Processing factors influencing the free carbon contents in boron carbide powder by rapid carbothermal reduction

High quality boron carbide powder without free carbon is desired for many applications. In this study, the factors that influence free carbon content in boron carbide powders synthesized by rapid carbothermal reduction reaction were evaluated. The dominant factors affecting free carbon contents in boron carbide powder were reaction temperature, precursor homogeneity, the particle size of reactants, and excess boron reactant amount. The reaction temperature at 1850 °C was sufficient to synthesize boron carbide with low free carbon content. Depending on process conditions, precursor homogeneity was also affected by the calcination temperature and time. Smaller particle size of reactants contributed to less carbon content and more uniformity in synthesized boron carbide. Excess boric acid effectively compensated for B₂O₃ volatilization. In the optimal sample, using 80 mol% excess nano boric acid and calcined at 500 °C, the free carbon in the synthesized boron carbide was negligible (0.048 wt.%).     

Carbothermal reduction synthesis of TiB2 ultrafine powders

Submicrometric TiB₂ powders were synthesized by carbothermal reduction process using titanium dioxide, boron carbide and carbon black as the starting materials. The influence of different amount of boron carbide (22.0–26.8 wt%), calcination temperature (1400–1900 °C) and holding time (15–90 min) on the composition and microstructure of the product was investigated. The resultant powders were characterized by X-ray diffraction (XRD) and scanning electron microscope (SEM). Results showed that hexagonal impurity-free TiB₂ crystalline powders with the grain size below 1.0 μm could be successfully prepared at 1600 °C for 30 min in Ar atmosphere when the amount of boron carbide was 25.3 wt%. The increase in temperature contributed to reaction completion and grain growth, but the abnormal grain growth and oversintering took place above 1800 °C.     

Oxidation behavior of carbon materials derived from a carborane- and silicon-incorporated polymer

The oxidation behavior and oxidation mechanism of carbon materials containing silicon and boron elements (C–Si–B materials) were investigated at different high temperatures in air. The carbon materials were prepared by oxidative pyrolysis of the polymer precursor, carborane-incorporated poly(dimethylsilylene-ethynylenephenyleneethynylene) (CB-PSEPE), at 800, 1000, or 1200 °C for 1 h under static air. Homogeneous dispersion of silicon and boron components in the carbon matrix could be achieved in the carbon materials after the pyrolysis. The oxidation behavior of the C–Si–B materials during the oxidation process was studied. The evolution of elemental composition and morphology of the surface layers of carbon materials was monitored by X-ray photoelectron spectroscopy and scanning electron microscopy, respectively. The results imply that the formation of protective borosilicate layer in the surface is the main mechanism to provide remarkable oxidation resistance of the carbon materials. The obtained borosilicate layer with a self-healing property can withstand oxidation at 1000 °C in air.     

Low temperature graphitization of interphase polyacrylonitrile (PAN)

Ordered polyacrylonitrile (PAN) interphase structures were formed in solution-cast PAN/carbon nanotube (CNT) composite films by enhancing polymer crystallization conditions and processing parameters for five types of CNTs. All film samples were heat-treated using similar stabilization and carbonization (up to 1100 °C) processes. Both the precursor and carbonized materials were characterized by electron microscopy and X-ray spectroscopy. Highly ordered graphitic structure was formed predominantly in the carbonized materials at 1100 °C (i.e., ∼1500 °C lower than the temperature used in a commercial graphitization process). The ordering of the graphite structure formed at 1100 °C was further improved by heat treatment up to 2100 °C. Multiple characterization results indicate that the early onset of PAN conversion to graphite is directly related to the polymer interphase formation as well as the CNT type. Based on the stabilization and carbonization parameters used in this study, PAN/single-wall carbon nanotube (SWNT) samples showed more prevalent graphite formation at 1100 °C. This work demonstrates the influence of CNT type regarding interfacial confinement toward this low-temperature polymer-to-graphite conversion process.     

