New Uniformly Porous CaZrO3/MgO Composites with Three-Dimensional Network Structure from Natural Dolomite

Porous CaZrO₃/MgO composites with a uniform three-dimensional (3-D) network structure have been successfully synthesized using reactive sintering of highly pure mixtures of natural dolomite (CaMg(CO₃)₂) and synthesized zirconia powders with LiF additive. Equimolar dolomite and zirconia powders doped with 0.5 wt% LiF were cold isostatically pressed at 200 MPa and sintered at 1100–1400°C for 2 h in air. Through the liquid formation via LiF doping, strong necks were formed between constituent particles before completion of the pyrolysis of dolomite, resulting in the formation of a 3-D network structure. During and after the formation of the network structure, CO₂ was given off to form a homogeneous open-pore structure. The pore-size distribution was very narrow (with pore size ∼ 1 μm), and the porosity was controllable (e.g., ∼30%–50%) by changing the sintering temperature. The porous composites can be applied as filter materials with good structural stability at high temperatures.     

Uniformly Porous Al2O3/LaPO4 and Al2O3/CePO4 Composites with Narrow Pore-Size Distribution

Porous Al₂O₃/20 vol% LaPO₄ and Al₂O₃/20 vol% CePO₄ composites with very narrow pore-size distribution at around 200 nm have been successfully synthesized by reactive sintering at 1100°C for 2 h from RE₂(CO₃)₃· x H₂O (RE = La or Ce), Al(H₂PO₄)₃ and Al₂O₃ with LiF additive. Similar to the previously reported UPC-3Ds (uniformly porous composites with a three-dimensional network structure, e.g. CaZrO₃/MgO system), decomposed gases in the starting materials formed a homogeneous open porous structure with a porosity of ∼40%. X-ray diffraction, ³¹P magic-angle spinning nuclear magnetic resonance, scanning electron microscopy, and mercury porosimetry revealed the structure of the porous composites.     

Low-Temperature Fabrication of Transparent Yttrium Aluminum Garnet (YAG) Ceramics without Additives

A carbonate precursor of yttrium aluminum garnet (YAG) with an approximate composition of NH₄AlY_0.6(CO₃)_1.9(OH)₂·0.9H₂O was synthesized via a coprecipitation method from a mixed solution of ammonium aluminum sulfate and yttrium nitrate, using ammonium hydrogen carbonate as the precipitant. The precursor precipitate was characterized using chemical analysis, differential thermal analysis/thermogravimetry, X-ray diffractometry, and scanning electron microscopy. The sinterability of the YAG powders was evaluated by sintering at a constant rate of heating in air and vacuum sintering. The results showed that the precursor completely transforms to YAG at ∼1000°C via the formation of a yttrium aluminate perovskite (YAP) phase. YAG powders obtained by calcining the precursor at temperatures of ≤1200°C were highly sinterable and could be densified to transparency under vacuum at 1700°C in 1 h without additives.     

Fabrication of Transparent, Sintered Sc2O3 Ceramics

We report here the fabrication of transparent Sc₂O₃ ceramics via vacuum sintering. The starting Sc₂O₃ powders are pyrolyzed from a basic sulfate precursor (Sc(OH)_2.6(SO₄)_0.2·H₂O) precipitated from scandium sulfate solution with hexamethylenetetramine as the precipitant. Thermal decomposition behavior of the precursor is studied via differential thermal analysis/thermogravimetry, Fourier transform infrared spectroscopy, X-ray diffractometry, and elemental analysis. Sinterability of the Sc₂O₃ powders is studied via dilatometry. Microstructure evolution of the ceramic during sintering is investigated via field emission scanning electron microscopy. The best calcination temperature for the precursor is 1100°C, at which the resultant Sc₂O₃ powder is ultrafine (∼85 nm), well dispersed, and almost free from residual sulfur contamination. With this reactive powder, transparent Sc₂O₃ ceramics having an average grain size of ∼9 μm and showing a visible wavelength transmittance of ∼60–62% (∼76% of that of Sc₂O₃ single crystal) have been fabricated via vacuum sintering at a relatively low temperature of 1700°C for 4 h.     

