Potential use of Kraft pulp mill and flat glass cutting wastes in red ceramic products

This study assessed the incorporation of green liquor dregs, an inorganic solid waste from Kraft pulp mill, and flat glass cutting waste (FGCW) into red ceramic formulations. Since in Brazil sanitary landfills are still the main destination of industrial wastes such as those used in this research, a survey was conducted to identify the number of landfills in the region of origin of each waste and the amount of waste that could have this destination avoided. The effects of firing temperature and simultaneous incorporation of both industrial wastes were analyzed to optimize heat treatment and waste content in the formulation to manufacture red ceramic products. The influence of green liquor dregs and FGCW incorporation into clayey mass was evaluated varying waste content between 0 and 50 wt%. The specimens were prepared by uniaxial pressing, fired at 850 and 950 °C, and had their physical-mechanical properties and mineralogical and microstructural characteristics analyzed. The best results were obtained for the formulation with 10 wt% green liquor dregs and 30 wt% FGCW fired at 950 °C. This result highlights the potential of using green liquor dregs, a waste difficult to be recycled due to its chemical composition, associated with FGCW, which acts as a fluxing agent in ceramic formulations.     

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.     

Thermomechanical characterisation of coal tar pitch- based carbon containing SiC nanoparticles

Coal tar pitch (CTP) modified with silicon carbide nanoparticles (nSiC) was used as a carbon binder precursor for the manufacture of carbon materials. Carbon samples were prepared in the form of a composition consisting of synthetic coke, graphite and nSiC- modified CTP prior to heat treatment at temperatures from 800 °C to 2800 °C. The effect of ceramic nanofiller in CTP on oxidation resistance of carbon samples obtained at various temperatures was studied. Physical and mechanical properties of carbon samples obtained at 2000 °C and 2800 °C were analysed. nSiC presence in CTP was found to change the elevated temperature properties of carbon samples. The oxidation tests conducted at 600 °C in air showed a significant improvement of the resistance of carbon samples modified with small amount of nSiC and annealed at 2000 °C. Properties investigated included characteristics important for application of carbon materials for carbon electrode manufacturing, i.e., electrical and thermal conductivities as well as mechanical properties. Due to microstructural changes of carbon samples in the presence of nSiC filler physical and mechanical properties improved after annealing the samples at high temperature in comparison to unmodified carbon samples.     

Synthesis and characterization of calcium silicate insulating material using avian eggshell waste

This work focuses on the synthesis of calcium silicate insulating material via solid state reaction using avian eggshell waste as alternative calcium source. The calcium silicate formulations were mixed in a molar ratio SiO₂:CaO (1:1) and fired at 1100 °C for 24 h. The calcium silicate formulations were characterized by XRD, TG-DTA, dilatometry, SEM/EDS, and thermophysical properties (thermal diffusivity, heat capacity per unit volume, and thermal conductivity). The synthesized calcium silicate materials are composed mainly of wollastonite with minor amounts of larnite and rankinite. It was found that a processing of the avian eggshell waste (raw eggshell waste and calcined eggshell waste) had an influence on the thermophysical properties. Calcium silicate pieces were prepared by uniaxial pressing at 82 MPa, curing, and then testing to determine their use as thermal insulating material. The microstructure was evaluated by SEM. The results showed that both raw and calcined avian eggshell wastes could be used as an alternative calcium source in the calcium silicate formulation. It was found that the calcium silicate pieces reached low thermal conductivity values (0.252–0.293 W/mK). Thus, the developed calcium silicate materials using avian eggshell waste act as a good thermal insulation ceramic material.     

Eggshell derived mesoporous biphasic calcium phosphate for biomedical applications using rapid thermal processing

Biphasic calcium phosphate (BCP) has received much interest for making various bone substitutes since its physicochemical properties can be easily tailored by tuning its phase composition. Due to high temperature processing, it is hard to prepare BCP with nanoscale characteristics. In the present study, we have made an attempt to optimize the heat treatment parameters for the synthesis of BCP with nanoscale characteristics from eggshell derived hydroxyapatite (HA) through rapid thermal processing (RTP). To accomplish this, eggshell derived HA was prepared by wet precipitation method and subjected to RTP at 750°C and 1150°C for 3 and 10 minutes. For comparison we have also studied conventional calcination at 750°C and 1150°C for 3 hours. XRD, FTIR, SEM, EDX, HRTEM, and BET analyses were used to understand the effect of RTP and conventional calcination on eggshell derived HA. Our results indicate that eggshell derived HA on RTP at 1150°C for 3 minutes and 10 minutes can offer nanoscale BCP with good dissolution, bioactivity, cytocompatibility, and mesoporous nature. Hence, RTP can be a potential method to prepare BCP with nanoscale features for biomedical applications.     