Synthesis and pyrolysis behavior of a soluble polymer precursor for ultra-fine zirconium carbide powders

A soluble polymer precursor for ultra-fine zirconium carbide (ZrC) was successfully synthesized using phenol and zirconium tetrachloride as carbon and zirconium sources, respectively. The pyrolysis behavior and structural evolution of the precursor were studied by Fourier transform infrared spectra (FTIR), differential scanning calorimetry, and thermal gravimetric analysis (DSC–TG). The microstructure and composition of the pyrolysis products were characterized by X-ray diffraction (XRD), laser Raman spectroscopy, scanning electron microscope (SEM) and element analysis. The results indicate that the obtained precursor for the ultra-fine ZrC could be a Zr–O–C chain polymer with phenol and acetylacetone as ligands. The pyrolysis products of the precursor mainly consist of intimately mixed amorphous carbon and tetragonal ZrO₂ (t-ZrO₂) in the temperature range of 300–1200 °C. When the pyrolysis temperature rises up to 1300 °C, the precursor starts to transform gradually into ZrC, accompanied by the formation of monoclinic ZrO₂ (m-ZrO₂). The carbothermal reduction reaction between ZrO₂ and carbon has been substantially completed at a relatively low temperature (1500 °C). The obtained ultra-fine ZrC powders exhibit as well-distributed near-spherical grains with sizes ranging from 50 to 100 nm. The amount of oxygen in the ZrC powders could be further reduced by increasing the pyrolysis temperature from 1500 to 1600 °C but unfortunately the obvious agglomeration of the ZrC grains will be induced.     

Synthesis of nanocrystalline boron carbide by sucrose precursor method-optimization of process conditions

Nanocrystalline boron carbide powder was synthesized by a precursor method using B₂O₃ as the source of boron and sucrose as the source of carbon. Precursor was prepared at different temperatures ranging from 300 to 800 °C. The optimum temperature for the precursor preparation was found to be 600 °C. All the precursors were heat treated at different temperatures from 1000 to 1600 °C for different duration of heating, ranging from 5 to 240 min under vacuum. The products thus obtained after heat treatment were characterized using X-ray diffraction. The boron carbide obtained was nanocrystalline and the average X-ray crystallite size was found to be ~ 33 nm. Boron, total carbon and free carbon contents also were determined. The free carbon content was found to be less than 3% for samples heated at 1600 °C for 10 min. Effect of heat treatment temperature on the morphology of the synthesized product was studied using scanning electron microscope.     

Microstructure and deposition mechanism of CVD amorphous boron carbide coatings deposited on SiC substrates at low temperature

Amorphous boron carbide (α-B₄C) coatings were prepared on SiC substrates by chemical vapor deposition (CVD) from CH₄/BCl₃/H₂/Ar mixtures at low temperature (900–1050 °C) and reduced pressure (10 kPa). The deposited coatings were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), micro-Raman spectroscopy, energy dispersive X-ray spectroscopy (EDS) and X-ray photoelectron spectroscopy (XPS). The results showed that two kinds of α-B₄C coatings were deposited with different microstructures and phase compositions, and the effect of deposition temperature was significant. When deposited at 1000 °C and 1050 °C, the coatings exhibited a nodular morphology and had a relatively low content of boron. The free carbon was distributed in them inhomogeneously; in contrast, when deposited at 900 °C and 950 °C, the coatings presented a comparatively flat morphology and had a uniform internal structure and high boron content. They did not contain free carbon. At the last of this paper, the pertinent mechanisms resulting in differences in microstructure and phase composition were discussed.     

Microstructural characterization of spark plasma sintered boron carbide ceramics

Fully dense boron carbide specimens were fabricated by the spark plasma sintering (SPS) technology in the absence of any sintering additives. Densification starts at 1500 °C and the highest densification rate is reached at about 1900 °C. The microstructure of the ceramic sintered at 2200 °C, with heating rates in the 50–400 °C/min range, displays abnormal grain growth, while for a 600 °C/min heating rate a homogeneous distribution of finely equiaxed grains with 4.05 ± 1.62 μm average size was obtained. TEM analysis revealed the presence of W-based amorphous and of crystalline boron-rich B₅₀N₂ secondary phases at triple-junctions. No grain-boundary films were detected by HRTEM. The formation of a transient liquid alumino-silicate phase stands apparently behind the early stage of densification.     