Low-Temperature Synthesis of Praseodymium-Doped Ceria Nanopowders

Praseodymium-doped ceria (CeO₂) nanopowders have been synthesized via a simple but effective carbonate-coprecipitation method, using nitrates as the starting salts and ammonium carbonate as the precipitant. The precursors produced in this work are ammonium rare-earth double carbonates, with a general formula of (NH₄)_0.16Ce_{1− x} Pr _x (CO₃)_1.58·H₂O (0 < x ≤ 0.20), which directly yield oxide solid solutions on thermal decomposition at a very low temperature of ∼400°C. Praseodymium doping causes a gradual contraction of the CeO₂ lattice, because of the oxidation of Pr³⁺ to smaller Pr⁴⁺, and suppresses crystallite coarsening of the oxides during calcination. Dense ceramics have been fabricated from the thus-prepared nanopowders via pressureless sintering for 4 h at a low temperature of 1200°C.     

Wet-Chemical Routes Leading to Scandia Nanopowders

Two wet-chemical routes have been used to synthesize Sc₂O₃ nanopowders from nitrate solutions employing ammonia water (AW) and ammonium hydrogen carbonate (AHC) as the precipitants. The precursors and the resultant oxides are characterized by elemental analysis, X-ray diffractometry, differential thermal analysis/thermogravimetry, high-resolution scanning electron microscopy, and Brunauer-Emmett-Teller analysis. Crystalline γ-ScOOH· n H₂O ( n ≈ 0.5) is the only phase obtained by the AW method. This phase dehydrates to Sc₂O₃ at ∼400°C, yielding hard aggregated nanocrystalline Sc₂O₃ powders. Three types of precursors have been synthesized by the AHC method, depending on the AHC/Sc³⁺ molar ratio ( R ): amorphous basic carbonate [Sc(OH)CO₃·H₂O] at R ≤ 3, crystalline double carbonate [(NH₄)Sc(CO₃)₂·H₂O] at R ≥ 4, and a mixture of the two phases at 3 < R < 4. Among these precursors, only the basic carbonate shows spherical particle morphology, ultrafine particle size (∼50 nm), and weak agglomeration. Sc₂O₃ nanopowders (∼28 nm) with high surface area (∼49 m²/g) have been prepared by calcining the basic carbonate at 700°C for 2 h.     

Preparation of Porous Cr3C2 Grains with Cr2O3

Porous Cr₃C₂ grains (∼300 to 500 μm) with ∼10 wt% of Cr₂O₃ were prepared by heating a mixture of MgCr₂O₄ grains and graphite powder at 1450° to 1650°C for 2 h in an Al₂O₃ crucible covered by an Al₂O₃ lid with a hole in the center. The porous Cr₃C₂ grains exhibited a three-dimensional network skeleton structure. The mean open pore diameter and the specific surface area of the porous grains formed at 1600°C for 2 h were ∼3.5 (μm and ∼6.7 m²/g, respectively. The present work investigated the morphology and the formation conditions of the porous Cr₃C₂ grains, and this paper will discuss the formation mechanism of those grains in terms of chemical thermodynamics.     

Pore Drag and Pore-Boundary Separation in Alumina

Microdesigned interfacial pore structures were used to study pore drag and pore-boundary separation in Al₂O₃. This approach allows the creation of pore arrays containing pores of controlled size and spacing at well-defined singlecrystal seed/polycrystalline matrix interfaces, and enables experimental determination of the peak pore velocity. From the peak pore velocity, values of the surface diffusion coefficient pertinent to sintering can be extracted. At 1600°C, the surface diffusion coefficient is ∼1 × 10⁻⁷ cm²/s for undoped Al₂O₃ and ∼4 × 10⁻⁷ cm²/s for MgO-doped Al₂O₃. The values appear to be insensitive to the seed orientation for the two seed orientations studied. The results suggest a strong influence of pore spacing on the separation condition in undoped Al₂O₃, and a diminished influence in MgO-doped Al₂O₃. Quantitative agreement between theoretically predicted and experimentally observed separation/attachment conditions was obtained.     