Continuous aluminum oxide-mullite-hafnium oxide composite ceramic fibers with high strength and thermal stability by melt-spinning from polymer precursor

Continuous aluminum oxide-mullite-hafnium oxide (AMH) composite ceramic fibers were obtained by melt-spinning and calcination from polymer precursor that synthesized by hydrolysis of the aluminum isopropoxide, dimethoxydimethylsilane and hafnium alkoxide. Due to the fine diameter of 8–9 µm, small grain size of less than 50 nm and the composite crystal texture, the highest tensile strength of AMH ceramic fibers was 2.01 GPa. And the AMH ceramic fibers presented good thermal stability. The tensile strength retention was 75.48% and 71.49% after heat treatment at 1100 °C and 1200 °C for 0.5 h respectively, and was 61.57% after heat treatment at 1100 °C for 5 h. And the grain size of AMH ceramic fibers after heat treatment was much smaller than that of commercial alumina fibers even when the heat treatment temperature was elevated to 1500 °C, benefited by the grain size inhibition of monoclinic-HfO₂ (m-HfO₂) grains distributed on the boundary of alumina and mullite grains.     

B2O3-modified geopolymer and its liquid-phase sintered products for immobilization of strontium

Sr-containing ceramic products produced from geopolymer, (Na, Sr)-GP, have been reported as excellent candidate materials for the immobilization of radionuclide 90Sr, despite sintering temperature at 1200°C. In this work, the product possessing the best immobilization performance (leaching rate of 1.29% for Sr²⁺) can be produced at 1000°C in the method of liquid-phase sintering via the addition of fluxing agent B₂O₃ at 2.0 wt% in the geopolymer precursor. The mechanical properties of the geopolymer precursor (Na, Sr)-GP were also enhanced via the promotion role of B₂O₃ to geopolymerization. It was revealed that the overall anti-leaching ability of the Sr-containing ceramic product not only depends on the microstructure of the loading substrate but also can be affected by the chemical state of radioactive strontium retention in the loading matrix.     

Properties of sintered zinc hydroxyapatite bioceramic prepared using waste chicken eggshells as calcium precursor

In the recent years, research on the development of hydroxyapatite (HA) using calcium from natural resources such as limestone, mammalian bones, marine shells and avian eggshells have been extensively studied. However, many studies focused on the properties of prestine HA without incorporation of dopants for strengthening effect. In this work, HA bioceramic was prepared using waste chicken eggshells calcium with addition of various concentrations of zinc dopant (1, 3 and 5 mol% Zn). In this work, the zinc-doped HA (ZnHA) was synthesized using a wet-chemical precipitation technique followed by oven drying and unixial pressing to formed green compacts. Pressureless sintering was carried out at 1200, 1250 and 1300 °C. The results showed that 5 mol% ZnHA (5ZnHA) exhibited the overall best properties after sintering at 1250 °C. The improvement in the fracture toughness was attributed to the formation of β-TCP phase when zinc ion was incorporated into HA, combined with enhanced densification. It was observed that the HA grains were coarser and more densely when sintered at 1250 °C, indicating that there was strong interaction between pores and grain boundaries. However, fracture toughness slightly declined after sintering at 1300 °C due to rapid and abnormal HA grain growth.     

