Mechanical-Activation-Triggered Gibbsite-to-Boehmite Transition and Activation-Derived Alumina Powders

Mechanical activation of monoclinic gibbsite (Al(OH)₃) in nitrogen led to the formation of nanocrystalline orthorhombic boehmite (AlOOH) at room temperature. The boehmite phase formed after merely 3 h of mechanical activation and developed steadily as the mechanical-activation time increased. Forty hours of mechanical activation resulted in essentially single-phase boehmite, together with α-alumina (α-Al₂O₃) nanocrystallites 2–3 nm in size. The sequence of phase transitions in the activation-derived boehmite was as follows: boehmite to γ-Al₂O₃ and then to α-Al₂O₃ when flash-calcined at a heating rate of 10°C/min in air. γ-Al₂O₃ formed at 520°C, and flash calcination to 1100°C led to the formation of an α-Al₂O₃ phase, which exhibited a refined particle size in the range of 100–200 nm. In contrast, the gibbsite-to-boehmite transition in the unactivated gibbsite occurred over the temperature range of 220°–330°C. A flash-calcination temperature of 1400°C was required to complete the conversion to α-Al₂O₃ phase, with both δ-Al₂O₃ and θ-Al₂O₃ as the transitional phases. The resulting alumina powder consisted of irregularly shaped particles 0.4–0.8 μm in size, together with an extensive degree of particle agglomeration.     

New Sol–Gel Route for the Preparation of Pure α-Alumina at 950°C

An anhydrous alumina (Al₂O₃) sol was prepared from aluminum isopropoxide and an organic solvent, using an acetic acid stabilizer. The complete conversion of the dried sol to α-Al₂O₃ was accomplished at a temperature of 950°C by a single transition via γ-Al₂O₃. Al₂O₃ that was deposited via dip coating resulted in amorphous films, even after annealing at 1100°C, because of the silicon diffusion from the substrate. This phenomenon was avoided using a rapid thermal treatment in a flame after dip coating, which resulted in uniform thin films that are converted to α-Al₂O₃ via heat treatment.     

Growth of Single-Crystal and Polycrystalline Thin Films of MgAl2O4 and MgFe2O4

Single-crystal and polycrystalline films of Mg-Al₂O₄ and MgFe₂O₄ were formed by two methods on cleavage surfaces of MgO single crystals. In one procedure, aluminum was deposited on MgO by vacuum evaporation. Subsequent heating in air at about 510°C formed a polycrystalline γ-Al₂O₈ film. Above 540°C, the γ-Al₂O, and MgO reacted to form a single-crystal MgAl₂O₄ film with {001} MgAl₂O₄‖{001} MgO. Above 590°C, an additional layer of MgAl₂O₄, which is polycrystalline, formed between the γ-Al₂O₃ and the single-crystal spinel. Polycrystalline Mg-Al₂O₄ formed only when diffusion of Mg²⁺ ions proceeded into the polycrystalline γ-Al₂O₃ region. Corresponding results were obtained for Mg-Fe₂O₄. MgAl₂O₄ films were also formed on cleaved MgO single-crystal substrates by direct evaporation, using an Al₂O₃ crucible as a source. Very slow deposition rates were used with source temperatures of ∼1350°C and substrate temperatures of ∼800°C. Departures from single-crystal character in the films may arise through temperature gradients in the substrate.     

Synthesis of Magnesium Aluminate Spinel Platelets from α-Alumina Platelet and Magnesium Sulfate Precursors

Spinel platelets were formed from a powder mixture of 3–5 μm wide and 0.2–0.5 μm thick α-Al₂O₃ and 1–8 μm (average 3 μm) MgSO₄ heated 2 h at 1200°C. The hexagonal platelet shape of the original α-Al₂O₃ platelet was maintained in the spinel, although their size was slightly increased and their surface roughened. When a mixture of α-Al₂O₃ platelets and MgO powder was heated 3 h at 1400°C, the spinel formed lost the platelet morphology of the alumina.     

