narrower pore size distribution (PSD) than nanofibers synthesized at 100°C, the former showed higher CR adsorption efficiency. The stepwise growth mechanism of nanofibers to nanorods conversion with increase in solvothermal temperatures was illustrated.     

New Methods for Preparing Submicrometer Powders of The Tungstate‐Ion Conductor Sc2(WO4)3 and its Al and In Analogs

Two new methods for preparing submicrometer powders of M₂(WO₄)₃, M = Sc, In, and Al via combustion synthesis are reported. Stoichiometric combinations of trivalent metal nitrates, ammonium metatungstate, and either urea or carbohydrazide as the fuel were reacted at 550°C, producing amorphous or poorly crystallized powders with an average particle size ranging from 164 to 350 nm. Calcining the powders at 800°C for 1 h produced well‐crystallized, phase‐pure powders with an average particle size ranging from 210 to 711 nm. Powders sintered at 1000°C for 14 h resulted in pellets that were 87%–95% of the theoretical density, which is notably higher than typically obtained from powders prepared by solid‐state reaction. Whereas there was little difference in the microstructure of Al₂(WO₄)₃ pellets prepared with the two different powders, the carbohydrazide‐derived powders resulted in In₂(WO₄)₃ and Sc₂(WO₄)₃ pellets with a larger grain size than those prepared with urea‐derived powders. The electrical conductivity of the sintered pellets, while comparable to that reported for polycrystalline M₂(WO₄)₃ prepared by solid‐state reaction, was strongly influenced by grain‐boundary effects.     

Visible Light Transparency for Polycrystalline Ceramics of MgO·2Al2O3 and MgO·2.5Al2O3 Spinel Solid Solutions

Magnesium aluminate spinel solid solutions with the alumina‐rich compositions MgO·2Al₂O₃ and MgO·2.5Al₂O₃ have been prepared as polycrystalline ceramics with average in‐line transmissions at 550 nm of 85.5 ± 0.3% and 80.9 ± 0.4%, respectively. Starting powders are prepared from combinations of high purity Mg(OH)₂ and γ‐Al₂O₃ thoroughly mixed in an aqueous slurry, and the solids are collected, dried, calcined, mixed with LiF sintering aid, and sieved. The optimum amount of LiF added varies with the alumina composition of the spinel solid solution. The powders are sintered into dense ceramics by hot pressing at 1600°C under vacuum and 20 MPa uniaxial load followed by hot isostatic pressing at 1850°C under 200 MPa in Ar. Both compositions exhibit exaggerated grain growth with average sizes well over 500 μm. Knoop hardness measurements are 11.2 ± 0.3 GPa for MgO·2Al₂O₃ and 11.0 ± 0.4 GPa for MgO·2.5Al₂O₃.     

New Method of Synthesizing Aluminum Oxynitride Spinel Powders

Aluminum oxynitride spinel (AlON) powders were synthesized by aluminothermic reaction in a reducing N₂‐CO atmosphere. Low cost and easily available aluminum and γ‐Al₂O₃ alumina micrometer‐sized powders were employed as starting materials. Mixed powders consisting of 75 wt% Al and 25 wt% Al₂O₃ were milled together and pressed into billets with diameter of 20 mm and height of 15 mm. Green‐body billets were then calcined in charcoal‐protected condition (namely in a N₂‐CO atmosphere) at 1600°C. Phase composition and microstructure of final sintered products were analyzed. The results showed that AlON phase with AlN as a minor phase was formed at 1600°C for 3 h. At the same time, grains of AlON were tabular in shape and whiskers can be found in samples after being sintered at 1600°C.     

Effect of alkali roasting and sulfatization on the extraction of different metal oxides from waste alum sludge

Water treatment plants (WTP) generate a significant amount of sludge as byproducts with environmentally harmful elements. Thus, this work focused on the recycling of alum sludge through the extraction of different metal oxides, i.e., Al₂O₃, Fe₂O₃ and SiO₂, for use in different applications, such as ceramics, cement, and agriculture. The extraction of Al₂O₃, Fe₂O₃, and SiO₂ from alum sludge was performed using sulfatization and roasting to compare which of the two processes could produce the metal oxides of the highest purity. Precipitated powders were calcined at 700°, 900° and 1100 °C. Moreover, the obtained prepared and calcined powders were characterized by studying their phase compositions, microstructure, particle size, and surface area. Results indicated that roasting achieved the highest yield of alumina. Iron oxide was extracted mostly in maghemite form through roasting after calcination at 1100 °C. Further, silica was obtained in cristobalite and quartz phases after calcination at 1100 °C for the samples prepared through sulfatization. However, these phases of silica were combined with albite and obtained after calcination at 1100 °C for the samples prepared through roasting method.     