Calcium phosphate bioceramics synthesized from eggshell powders through a solid state reaction

Everyday millions of tons of eggshells are produced as biowaste around the world. Most of this waste is disposed of in landfills without any pretreatment. Eggshells in landfills produce odors and promote microbial growth as they biodegrade. The present invention provides an environmentally beneficial and cost-effective method of producing calcium phosphate bioceramics (hydroxyapatite or tricalcium phosphate) from eggshell waste. In this investigation, heat treatment produced solid state reactions between eggshell powders and dicalcium phosphate dihydrate (CaHPO₄·2H₂O, DCPD) or calcium pyrophosphate (Ca₂P₂O₇). When eggshell powders (CaO) and DCPD were heat treated at 1150 °C for 3 h, only a single hydroxyapatite (HA) phase was found; no diffraction peaks of starting materials and no β-TCP were observed. The XRD patterns of the product fabricated from raw eggshell powders (CaCO₃) and Ca₂P₂O₇ heat treated at 1100 °C for 3 h showed that almost only pure β-TCP remained with a trace amount of HA. The calcium phosphate ceramic synthesized from eggshell powders contains several important trace elements such as Na, Mg and Sr.     

Compressive strength and microstructure of alkali-activated mortars with high ceramic waste content

The present work investigated alkali-activated mortars with high ceramic waste contents. Tile ceramic waste (TCW) was used as both a recycled aggregate (TCWA) and a precursor (TCWP) to obtain a binding matrix by the alkali-activation process. Mortars with natural siliceous (quartz) and calcareous (limestone) aggregates, and with other ceramic waste materials (red clay brick RCB and ceramic sanitaryware CSW waste), were also prepared for comparison purposes. Given the lower density and higher water absorption values of the ceramic aggregates, compared to the natural ones, it was necessary to adapt the preparation process of the recycled mortars by presaturating the aggregate with water before mixing with the TCWP alkali-activated paste. Aggregate type considerably determined the mechanical behaviour of the samples cured at 65 °C for 3 days. The mortars prepared with the siliceous aggregate presented poor mechanical properties, even when cured at 65 °C. The behaviour of the limestone aggregate mortars depended heavily on the applied curing temperature and, although they presented the best mechanical properties of all those cured at room temperature, their compressive strength reached a maximum when cured at 65 °C, and then decreased. The mechanical properties of the mortars prepared with TCWA progressively increased with curing time (53 MPa at 65 °C for 28 days). An optimum 50 wt% proportion was observed for the limestone/TCWA mortars (≈43 MPa, 3 days at 65 °C), whereas the mechanical properties of that prepared with siliceous particles (10 MPa) progressively increased with the TCWA content, up to 100 wt% substitution (23 MPa). Limestone particles interacted with the binding matrix, and played an interesting beneficial role at the 20 °C curing temperature, with a slight reduction when cured long term (28 days) at 65 °C. The results demonstrated a potential added value for these ceramic waste materials.     

Recycling and Utilization of some Waste Clays for Production of Sintered Ceramic Bodies

The recycling of industrial waste clays for production of an interesting ceramic product is the main goal of the present research work. Ceramic bodies were prepared using Feeders or Cyclons waste clays, sand and feldspar. 0.0, 15, 20, and 25 wt.% of sand were added at the expanse of kaolin (75-50 wt.%). Constant mass percent (25 wt.%) of feldspar was added for all ceramic compositions. The designed batches were sintered at 1200–1400 °C. Physical properties were determined by water displacement method. Phase composition and microstructure were investigated by x-ray diffraction and scanning electron microscope, respectively. The compressive strength was also determined. The results indicated that the ceramic bodies prepared from Cyclons’ waste clay exhibited higher physical and mechanical properties than that prepared from Feeders’ clay after sintering at 1400 °C. The addition of sand enhances the porosity, water absorption, bulk density and mechanical strength after sintering at 1400 °C due to the formation of mullite network and glassy phases.

     

High-temperature flexural strength of SiC ceramics prepared by additive manufacturing

Silicon carbide (SiC) ceramics, as a kind of candidate material for aero-engine, its high-temperature performance is a critical factor to determine its applicability. This investigation focuses on studying the high-temperature properties of SiC ceramics fabricated by using additive manufacturing technology. In this paper, SiC ceramics were prepared by combining selective laser sintering (SLS) with precursor infiltration and pyrolysis (PIP) technique. The microstructure, phase evolution, and failure mechanism after high-temperature tests were explored. SiC ceramic samples tested at room temperature (RT), 800°C, 1200°C, 1400°C, and 1600°C demonstrated bending strengths of 220.0, 226.1, 234.9, 215.5, and 203.7 MPa, respectively. The RT strength of this material can be maintained at 1400°C, but it decreased at 1600°C. The strength retention at 1400°C and 1600°C were 98% and 92%, respectively. The results indicate that the mechanical properties of SiC ceramics prepared using this method have excellent stability. As the temperature increases, the bending strength of the specimens increased slightly and reached the peak value at 1200°C, and dropped to 203.7 MPa at 1600°C. Such an evolution could be mainly due to the crack healing, and the softening of the glassy phase.     