Bimodal Sintering of Al2O3/Al2O3 Platelet Ceramic Composites

The sintering behavior of an Al₂O₃ compact containing uniformly dispersed Al₂O₃ platelets has been investigated. The results reveal a significant decrease in the sintering rate as well as the formation of voids and cracklike defects in the presence of nonsinterable platelets. The addition of a small amount (2 vol%) of tetragonal-ZrO₂ particles enhances the sintering rate, increases end-point density (∼99.5% of theoretical density) and prevents formation of sintering defects.     

Mechanical Activation-Assisted Synthesis of Pb(Fe2/3W1/3)O3

Perovskite Pb(Fe_2/3W_1/3)O₃ (PFW) was prepared via a mechanical activation-assisted synthesis route from mixed oxides of PbO, Fe₂O₃, and WO₃. The mechanically activated oxide mixture, which exhibited a specific area of >10 m²/g, underwent phase conversion from nanocrystalline lead tungstate (PbWO₄) and pyrochlore (Pb₂FeWO_6.5) phases on sintering to yield perovskite PFW, although the formation of perovskite phase was not triggered by mechanical activation. When heated to 700°C, >98% perovskite phase was formed in the mechanically activated oxide mixture. The perovskite phase was sintered to a density of ∼99% of theoretical density at 870°C for 2 h. The sintered PFW exhibited a dielectric constant of 9800 at 10 kHz, which was ∼30% higher than that of the PFW derived from the oxide mixture that was not subjected to mechanical activation.     

Toughening and Strengthening of NiAl with Al2O3 by the Addition of ZrO2(3Y)

NiAl/10-mol%-ZrO₂(3Y) composites of almost full density have been fabricated via spark plasma sintering (SPS) for 10 min at 1300°C and 30 MPa. The former intermetallic compound, which contains a trace amount of Al₂O₃, has been prepared via self-propagating high-temperature synthesis. The composite microstructures are such that tetragonal ZrO₂ (∼0.2 μm) and Al₂O₃ (∼0.5 μm) particles are located at the grain boundaries of the NiAl (∼46 μm) matrix. Improved mechanical properties are obtained: the fracture toughness and bending strength are 8.8 MPa·m^1/2 and 1045 MPa, respectively, and high strength (>800 MPa) can be retained up to 800°C.     

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.     

Optimization of Chemical Vapor Deposition Parameters for Fabrication of Oxidation-Resistant Mullite Coatings on Silicon Nitride

Fabrication of mullite (3Al₂O₃·2SiO₂) coatings by chemical vapor deposition (CVD) using AlCl₃–SiCl₄–H₂–CO₂ gas mixtures was studied. The resultant CVD mullite coating microstructures were sensitive to gas-phase composition and deposition temperature. Chemical thermodynamic calculations performed on the AlCl₃–SiCl₄–H₂–CO₂ system were used to predict an equilibrium CVD phase diagram. Results from the thermodynamic analysis, process optimization, and effects of various process parameters on coating morphology are discussed. Dense, adherent crystalline CVD mullite coatings ∼2 μm thick were successfully grown on Si₃N₄ substrates at 1000°C and 10.7 kPa total pressure. The resultant coatings were 001 textured and contained well-faceted grains ∼0.3–0.5 μm in size.     