Synthesis,Characterization, and Microstructure of ZrC/SiC Composite Ceramics via Liquid Precursor Conversion Method

The ceramic precursor for ZrC/SiC was prepared via solution‐based processing using polyzirconoxane, polycarbosilane, and divinylbenzene. The precursor could be transformed into ZrC/SiC ceramic powders at relative low temperature (1500°C). The cross‐linking process of precursor was studied by FT–IR. The conversion from precursor into ceramic was investigated by TGA, XRD. The ceramic compositions and microstructures were identified by element analysis, Raman spectra, SEM, and corresponding EDS. The results indicated that the ceramic samples remained amorphous below 1000°C and t–ZrO₂ initially generated at 1200°C. Further heating to 1400°C led to the formation of ZrC and SiC with the phase transformation of ZrO₂ and almost pure ZrC/SiC could be obtained upon heat‐treatment at 1500°C. During heat treatments, the ceramic sample changed from compact to porous due to carbothermal reduction. The ceramic powders with particle size of 100 nm~400 nm consisted of high crystalline degree ZrC and SiC phases, and Zr, Si, C were well distributed at the different sites in ceramic powders. The free carbon content was lowered to 1.60 wt% in final ZrC/SiC composite ceramics.     

Effect of calcination temperature on the microstructure,composition and properties of nanometer agglomerated 8YSZ powders for plasma spray-physical vapor deposition (PS-PVD) and coatings thereof

Homemade nano-agglomerated powders 8YSZ powders for PS-PVD were prepared by the spray drying, then calcination processes at four different temperatures (500 °C, 700 °C, 900 °C and 1100 °C) were carried out on the spray-dried powders. Checked by laser particle sizer, scanning electron microscope (SEM) and X-ray diffraction (XRD), the physical properties, microstructure and phase constitutions of the calcined powders were investigated. The results show that the size of powders calcined at 500 °C is increased relative to the spray-dried powder, whereas the powders calcined at 700 °C, 900 °C and 1100 °C possess smaller size. The binding force of the primary particles tend to rise with the increase of calcination temperature. When the temperature was up to 900 °C and above, it was found that the sintering neck indicating with strong binding was formed between the primary particles. In parallel, the powders underwent an m-ZrO₂ to t-ZrO₂ transition as the calcination temperature rose. It is also found that the PS-PVD prepared coatings which were obtained by using the above powders undergo a transformation from a feather-like to a dense laminate structure as the calcination temperature rises. It is noteworthy that the coating obtained by the powders calcined at 700 °C have a special three-layer composite structure of near dense surface layer, columnar intermediate layer and dense sub-layer. The composite structural coating has excellent adhesion and thermal shock resistance, with a bonding strength of 81MPa and no major spalling when water quenched 100 cycles at 1100 °C.     

Enhanced Activation Energy of Crystallization of Pure Zirconia Nanopowders Prepared via an Efficient Way of Synthesis Using NaBH4

An efficient way through borohydride synthesis route using NaBH₄ was performed to prepare pure zirconia nanopowders via three different conditions such as gelation, precipitation, and constant pH. Zirconia powders prepared through constant pH route show highest activation energy of crystallization (E_a = 260 kJ/mol) or higher exothermic peak temperature (717°C), when compared with gelation or precipitation route due to its controlled growth of smaller crystallites. The released huge amount of H₂ gas bubbles during borohydride synthesis via constant pH route play a major role for formation of loose smaller crystallites and thus enhances the activation energy of crystallization of pure zirconia. So, the as‐prepared zirconia powders prepared through constant pH route remain amorphous up to 600°C and pure t‐ZrO₂ (~20 nm) was stable up to 800°C.     

Effect of Pluronic F-127 debinding temperature on the sintering and densification of alumina by direct ink writing

Hydrogel-based alumina (Al₂O₃) inks were prepared using Pluronic F-127 with 65 wt% of solid loading (Al₂O₃). The Al₂O₃ inks were deposited, and the freestanding samples were studied using TGA/DTA. Significant weight loss was observed between 180 and 360°C. A two-stage hydrogel debinding process of Al₂O₃ samples was carried out at 180 and 360°C with holding times of 30, 60, 90, 120, and 150 min. The Al₂O₃ samples were then sintered at 1600°C. X-ray diffraction was used for the phase analysis of the alumina inks, and a scanning electron microscope was used microstructural analysis. Based on the TGA/DTA analysis, a two-stage debinding process was adopted. Significant effect of hydrogel debinding temperature was observed on the sintering and densification behavior of alumina. It was observed that the porosities in the alumina samples were increasing when the debinding time was increased from 30 to 150 min, with the debinding temperature at 180 and 360°C. Moreover, the nature of the porosities was changing from closed porosities to interconnected porosities.     