Microwave-Hydrothermal Synthesis of Monodispersed Nanophase α-Fe2O3

Synthesis of monodispersed nanophase α-Fe₂O₃ (hematite) powder to be used as a red pigment in porcelains was investigated using microwave-hydrothermal and conventional-hydrothermal reactions using 0.018 M FeCl₃·6H₂O and 0.01 M HCl solutions at 100°–160°C. Acicular and yellow β-FeOOH (akaganite) particles 300 nm in length and 40 nm in thickness were dominantly formed at 100°C after 2–3 h, while spherical α-Fe₂O₃ particles 100–180 nm in diameter were preferentially formed after 13 h using a conventional-hydrothermal reaction. However, a microwave-hydrothermal reaction at 100°C led to monodispersed and red α-Fe₂O₃ particles 30–66 nm in diameter after 2 h without the formation of β-FeOOH particles. In this paper, the effect of microwave radiation during hydrothermal treatment at 100°–160°C on the formation yield, kinetics, morphology, phase type, and color of α-Fe₂O₃ was investigated.     

Reaction-Bonded Mullite/Zirconia Composites

The feasibility of fabricating dense, low-shrinkage, mullite/ ZrO₂ composites based on the reaction bonding of alumina (RBAO) process and the reaction sintering of zircon is examined. Compacts pressed from an attrition-milled powder mixture of Al, A1₂O₃ and zircon were heated in air according to a two-step heating cycle. The phase evolution and microstructural development during reaction bonding were traced by X-ray diffraction, nuclear magnetic resonance, and scanning electron microscopy on samples extracted from various points along the heating cycle. It is seen that, as in conventional RBAO, AI oxidizes to γ-Al₂O₃ which then transforms to α-AI₂O₃ between 1100° and 1200°C. The zircon dissociation commences at ∼1400°C and is practically complete by 1500°C. Mullite enriched in Al₂O₃ forms initially, but 3:2 stoichiometry is attained in the final product which consists of mullite, t - and m-ZrO₂, and residual α-AI₂O₃. The flexure strength of the composite is superior to that of pure mullite, and ∼80% of the strength is retained up to 1200°C. Although there was no toughness enhancement relative to mullite, this should be achievable by optimizing the fabrication procedure.     

Synthesis and Electrical Properties of Stabilized Manganese Dioxide (α-MnO2) Thin-Film Electrodes

Manganese dioxide (α-MnO₂) thin films have been explored as a cathode material for reliable glass capacitors. Conducting α-MnO₂ thin films were deposited on a borosilicate glass substrate by a chemical solution deposition technique. High carbon activities originated from manganese acetate precursor, (Mn(C₂H₃O₂)₂·4H₂O) and acetic acid solvent (C₂H₄O₂), which substantially reduced MnO₂ phase stability, and resulted in Mn₂O₃ formation at pyrolysis temperature in air. The α-MnO₂ structure was stabilized by Ba²⁺ insertion into a (2 × 2) oxygen tunnel frame to form a hollandite structure. With 15–20 mol% Ba addition, a conducting α-MnO₂ thin film was obtained after annealing at 600–650°C, exhibiting low electrical resistivity (∼1 Ω·cm), which enables application as a cathode material for capacitors. The hollandite α-MnO₂ phase was stable at 850°C, and thermally reduced to the insulating bixbyte (Mn₂O₃) phase after annealing at 900°C. The phase transition temperature of Ba containing α-MnO₂ was substantially higher than the reported transition temperature for pure MnO₂ (∼500°C).     