Room and high temperature flexural failure of spark plasma sintered boron carbide

Dense (95–98.6%) bulk boron carbide prepared by Spark Plasma Sintering (SPS) in Ar or N₂ atmospheres were subject to three-point flexural tests at room and at 1600 °C. Eight different consolidation conditions were used via SPS of commercially available B₄C powder. Resulting specimens had similar grain size not exceeding 4 µm and room-temperature bending strength (σ_25 °C) of 300–600 MPa, suggesting that difference in σ_25 °C is due to development of secondary phases in monolithic boron carbide ceramics during SPS processing. To explain such difference the composition of boron carbide and secondary phases observed by XRD and Raman spectroscopy. The variation in intensity of the Raman peak at 490 cm⁻¹ of boron carbide suggests modification of the boron carbide composition and a higher intensity correlates with a higher room-temperature bending strength (σ_25 °C) and Vickers hardness (HV). Secondary phases can modify the level of mechanical characteristics within some general trends that are not dependent on additives (with some exceptions) or technologies. Namely, HV increases, σ_25 °C decreases, and the ratio σ_1600 °C/σ_25 °C (σ_1600 °C – bending strength at 1600 °C) is lower when fracture toughness (K_IC) is higher. The ratio σ_1600 °C/σ_25 °C shows two regions of low and high K_IC delimited by K_IC=4.1 MPa m^0.5: in the low K_IC region, boron carbide specimens are produced in nitrogen.     

Synthesis and characterization of mesoporous NiO2/ZrO2-CeO2 catalysts for total methane conversion

This work reports the synthesis and characterization of mesoporous NiO/ZrO₂^-CeO₂ composites. These materials are still being developed due to their excellent morphological and structural properties, especially for solid oxide fuel cells (SOFCs) anodes. A soft chemical route using a polymeric template was utilized to synthesize the samples. The structure after two different calcination processes at 400 °C and 540 °C was studied by X-ray diffraction and Rietveld refinement, before and after NiO loading. Nitrogen adsorption, scanning/transmission electron microscopy and small angle X-ray scattering revealed a nanocrystalline bi-phasic porous material. Temperature programmed reduction experiments showed higher Ni and Ce reduction values for samples calcined at 400 °C and 540 °C, respectively. Methane conversion values in the temperature range studied were similar for both calcination temperatures, showing 50% CH₄ conversion around 550 °C and 80% around 650 °C. However, a sample calcined at 400 °C exhibited better morphological and textural properties leading to an enhancement in NiO and CeO₂ reducibility that might be responsible for an improvement in oxygen surface exchange and gasification of carbon species in catalytic experiments.     

Boron carbide coatings on diamond particles

Boron carbide (B₄C) coatings on diamond offer potential for obtaining homogeneous B₄C-diamond composites with improved properties. A method was developed for coating diamond particles with B₄C at 1150 °C under argon atmosphere for dwell times of 2–6 hours in a powder mixture of boric acid (H₃BO₃) and amorphous boron. The B₄C coating showed very good adhesion to the diamond substrate, and an unusual five-fold symmetry thought to be due to a twinned growth mechanism. The sudden onset of nucleation at T > 1000 °C is ascribed to the stabilising effect of hydrogen from the decomposition of H₃BO₃ on the diamond surface reactivity.     

Wear resistant boron carbide compacts produced by pressureless sintering

Boron carbide compacts were produced by pressureless sintering at 2200 °C/2 h and 2250 °C/2 h in Ar atmosphere, using a starting powder with a particle size smaller than 3 µm. Effects of carbon addition (3.5 wt%) and methanol washing of the starting powder were investigated on the densification, Vickers hardness, and micro-abrasive wear resistance of the samples. The removal of oxide phases by methanol washing allowed the production, with no sintering additive, of highly densified (93.6% of theoretical density), hard (25.4 GPa), and highly wear resistant (wear coefficient =2.9×10^–14 m³/N.m) boron carbide compacts sintered at 2250 °C. This optimized combination of properties was a consequence of a reduced grain growth without the deleterious effects associated to the carbon addition. Methanol washing of the starting powder is a simple and general approach to produce, without additives, high quality, wear resistant boron carbide compacts by pressureless sintering.     