Reactive Synthesis of a Porous Calcium Zirconate/Spinel Composite with Idiomorphic Spinel Grains

Porous CaZrO₃/MgAl₂O₄ composites were synthesized in air by pressureless reactive sintering of an equimolar mixture of dolomite (CaMg(CO₃)₂), monoclinic zirconia ( m -ZrO₂), and α-alumina powders, with a 0.5 wt% lithium fluoride additive. The reaction behavior of the mixed powders (with/without LiF additive) was studied using high-temperature X-ray diffraction. A bulk porous composite resulted from sintering at 1300°C for 2 h (in a nearly closed container, so as to increase the LiF-doping effect), which consisted of fine grains (CaZrO₃ and MgAl₂O₄, ∼0.5–1 μm) and well-grown idiomorphic ones (MgAl₂O₄ octahedra ∼ 2–4 μm). The idiomorphic spinel grains were located around the inner walls of relatively large pores. The composite showed appreciably high bending strength (σ_f= 110 ± 8 MPa for a porosity of 31%). The porous CaZrO₃/MgAl₂O₄ composites can be applied as high-temperature filters and lightweight structural components.     

Thermal Analysis of Reactions in Soda–Lime Silicate Glass Batches Containing Melting Accelerants: I, One- and Two-Component Systems

To identify each glass melting reaction in a multicomponent system, one-component and two-component reaction processes were studied using DTA, TGA, and XRD. Two-component mixtures were prepared by choosing pairs in the same ratio as in a commercial container glass batch composition (sand-soda ash-calcite-dolomite-feldspar). The presence of silica in the silica-calcite system decreased the termination temperature of the decomposition of calcite, but did not alter the onset of decomposition. Similar behavior was found in the dolomite-silica system. A double carbonate (Na₂Ca(CO₃)₂) formed via solid-state reaction in the calcite-soda ash system, and metasilicate/disilicate phases were detected during the fusion process in the soda ash-silica system. The effects of reaction accelerant additions in the soda ash-silica system were investigated using 1 wt% additions of sodium sulfate, sodium nitrate, and sodium chloride. Sodium chloride was the most effective melting accelerant, lowering the termination temperature of CO₂ release by ∼80°C compared with the soda ash-silica system with no additives. NaCl additions caused complete reaction and/or fusion of Na₂CO₃ prior to its melting temperature. Sodium sulfate additions acted to suppress metasilicate/ disilicate formation by coating quartz grains and shifted consequent CO₂ release to higher temperature.     

Rapid Preparation of Lead Titanate Sputtering Target Using Spark-Plasma Sintering

PbTiO₃ sputtering targets 8 cm in diameter were prepared using spark-plasma sintering (SPS) for relatively short periods, ∼2 min. Submicrometer-sized PbTiO₃ powders with a relatively large size distribution were densified to ∼86% of the theoretical X-ray density using the SPS process. In contrast, large-sized (8 cm in diameter) ceramics could not be prepared from starting powders with a relatively narrow particle-size distribution. Formation of cracks in the large PbTiO₃ targets was observed when samples were prepared under higher pressures (>50 MPa) or at higher temperatures (>900°C). Crack formation was attributed to unrelaxed internal stress originating from lower pore contents and from an inhomogeneous distribution of cations in the ceramics prepared under these conditions.     