Analytical Electron Microscope Analysis of the Formation of BaO · 6Al2O3

The formation process of barium hexaaluminate (BaO 6Al₂O₃) from BaCO₃/γ-Al₂O₃ powders or hydrolyzed alkoxides was studied by analytical electron microscopy. Barium hexaaluminate is produced by a two-step solid-state reaction from BaCO₃ and Al₂O₃ via formation of BaO·Al₂O₃. Marked grain growth and inclusion of nonequilibrium phase were inevitable in this powder mixture process. However, in an alkoxide-derived precursor, homogeneous mixing of components is attained and hence the formation of BaO·6Al₂O₃ proceeds readily. Powders obtained by this latter route consisted of fine planar particles with a uniform size and retained a large surface area (20.2 m²/g) even after heating at 1300°C. Electron diffraction results implied that suppression of crystal growth along the c axis is the reason for the large surface area of BaO·6Al₂O₃.     

Phase Transformation of Diphasic Aluminosilicate Gels

Aluminosilicate gels with compositions Al₂O₂/SiO₂ and 2 were prepared by gelling a mixture of colloidal pseudo-boehmite and a silica sol prepared from acid-hydrolyzed Si(OC₂H₅)₄. Upon heating the pseudo-boehmite transforms to γ-Al₂O₃ around 400°C, then to δ-Al₂O₃ at 1050°C, and at 1200°C reacts with amorphous SiO₂ to form mullite. Some twinned θ-Al₂O₃ forms before mullite. Nonstoichiometric specimens have a similar transformation sequence, but form mullite grains with inclusions of either Al₂O₃ or cristobalite, often associated with dislocation networks or micropores. Mullite grains are formed by nucleation and growth and have equiaxed shape.     

Synthesis of Zinc Aluminate Spinel Film through the Solid-Phase Reaction between Zinc Oxide Film and α-Alumina Substrate

We synthesized spinel ZnAl₂O₄ film on α-Al₂O₃ substrate using a solid-phase reaction between the pulsed-laser-deposited ZnO film and α-Al₂O₃ substrate. Auger electron spectroscopy showed that the atomic distribution in the spinel ZnAl₂O₄ was inhomogeneous, which indicated that the reaction was diffusion controlled. Based on X-ray fluorescence measurements, the apparent growth activation energy of ZnAl₂O₄ was determined as 504 kJ/mol. X-ray diffractometry spectra showed that, as the growth temperature increased, the ZnAl₂O₄ film became disoriented from the single (111) orientation. The ZnAl₂O₄ (333) diffraction peak shifted toward a small angle, and its full-width at half-maximum decreased from 1.30° to 0.37°. At the growth temperature of 1100°C, the morphology of the ZnAl₂O₄ was initially transformed from islands to stick structures, then to bulgy-line structures with increased growth time. X-ray diffractometry spectra showed that these transformations were correlated with changes of ZnAl₂O₄ orientation.     

Synthesis and Processing of Barium Hexaaluminogallates

Barium hexaaluminogallate was synthesized by the mixed-oxide method and the coprecipitation method. Barium hexaaluminate and barium hexagallate were found to form barium hexaaluminogallate, Ba(Al,Ga)₁₂O₁₉, at 1400°C. BaCo(Al,Ga)₁₁O₁₉ of magnetoplumbite structure was formed from a mixture of metal oxides at 1200°C for 6 h. Co was successfully introduced to barium hexaaluminogallate, although the synthesis of BaCoAl₁₁O₁₉ is quite difficult via solid-state reaction of oxide powders. Anisotropic BaCo(Al,Ga)₁₁O₁₉ particles crystallized at 1100°C for 2 h through the coprecipitation method using metal nitrates and ammonium carbonate. BaCo(Al,Ga)₁₁O₁₉ supported on a cordierite honeycomb had the ability to reduce NO _x with methane over 500°C in the presence of excess oxygen.     

Preparation of Larnthanum β-Alumina with High Surface Area by Coprecipitation

Mixtures of La₂O₃ and Al₂O₃ with various La contents were prepared by co-precipitation from La(NO₃)₃ and Al(NO₃)₃ solutions and calcined at 800° to 1400°C. The addition of small amounts of La₂O₃ (2 to 10 mol%) to Al₂O₃ gives rise to the formation of lanthanum β-alumina (La 2 O₃·11–14Al₂O₃) upon heating to above 1000°C and retards the transformation of γ-Al₂O₃ to α-Al₂O₃ and associated sintering.     