Synthesis and characterization of magnesium–carbon compounds for hydrogen storage

Magnesium (Mg) and carbon (C) compounds were synthesized by ball-milling a mixture of Mg and different graphites with different crystallinities. The materials were characterized by X-ray diffraction, X-ray absorption spectroscopy, and X-ray total scattering techniques. Hydrogen storage properties were also investigated. In the case of the material using low-crystalline graphite, a Mg and C compound was formed as main phase, and its chemical bonding state was similar to that of magnesium carbide (Mg₂C₃). The hydrogen absorption reaction of the Mg–C compound occurred at around 400 °C under 3 MPa of hydrogen pressure to form magnesium hydride (MgH₂) and the C–H bonds in the carbon material. The hydrogenated Mg–C material desorbed about 3.7 mass% of hydrogen below 420 °C with two processes, which were the decomposition of MgH₂ and the subsequent reaction of the generated Mg and the C–H bonds. From the results, it is concluded that the Mg–C compound absorb and desorb about 3.7 mass% of hydrogen below 420 °C.     

Influence of polymer type on adhesion performance of a blended cement mortar

The purpose of this study was to examine the influence of various polymeric materials on the adhesion characteristics of a rapid setting, minimum defect mortar based upon a blend of calcium sulfoaluminate (CSA) cement and ordinary Portland cement (OPC). Four different polymer powders were added to the base mortar at a polymer/cement ratio (p/c) of 0.15. The water/cement (w/c) ratio remained constant for all mortars at 0.42. The polymeric materials consisted of an acrylic polymer powder with T_g=−10 °C, a styrene butadiene rubber (SBR) polymer powder with T_g=15 °C and two vinyl acetate/ethylene (VAE) polymer powders, one with T_g=−7 °C and the other with T_g=20 °C. Mortars were tested for direct tensile strength following ASTM C307 and pull-off strength following a variant of ASTM C1583 after curing for either 24 h or 13 days at ambient laboratory temperature of 23 °C. Mortars were cast over concrete, wood, metal and glass substrates. Pull-off tests over concrete substrate resulted in substrate failure for all polymer modified mortars. Pull-off tests cast over wood, glass and metal substrate materials highlighted the SBR polymer for demonstrating the poorest adhesion performance. Statistical analysis was performed with Minitab software.     

Linear organodecaborane block copolymer as a single-source precursor for porous boron carbide ceramics

Boron carbide is one of the most widely used non-oxide ceramics as it possesses excellent physical and chemical properties. Much attention has been paid to prepare boron carbide ceramics via precursor derived method. In this work, poly(6-norbornenyldecaborane)-b-poly(6-cyclooctenyldecaborane) (PND-b-PCD) block copolymer was synthesized by the ruthenium-catalyzed ring-opening metathesis polymerization (ROMP) of 6-norbornenyldecaborane with 6-cyclooctenyldecaborane. The synthesized boron carbide preceramic polymer had good solubility and film-forming ability with a high ceramic yield of 75% at 850 °C. TGA, XRD and TG-IR-GC–MS were used to investigate the ceramization process of the precursor. Boron carbide ceramic foams were prepared by the precursor via replicating polyurethane foam template. The component, crystalline and morphology were investigated in detail. The ceramic foams showed a good high temperature performance and could keep their structure even up to 1800 °C.     

Preparation of carbon foams with enhanced oxidation resistance by foaming molten sucrose using a boric acid blowing agent

Boric acid was used as a blowing agent as well as a boron precursor for the preparation of boron-doped carbon foams from molten sucrose. The H⁺ generated, due to the formation of a complex between sucrose and boric acid, catalyzes the –OH to –OH condensation reaction leading to the polymerization and the foaming of the molten sucrose. The char yield of the solid organic foams increased from 24 to 39 wt.% when the boric acid concentration increased from 0 to 8 wt.%, due to the formation of the B–O–C cross-links between sucrose polymer by B–OH to C–OH condensation. The inductively coupled plasma analysis showed the presence of 0.44–3.4 wt.% boron in the carbon foams. The density and compressive strength decreased and cell size increased with boric acid concentration. The room temperature thermal conductivity of the boron-doped carbon foams was in the range of 0.057–0.043 W m⁻¹ K⁻¹. The weight loss studies by dynamic and isothermal heating showed the increased oxidation resistance with boron concentration.     