Carbon nanotube reinforced pyrocarbon matrix composites with high coefficient of thermal expansion for self-adapting ultra-high-temperature ceramic coatings

The mismatch in the coefficients of thermal expansion (CTE) of the carbon fiber reinforced pyrocarbon (Cf/C) composites and their thermal barrier coatings (TBCs) has significantly restricted the service life of Cf/C composites in high-temperature environments. Owing to the high CTE of TBCs, it is vital to find a material with similar mechanical properties and higher CTE than Cf/C composites. In this work, carbon nanotube reinforced pyrocarbon (Ct/C) nanocomposites with high CTEs were prepared to self-adapt to the TBCs. Different CTEs (～4.0–6.5 × 10^?6/°C) were obtained by varying the carbon nanotube (CNT) content of the Ct/C composites. Owing to the decreased mismatch in the CTEs, no cracks were formed in the TBCs (SiC and HfB₂-SiC-HfC coatings) deposited on the Ct/C composites. After heat treatment at 2100 °C, several wide cracks were found in the TBCs on the Cf/C composite, whereas the TBCs on the Ct/C composites were intact without cracks. We found that the CTE-tunable Ct/C composites can self-adapt to different TBCs, protecting the composites from oxidation at high temperatures.     

Aluminum diboride synthesis from elemental powders by mechanical alloying and annealing

In this study, AlB₂ powders were synthesized by using a combined method of mechanical alloying (MA) and annealing of elemental aluminum (Al) and boron (B) powders. Milling was performed in a planetary ball-mill (Fritsch? Pulverisette 7 Premium Line) up to 15 h under argon (Ar) atmosphere. Annealing process was carried out in a tube furnace at 650 °C for 6 h under Ar atmosphere. The effects of MA durations on the annealing process and AlB₂ formation were investigated. The conversion of Al and B powders to AlB₂ starts after only MA for 3 h or after MA for 1 h and subsequent annealing. A slight formation of AlB₁₂ occurs at 242 °C for as-blended powders and it shifts to about 272 °C for MA’d powders. Al–B powder blends MA’d for 9 h and annealed have AlB₂ particles in size between 35 and 75 nm in the presence of Al₁₃Fe₄, Fe₃B and Fe₂B contaminations.     

Characteristics of BaNd2Ti5O14 powders directly prepared by high-temperature spray pyrolysis

BaNd₂Ti₅O₁₄ powders were directly prepared by high-temperature spray pyrolysis. The powders prepared at temperatures of 1300 and 1500 °C exhibited a pure BaNd₂Ti₅O₁₄ phase. The powders prepared at 1300 °C were spherical in shape. However, the powders prepared at 1500 °C showed non-spherical shapes. The BaNd₂Ti₅O₁₄ powders had a composition similar to that of the spray solution. The mean sizes of the BaNd₂Ti₅O₁₄ powders increased from 0.23 to 0.60 μm when the concentration of the spray solution was increased from 0.01 to 0.2 M. At a sintering temperature of 1100 °C, bridge-like structures were formed between the powders. Pellets sintered at 1300 °C exhibited a dense structure comprising rod-like crystals.     

Preparation of mullite ceramics with equiaxial grains from powders synthesized by the sol-gel method

Four different alumina content of mullite ceramics were fabricated by powders synthesized using the sol-gel method. The synthesis process of powders, microstructure evolution, mechanical and optical properties of the mullite ceramics were studied. The XRD results showed that the precursors transformed into aluminosilicate spinel phase at 1000 °C and mullite phase at 1200 °C. Equiaxial grains were easy to form in the alumina-rich mullite ceramics while elongated grains were easy to form in the alumina-poor mullite ceramics. With the increase of alumina content, the grain size of the samples firstly increased and then decreased, the number of elongated grains decreased while equiaxed grains increased. The flexural strength, compression strength, fracture toughness, and Vickers hardness all decreased firstly and then increased. While the infrared transmittance increased firstly and then decreased. The transmittance at 4 μm (thickness of 0.75 mm) of the ceramics containing 66mol% Al₂O₃ reached the highest (72%) when sintered at 1780 °C because of the equiaxial grains.     