Sol-Gel Process for the Preparation of Ba2Ti9O20 and BaTi5O11

Barium titanate precursors with Ba/Ti ratio 2:9 and 1:5 were prepared by first hydrolyzing titanium alkoxide and then mixing the resulting titania sol with a barium alkoxide-methanol solution. After drying, the xerogels of the precursors of barium titanates were sintered at temperatures from 700°C (4 h) to 1200°C (110 h or longer). Characterization of the product was performed using X-ray diffraction and laser Raman spectroscopy. At 700°C, BaTi₅O₁₁ was formed from the 1:5 precursor and a two-phase mixture of BaTi₂O₅ and BaTi₅O₁₁ was formed from the 2:9 precursor. After prolonged heating at 1200°C, the latter mixture converted to a single-phase material, Ba₂Ti₉O₂₀.     

High-Temperature Transmission Electron Microscopy and X-Ray Powder Diffraction Studies of Polymorphic Phase Transitions in Ba4Nb2O9

Polymorphic phase transitions in Ba₄Nb₂O₉ were studied by thermal analyses, high-temperature transmission electron microscopy and X-ray powder diffractometry. Two stable polymorphs were isolated, low-temperature α-modification and high-temperature γ-modification, with the endothermic phase transition at 1176°C. The α→γ transformation is accompanied by the formation of a 120° domain structure, which is a consequence of hexagonal→orthorhombic unit cell reconstruction. Reheating the presintered γ-Ba₄Nb₂O₉ results in the formation of a metastable γ'-modification (formerly known as β-polymorph) in the temperature range between 360° and 585°C, before the γ→α transformation at 800°C. Above ∼490°C Ba₄Nb₂O₉ becomes moderately sensitive to a loss of BaO. In air the surface of Ba₄Nb₂O₉ grains decomposes to nanocrystalline Ba₅Nb₄O₁₅ and BaO, which instantly reacts with atmospheric CO₂ to form BaCO₃. Surface reaction delays γ→α transformation up to 866°C in air. In vacuum the loss of BaO is even more enhanced and consequently the formation of minor Ba₃Nb₂O₈ phase is observed above 1150°C.     

High-Temperature Stability of Lanthanum Orthophosphate (Monazite) on Silicon Carbide at Low Oxygen Partial Pressures

The stability of lanthanum orthophosphate (LaPO₄) on SiC was investigated using a LaPO₄-coated SiC fiber at 1200°–1400°C at low oxygen partial pressures. A critical oxygen partial pressure exists below which LaPO₄ is reduced in the presence of SiC and reacts to form La₂O₃ or La₂Si₂O₇ and SiO₂ as the solid reaction products. The critical oxygen partial pressure increases from ∼0.5 Pa at 1200°C to ∼50 Pa at 1400°C. Above the critical oxygen partial pressure, a thin SiO₂ film, which acts as a reaction barrier, exists between the SiC fiber and the LaPO₄ coating. Continuous LaPO₄ coatings and high strengths were obtained for coated fibers that were heated at or below 1300°C and just above the critical oxygen partial pressure for each temperature. At temperatures above 1300°C, the thin LaPO₄ coating becomes morphologically unstable due to free-energy minimization as the grain size reaches the coating thickness, which allows the SiO₂ oxidation product to penetrate the coating.     

Synthesis of α-Alumina Hexagonal Platelets Using a Mixture of Boehmite and Potassium Sulfate

Single-crystal α-alumina (Al₂O₃) hexagonal platelets with a diameter of about 200 nm and 25 nm in thickness were synthesized by heating a mixture of boehmite and potassium sulfate at 1000°C for 2 h and washing with water. The potassium sulfate addition effects on the Al₂O₃ phase and morphology were investigated using differential thermal analysis (DTA), X-ray diffraction (XRD), and transmission electron microscopy (TEM). It was found that potassium sulfate addition helps in the formation of single-crystal α-Al₂O₃ hexagonal platelets and promotes phase transformation from intermediate γ-Al₂O₃ to α-Al₂O₃.     