Processing and properties of Nextel™ 720 fiber reinforced alumina-zirconia ceramic matrix composites

The continuous Nextel? 720 fiber-reinforced zirconia/alumina ceramic matrix composites (CMCs) were prepared by slurry infiltration process and precursor infiltration pyrolysis (PIP) process. The introduction of submicron zirconia powders into the aqueous slurry was optimized to offer comprehensively good sintering activity, high thermal resistance and good mechanical properties for the CMCs. Meanwhile, the zirconia and alumina preceramic polymers were used to strengthen the porous ceramic matrix through the PIP process. The final CMC sample achieved a high flexural strength of 200 MPa after one infiltration cycle of alumina preceramic polymer and thermal treatment at 1150 °C for 2 h. The flexural strength retention of the improved CMC sample was 104% and 89% respectively after thermal exposure at 1100 °C and 1200 °C for 24 h.     

Low-temperature synthesis of tantalum carbide by facile one-pot reaction

Tantalum carbide (TaC) was synthesized by polycondensation and carbothermal reduction reactions from an inorganic hybrid. Tantalum pentachloride (TaCl₅) and phenolic resin were used as the sources of tantalum and carbon, respectively. FTIR of as-synthesized dried complexes revealed formation of Ta-O. Pyrolysis of the complexes at 800 °C/1 h under argon resulted in tantalum oxide which after heat treatment at 1000–1200 °C transformed to tantalum carbide. The mean crystallite size of the precursor-derived TaC ceramics was less than 40 nm and Ta and C elements were homogeneously distributed in the ceramic samples. Mechanism for formation of TaC ceramic was analyzed.     

Preparation and performance of ceramizable heat-resistant organic adhesive for joining Al2O3 ceramics

Ceramizable heat-resistant organic adhesive (CHA) was prepared by using preceramic polymer polysiloxane as matrix, TiB₂ ceramic powder and low melting point glass powder as additives. The curing mechanism, thermal stability properties, phase composition after pyrolysis, structural evolution of bonding layer and bonding mechanism of the adhesive were investigated by FTIR, TGA-DSC, XRD, SEM, FESEM and bonding strength tests. Results of bonding tests showed the maximum shear strength of the joints was 21 MPa when heat treatment at 1200 °C for 2 h in air. Polysiloxane resin acted as crosslinking adhesive at low temperatures and tended to convert to ceramic bonding layer at high temperatures, resulting from ceramization reaction with active fillers. The formation and growth of ceramic phase after heat treatment enhanced the thermal stability and bonding performance of the adhesive at high temperature.     

Composition,structure and mechanical properties of the titanium surface after induction heat treatment followed by modification with hydroxyapatite nanoparticles

Coatings of titania (TiO₂) and "titania–hydroxyapatite" were prepared by oxidation of commercially pure titanium VT1-00 using induction heat treatment (IHT), followed by modification with colloidal hydroxyapatite (HAp) nanoparticles. The IHT treatment was performed at temperatures within 600–1200 °C for 300 s. According to the results of scanning electron microscopy (SEM), X-ray diffraction (XRD), energy dispersive X-ray fluorescent analysis (EDX), nanoindentation and in vitro testing, titania coatings of high morphological heterogeneity, and high mechanical properties and biocompatibility were formed on the titanium surface after IHT. The coatings were found to consist of nano- and submicron crystals of oval, needle-like, plate and prismatic shapes. A subsequent modification with HAp nanoparticles of the coated titanium substrate leads to accelerated formation of mechanically strong oxidebioceramic composite coatings. It was established that the porous oxide coatings modified with nanoparticles of HAp that were formed at temperatures from 800 to 1000 °C and holding for at least 30 s had a high biocompatibility.     