Ni(II)–Mg(II)–Al(III) catalysts for hydrogen production from ethanol steam reforming: Influence of the activation treatments

The effect of the Ni(II)–Mg(II)–Al(III) layered double hydroxide (LDH) activation conditions over the surface and bulk composition and the catalytic performance in ethanol steam reforming (ESR) is studied. Ternary oxides were prepared by thermal decomposition of LDHs synthesized using the homogeneous precipitation method with urea. Catalyst precursor is submitted to two different activation treatments: calcinations at 400, 500, 600 and 700 °C with subsequent reduction at 720 °C, or direct reduction at 720 °C. The samples were characterized by sorptometry, H₂ chemisorption, ICP chemical analysis, thermogravimetric analysis, X-ray diffraction, X-ray photoelectronic spectroscopy and temperature programming reduction. The catalysts obtained by calcination at 600 °C and then reduction at 720 °C and those directly reduced at 720 °C showed the better performance in ESR. The precursor submitted to a proper thermal treatment develops, through a decoration-demixing process, a Ni(II)-poor spinel-type shell onto NiO domains.     

Synthesis of fine dispersed titanium diboride from nanofibrous carbon

This paper presents the experimental data on the synthesis of titanium diboride (TiB₂) fine dispersed powder carried out in laboratory scale. TiB₂ powder was prepared by the reduction of titanium dioxide with boron carbide and nanofibrous carbon in an argon atmosphere. The powders of TiB₂ were characterized by X-ray diffraction (XRD), elemental analyses, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), low-temperature nitrogen adsorption, particle size analysis, simultaneous thermogravimetry and differential scanning calorimetry (TG-DSC). The resulting material contains a single phase – titanium diboride. The particles of the powder were predominantly aggregated. The average size of the particles and the aggregates were 7.4–8.0 µm with a wide size of distribution. The specific surface values of samples obtained were 2.4–5.8 m²/g. The oxidation of titanium diboride began from the temperature of 450 °C. In this work, the optimal synthesis conditions were estimated: the molar ratio was TiO₂:B₄C:C=2:1:3 (according to stoichiometry), the temperature was 1600 °C, the process duration was 20–30 min.     

Characterisation of BN-supported palladium oxide catalyst used for hydrocarbon oxidation

Hexagonal boron nitride (BN), with a graphite-type structure and with surface area of 184 m²/g was used as a support for palladium oxide (PdO/BN). About 1 wt% of palladium was deposited on BN by incipient wetness method by using palladium nitrate as precursor. The support and the catalyst were characterized by BET, TEM, XRD, XPS, ICP, TG, TPD, in situ ac electrical conductivity and by ammonia adsorption microcalorimetry. Oxidation of propylene and methane were used as model reactions to study the catalytic properties of the PdO/BN catalyst. The BN support was practically inactive in propylene oxidation up to 400 °C, while the onset of the oxidation was detected around 200 °C on PdO/BN, which points out the role of the palladium in adsorption of the reactive hydrocarbon species. At the same time, this temperature is coincident with the increase of the electronic conductivity on both BN and PdO/BN samples, which is important for oxygen adsorption/activation as electrophilic species. The catalyst was inactive in methane oxidation below 400 °C. Only about 2% CH₄ conversion was observed at 400 °C, increasing sharply up to 87% at 550 °C with methane transformation only to CO₂ and water.     

A microstructural study of carbon–carbon composites impregnated with SiC filaments

Porous multidirectional carbon/carbon composite obtained by pulse chemical vapour infiltration (PCVI) was impregnated with silicon carbide (SiC) derived from pyrolysis of polymethylsiloxane resin (PMS). The impregnation process was made to improve oxidation resistance and mechanical properties of MD C/C composite. The resin was used as a source of silicon carbide component of the composite forming after heat treatment above 1000 °C. During this process SiC thin filaments were formed inside the porous carbon phase. The aim of this work was to investigate the structure and microstructure of the constituents of carbon composite obtained after pyrolysis of SiC PMS precursor. Microscopic observations revealed that during careful heat treatment of crosslinked polymethylsiloxane resin up to 1700 °C, the filaments (diameter 200–400 nm) crystallized within porous carbon phase. The filaments were randomly oriented on the composite surface and inside the pores. FTIR spectra and XRD analysis of the modified C/C composite showed that filaments had silicon carbide structure with the crystallite size of silicon carbide phase of about 45 nm. The Raman spectra revealed that the composite contains two carbon components distinctly differing in their structural order, and SiC filaments present nanocrystalline structure.