Sol–Gel Preparation of BaTi4O9 and Ba2Ti9O20

BaTi₄O₉ and Ba₂Ti₉O₂₀ precursors were prepared via a sol–gel method, using ethylenediaminetetraacetic acid as a chelating agent. The sol–gel precursors were heated at 700°–1200°C in air, and X-ray diffractometry (XRD) was used to determine the phase transformations as a function of temperature. Single-phase BaTi₄O₉ could not be obtained, even after heating the precursors at 1200°C for 2 h, whereas single-phase Ba₂Ti₉O₂₀ (as determined via XRD) was obtained at 1200°C for 2 h. Details of the synthesis and characterization of the resultant products have been given.     

Chemical Vapor Deposition of Polycrystalline Al2O3

Polycrystalline Al₂O₃ was chemically vapor-deposited onto sintered Al₂O₃ substrates by reaction of AlCl₃ with (1) H₂O, (2) CO:H₂, and (3) O₂ at 1000° and 1500°C and 0.5 and 5.0 torr. Although the thermodynamics of all these reactions predict the formation of solid Al₂O₃, the deposition rate of the first reaction was considerably greater than that of the second. The third reaction was so slow that no measurable deposit was formed in 6 h at 1500°C. Formation of dense deposits of α-Al₂O₃ was favored by increasing temperature and decreasing pressure. Microstructural examination of the dense deposits showed long columnar grains, the largest of which extended through the deposit from the substrate to the surface.     

Transformation, Microstructure Development, and Densification in α-Fe2O3-Seeded Boehmite-Derived Alumina

Addition of α-Fe₂O₃ seed particles to alkoxide-derived boehmite sols resulted in a 10-fold increase in isothermal rate constants for the transformation of γ- to α-Al₂O₃. Changes in porosity and surface area with sintering temperature showed no effect of seeding on coarsening of the transition alumina gels, but the 200-fold decrease in surface area associated with transformation to α-Al₂O₃ occurred ∼ 100°C lower in seeded gels compared with unseeded materials. As a result of high nucleation frequency and reduced microstructure coarsening, fully transformed seeded alumina retained specific surface areas >22 m²/g and exhibited narrow pore size distributions, permitting development of fully dense, submicrometer α-Al₂O₃ at ∼ 1200°C.     

Synthesis of Celsian (BaAl2Si2O8) from Solid Ba-Al-Al2O3-SiO2 Precursors: I, XRD and SEM/EDX Analyses of Phase Evolution

An intimate Ba-Al-Al₂O₃-SiO₂ powder mixture, produced by high-energy milling, was pressed to 3 mm thick cylinders (10 mm diameter) and hexagonal plates (6 mm edge-to-edge width). Heat treatments conducted from 300° to 1650°C in pure oxygen or air were used to transform these solid-metal/oxide precursors into BaAl₂Si₂O₈. Barium oxidation was completed, and a binary silicate compound, Ba₂SiO₄, had formed within 24 h at 300°C. After 72 h at 650°C, aluminum oxidation was completed, and an appreciable amount of BaAl₂O₄ had formed. Diffraction peaks consistent with hexagonal BaAl₂Si₂O₈, BaAl₂O₄, β-BaSiO₃, and possibly β-BaSi₂O₅ were detected after 24 h at 900°C. Diffraction peaks for BaAl₂O₄ and BaAl₂Si₂O₈ were observed after 35 h at 1200°C, although SEM analyses also revealed fine silicate particles. Further reaction of this silicate with BaAl₂O₄ at 1350° to 1650°C yielded a mixture of hexagonal and monoclinic BaAl₂Si₂O₈. The observed reaction path was compared to prior work with other inorganic precursors to BaAl₂Si₂O₈.