Untreated coffee husk ashes used as flux in ceramic tiles

The agro-industrial activities are responsible for the production of large amounts of solid wastes, which, so far, have found scarce reuse alternatives. Among the former, coffee bean beneficiation generates an equal amount of coffee husks whose highest reuse potential is as fuel. The resulting ashes are frequently an object of illegal covert disposal and a serious source of environmental impact. However, coffee husk ashes (CHA) are particularly rich in alkaline and alkaline-earth metals, and might be adequate to replace the traditional feldspars, which are used in high content as fluxes in clay-based ceramic formulations but are becoming scarce and costly. In this work, the fluxing effect of CHA additions to an industrial clay-based mixture was evaluated. Based on the characterization results and the mullite–silica–leucite phase diagram, additions of 5 to 20 wt.% CHA were made to the clay-based mixture and the resulting compositions were evaluated after sintering at temperatures between 1100 and 1200 °C (60 min soaking time). The results obtained show that firing temperatures near 1180 °C and ~ 10 wt.% CHA addition lead to linear shrinkage, water absorption and flexural strength values that fall within the range specified by floor tile standards (NBR 13817, EN 176 and ISO 13006), requiring no significant changes in processing parameters. Coffee husk ashes can thus advantageously replace feldspars in the role of fluxing material, with the potential to reduce not only natural ceramic raw material consumption, but also production and landfill costs as well as waste disposal area requirements.     

Optical and mechanical characterization of transparent α-alumina fabricated by spark plasma sintering

The aim of this work was the analysis of the experimental results of a transparent alumina (BMA15) ceramic which was fabricated by Spark Plasma Sintering (SPS) from nanopowder (BMA15, Baikowski Chimie, France), at different temperatures (1200°C, 1250°C, 1300°C). With the application of a maximum uniaxial pressure of 73 MPa during all the fabrication-cycle (more than 3 hours). We sought an optimal sintering temperature combining better optical and mechanical properties of our pellets. The sintered alumina (BMA15) has a crystalline and dense microstructure. The samples sintered at 1200°C exhibit the best optical properties, in particular: good real inline transmission (RIT) and an optical gap greater than those of the samples sintered at 1250°C and 1300°C. Due to their low density, the Young modulus of alumina sintered at 1200 °C, deduced by ultrasound, has a low value which is about 385 GPa. Similarly, its small grain size gives it a better Vickers hardness ~ 21 GPa. Therefore, the value of the coefficient of friction μ stabilizes around the mean value of 0.21.     

Cure behaviour and mechanical properties of Si3N4 ceramics with bimodal particle size distribution prepared using digital light processing

Digital light processing is a vital additive manufacturing technology used for manufacturing ceramic parts. The particle size distribution of ceramic suspensions significantly affects the cure behaviour and mechanical properties of ceramics. In this study, the cure behaviour and mechanical properties of Si₃N₄ ceramics with a bimodal particle size distribution were studied. The results indicated that the suspension with coarse particles had a higher cure depth for a lower absorbance but poor mechanical properties. The bending strength of the samples with the optimal ratio (coarse:fine particles = 3:7) reached a maximum of 728.7 ± 10.33 MPa, which is 16.5% higher than that of the samples prepared using only fine particles.     

Heat treatment effects on microstructure and mechanical properties of CVI SiCf/PyC/SiC composites with Cansas-Ⅲ SiC fibers

The microstructure and mechanical properties of CVI-Cansas-III/PyC/SiC composites were systematically investigated after heat treatment under high temperature argon atmosphere, ranging from 1000 °C to 1500 °C, for different time durations. The results showed that the Cansas-III fibres degraded with increasing heat treatment temperature, resulting in degradation of the fibre properties due to pyrolysis of the SiOC phase inside the fibres. The bending strength of the composites remained nearly constant upon heat treatment at 1000 °C and 1250 °C, while a decline in bending strength was observed upon increasing the heat treatment temperature and time, specifically at 1350 °C and above. Moreover, the composites maintained their pseudo-plastic fracture behaviour below 1450 °C, while displaying brittle fracture of the ceramic after 100 h of heat treatment at 1500 °C, due to the complete crystallisation of the fibres.