Synthesis of Er3+ Doped Y2O3 Nanophosphors

The synthesis and characterization of yttrium hydroxyl carbonate (Y(OH)CO₃²⁻) and yttrium nitrate hydroxide hydrate (Y(OH)NO₃H₂O) precursor materials as well as Y₂O₃ nanoparticles are reported. The resultant precursor particle size is about 10–12 nm with a narrow size distribution by the enzymatic decomposition method, whereas the particle size was smaller than those acquired by the homogeneous and alkali precipitation methods. The formation of Y(OH)CO₃²⁻ and Y(OH)NO₃H₂O species was also evident from the fourier-transform infrared spectrometry (FT-IR) analysis. Precipitated Y(OH)CO₃²⁻ precursors have an amorphous nature whereas Y(OH)NO₃H₂O precursors have a crystalline nature, which was manifested from the XRD analysis. Moreover, precipitated Y(OH)NO₃H₂O precursors were found in the agglomerated form and Y(OH)CO₃²⁻ was established in the monodispersed form, as determined from the FE-SEM, TEM and DLS measurements. It was demonstrated that calcination of precursor materials at 900°C eventually removed the inorganic anions from the precursors and consequently produced crystalline Y₂O₃ nanoparticles, which was evident from the XRD and FT-IR analysis. The EDS analysis confirms Er³⁺ doping in the Y₂O₃ nanoparticles. The morphology and the size of the Y₂O₃ nanoparticles are almost unchanged before and after the calcination.     

Effects of Sintering Atmosphere on Densification Behavior and Piezoelectric Properties of Pb(Ni1/3Nb2/3)O3–PbZrO3 Ceramics

Densification of polycrystalline Pb(Ni_1/3Nb_2/3)O₃–PbTiO₃–PbZrO₃ (PNN–PT–PZ) specimens was enhanced as the partial pressure of O₂ in the sintering atmosphere was increased. This observation was attributed to the increase in the internal pressure of a closed pore due to the thermal decomposition of PbO at a low partial pressure of O₂. The relative dielectric permittivity (ε_r), d ₃₃, k _p, and grain size of sintered specimens were also increased as the partial pressure of O₂ in the sintering atmosphere was increased. The observed dependence of piezoelectric properties on the partial pressure of O₂ was discussed in terms of the enhanced formation of the A-site vacancy ( V "_Pb) or the suppression of the B-site defect ( V ¨_O) as the oxygen potential increased.     

Surface Decomposition of Strontium-Doped Soft PbZrO3–PbTiO3

Sintering temperature has a pronounced effect on perovskite phase stability at the surface of Pb_0.88Sr_0.12Zr_0.54Ti_0.44Sb_0.02O₃ (PSZT) soft piezoelectric ceramics ( d ₃₃≈ 600 pC/N). After sintering 4 h at 1070°C, XRD reveals only perovskite PSZT peaks in the bulk and at the surface. As sintering temperature increases, XRD from the ceramic surface reveals a second-phase peak at ∼27° (2θ), 0.316 nm ( d -spacing). After 4 h at 1280°C, further second-phase peaks are observed, confirming it to be monoclinic ZrO₂, accompanied by a strong increase in the degree of tetragonality of the perovskite phase. These observations are consistent with decomposition of the PSZT to ZrO₂ and tetragonal PZT (PbZrO₃–PbTiO₃) associated with PbO loss. SEM and cross-sectional TEM indicated that surface decomposition had progressed ∼0.5 mm into the sample after 4 h at 1280°C.     

Synthesis and Processing Characteristics of Ba0.65Sr0.35TiO3 Powders from Catecholate Precursors

Powders of composition Ba_0.65Sr_0.35TiO₃ were prepared from catecholate precursor phases, BaTi(C₆H₄O₂)₃ and SrTi (C₆H₄O₂)₃. The physical and chemical properties of the base powders, and those doped with 0.2 wt% manganese, are reported in detail. The dimensions of the primary particles in the starting powders were of the order of 20–50 nm, but the occurrence of abnormal grain growth during sintering promoted grain sizes in the ceramic of up to ∼100 μm. In some microstructures, coarse grains coexisted with a ∼1-μm fraction to produce a characteristic bimodal grain size distribution. By contrast, under comparable sintering conditions, namely 1350° or 1400°C for 1 h, grain growth in Mn-doped samples was suppressed, leading to uniform microstructures with a grain size of only a few micrometers. The pellet densities were nevertheless similar, 97% of theoretical in both doped and undoped samples. No significant difference was observed in the dielectric permittivity of the two compositions: the peak relative permittivity occurred at ∼20°C, with a maximum value of ∼22 000.