Low‐Temperature Sintering of β‐Spodumene Ceramics Using Li2O–GeO2 as a Sintering Additive

Low‐temperature sintering of β‐spodumene ceramics with low coefficient of thermal expansion (CTE) was attained using Li₂O–GeO₂ sintering additive. Single‐phase β‐spodumene ceramics could be synthesized by heat treatment at 1000°C using highly pure and fine amorphous silica, α‐alumina, and lithium carbonate powders mixture via the solid‐state reaction route. The mixture was calcined at 950°C, finely pulverized, compacted, and finally sintered with or without the sintering additive at 800°C–1400°C for 2 h. The relative density reached 98% for the sample sintered with 3 mass% Li₂O–GeO₂ additive at 1000°C. Its Young's modulus was 167 GPa and flexural strength was 115 MPa. Its CTE (from R.T. to 800°C) was 0.7 × 10^?6 K^?1 and dielectric constant was 6.8 with loss tangent of 0.9% at 5 MHz. These properties were excellent or comparative compared with those previously reported for the samples sintered at around 1300°C–1400°C via melt‐quenching routes. As a result, β‐spodumene ceramics with single phase and sufficient properties were obtained at about 300°C lower sintering temperature by adding Li₂O–GeO₂ sintering additive via the conventional solid‐state reaction route. These results suggest that β‐spodumene ceramics sintered with Li₂O–GeO₂ sintering additive has a potential use as LTCC for multichip modules.     

Thermodynamic calculation and microstructure characterization of spinel formation in MgO–Al2O3–C refractories

In this paper, by simulating the gas phase conditions inside the MgO–Al₂O₃–C refractories during continuous casting process and combining with thermodynamic analysis, as well as SEM analysis, the gas-gas and gas-solid formation of MA spinel were clarified in carbon containing refractories. Thermodynamic calculations showed that gas partial pressure of CO, O₂ and Mg could meet the formation and stable existence conditions of MA spinel in MgO–Al₂O₃–C refractories under service environment, and nitrogen could not affect the formation of MA spinel at 1550 °C in the thermodynamic condition. The formation processes of MA spinel were analyzed experimentally under embedding carbon atmosphere. The carbon-coated alumina powders in MgO–Al₂O₃–C refractories prevented the direct contact between magnesia and alumina. Mg gas was formed by carbon thermal reaction, then reacted with alumina (gas-solid) and gas containing aluminum (gas-gas) to generate MA spinel. Through gas-gas or gas-solid reaction, the formation of MA spinel was effectively controlled. By means of SEM analysis, a two-layer structure with dense outer spinel layer and loose inner layer was formed in MgO–Al₂O₃–C refractories.     

Preparation of Co3O4/ZrO2(Y2O3) Catalyst and its Enhanced Catalytic Oxidation of CO

Yttria-stabilized zirconia powders were prepared by the sol–gel method coupled with supercritical CO₂ fluid-drying technology, using ZrOCl₂·8H₂O as the precursor, urea as the precipitant, and yttria as the stabilizer. The particles were characterized by X-ray diffraction, TEM and BET. The Co₃O₄/ZrO₂(Y₂O₃) catalysts were prepared by the impregnation method. The content of cobalt was varied from 5 to 12 wt%. The prepared catalysts were calcined at 200–500 °C and the pretreating temperature was varied from 200–400 °C. The performance of CO catalytic oxidation was tested and the catalyst with 8% Co loading, calcined at 200 °C, and with a pretreating temperature of 300 °C, showed the highest catalytic activity. The temperature for 95% CO conversion was as low as 113 °C; and, the catalyst showed both good cycling stability and excellent long-term stability.     

Preparation of Phase‐Pure K0.5Na0.5NbO3 Fine Powders by a Solid‐State Reaction at 625°C from a Precursor Comprising Nb2O5 and K,Na Acetates

Phase‐pure K_0.5Na_0.5NbO₃ (KNN) fine powders were synthesized via a solid‐state route from a homogeneous solid mixture. A colloidal dispersion comprising a mixed ethanol solution of potassium and sodium acetates and Nb₂O₅ fine particles was attrition milled and dried carefully to avoid water absorption. Two‐step calcination in air at 450°C and 625°C, each for 3 h, resulted in the phase‐pure KNN powders. The volume‐based median diameter of the final product was ca. 0.8 μm. Starting from the same precursors without dissolving the acetates, the phase‐pure KNN was never achieved even when the two calcination temperatures were increased to 550°C and 700°C, in spite of the same milling conditions. Key issues of eliminating second phases were (i) starting from a wet‐milled mixture with a single solution containing both of the A‐site species, and (ii) repeated wet milling of the reaction mixture to disintegrate reaction‐induced agglomerates. These enabled rapid nuclei growth from chemically interacted precursor prior to calcination, and short diffusion path due to repeated deagglomeration, excluding formation of off‐stoichiometric second phases. All these items were confirmed by different analytical tools, among others, thermo‐gravimetry and differential thermal analysis (TG‐DTA), particle size analyses, and XPS at various reaction stages. On the heating stage microscope, a shrinkage onset was observed at 850°C, that is, 150 K lower than that of conventionally prepared KNN, that is, via a solid‐state synthesis from carbonates by a two‐step calcination at 800°C and 750°C, for 4 h each. No second phase was observed after sintering up to 1100°C.