Glass-ceramic glazes for future generation floor tiles

Glaze in the CaO–MgO–Al₂O₃–SiO₂ system was heated at 950–1190 °C for 2 h and characterized. X-ray diffraction showed that only trace amount of mullite was formed in the glass-ceramic glaze heated at 950 °C. Both mullite and α-cordierite were formed in the glass-ceramic glaze heated at 1050 °C as primary and secondary phases. Glass-ceramic glazes heated at 1120 °C and 1190 °C contained α-cordierite and mullite as major and minor phases. Rietveld analysis revealed that the amount of α-cordierite increased and mullite decreased with increasing heating temperature. Field emission scanning electron microscopy showed presence of mullite crystals dispersed within residual glassy phase in the glass-ceramic glazes heated at 950 °C and 1050 °C. In the microstructures of glass-ceramic glazes heated at 1120 °C and 1190 °C α-cordierite crystals were mainly appeared. Energy Dispersive X-ray analysis corroborated X-ray diffraction results. Vickers microhardness measurement demonstrated highest hardness (8.38 ± 0.07 GPa) of the glass-ceramic glaze heated at 1190 °C.     

Effect of boron oxide on the microstructure of mullite-based glass-ceramic glazes for floor-tiles in the CaO–MgO–Al2O3–SiO2 system

The effect of increasing replacement of Al₂O₃ by B₂O₃ in a parent glass on the sintering and further crystallization of mullite was investigated. The composition of the parent glass was chosen in the mullite primary phase field of the CaO–MgO–Al₂O₃–SiO₂ quaternary system. Glass powder pellets were heated under standard (10 °C/min and 2 h of hold time) and fast heatings (25 °C/min and 5 min of hold time) at different temperatures from 700 to 1190 °C. Sintering of B₂O₃-containing glasses took place in the range between 850 and 1050 °C. X-ray diffraction results showed that mullite formed as unique crystalline phase for glasses containing amounts of B₂O₃ larger than 6 wt%. For lower amounts of boron oxide cordierite was formed as secondary crystalline phase. Quantitative determination of mullite by Rietveld analysis indicated that the higher amount of mullite present in the glass-ceramic fast heated at 1160 °C was 19.5 wt% for the glass containing 9 wt% of B₂O₃. The final microstructure of the glass-ceramic glazes showed the presence of well shaped, long acicular mullite crystals dispersed within the residual glassy phase. Results of glass-ceramic glazes when applied as slurry and under industrial heating conditions pointed out promising mechanical properties.     

Low-temperature sintering and microwave dielectric properties of CaWO4 ceramics for LTCC applications

Microwave dielectric properties of CaWO₄ ceramics were investigated as a function of H₃BO₃ and/or Bi₂O₃ content and sintering temperature. For a single addition of H₃BO₃ (1 ≤ x (wt.%) ≤ 5), the density of specimen increased up to 3 wt.% H₃BO₃, and then decreased. The dielectric constant (K) and the quality factor (Q × f) of the specimens sintered at 850 °C showed lower value than those of specimens sintered above 900 °C due to the poor sinterability. With the increase of H₃BO₃ content of 0.5 wt.% Bi₂O₃–yH₃BO₃ (5 ≤ y (wt.%) ≤ 20), the sintering temperature of CaWO₄ ceramics could be effectively reduced from 1100 to 850 °C without degradation of dielectric properties. For the specimens sintered at 850 °C for 30 min, K was not changed remarkably with Bi₂O₃–H₃BO₃ content; however, Q × f value increased up to 9 wt.% H₃BO₃ of 0.5 wt.% Bi₂O₃–yH₃BO₃, and then decreased. The temperature coefficient of resonant frequency (TCF) shifted to the positive value with increasing Bi₂O₃–H₃BO₃ content. Typically, K of 8.7, Q × f of 70,220 GHz and TCF of −15 ppm/°C were obtained for the specimens with 0.5 wt.% Bi₂O₃–9 wt.% H₃BO₃ sintered at 850 °C for 30 min.     

Y2O3–Al2O3–SiO2-based glass-ceramic fillers for the laser-supported joining of SiC

Four glass-ceramic filler compositions within the Y₂O₃–Al₂O₃–SiO₂ system were tested for their suitability in laser-supported joining of SiC materials. The compositions differed in terms of their primary crystallization behavior. Joint zone microstructures were investigated and joint tightness was determined using helium leak rate measurements after joining and subsequent annealing at 900 °C and 1050 °C.Yttria- and silica-rich compositions showed a partial crystallization of yttrium silicates during the short laser processing. Subsequent heat treatment effected further crystallization toward equilibrium conditions. Despite the strong change in the degree of crystallization no reduction of the tightness was observed for the best compositions; after 500 h annealing at 1050 °C tightness values of less than 10⁻⁸ mbar l s⁻¹ were measured. These results demonstrate the potential of the investigated filler system for high temperature stable hermetic sealing. At the same time the creation of homogeneously structured joints from glass-ceramic fillers using a laser-supported technology needs the understanding of the crystallization kinetics.     

Liquid phase sintering of Al2O3/SiC nanocomposites

Al₂O₃/SiC nanocomposites are usually prepared by hot pressing or using high sintering temperatures, viz. 1700°C. This is due to the strong inhibiting effect of the nano-sized SiC particles on the densification of the material. Liquid phase sintering (LPS) can be used to improve densification. This work explored two eutectic additive systems, namely MnO₂.SiO₂ (MS) and CaO.ZnO.SiO₂ (CZS). The additive content in Al₂O₃/5 wt% SiC nanocomposite material varied from 2 to 10 wt%. Densities of up to 99% of the theoretical value were achieved at temperatures as low as 1300°C. Characterisation of the materials by XRD, indicated the formation of secondary crystalline phases in addition to Al₂O₃ and SiC. SEM and TEM analysis showed the presence of a residual glassy phase in the grain boundaries, and an increase in the average grain size when compared to nanocomposites processed without LPS additives.     

Spark plasma sintering of ultra-porous γ-Al2O3

Nanocrystalline gamma alumina (γ-Al₂O₃) powder with a crystallite size of ~10 nm was synthesized by oxidation of high purity aluminium plate in a humid atmosphere followed by annealing in air. Spark plasma sintering (SPS) at different sintering parameters (temperature, dwell time, heating rate, pressure) were studied for this highly porous γ-Al₂O₃ in correlation with the evolution in microstructure and density of the ceramics. SPS sintering cycles using different heating rates were carried out at 1050–1550 °C with dwell times of 3 min and 20 min under uniaxial pressure of 80 MPa. Alumina sintered at 1550 °C for 20 min reached 99% of the theoretical density and average grain size of 8.5 µm. Significant grain growth was observed in ceramics sintered at temperatures above 1250 °C.     

Synthesis,characterization, and microwave dielectric properties of ZnTiTa2O8 ceramics with ixiolite structure obtained through the aqueous sol–gel process

Nano-sized ZnTiTa₂O₈ powders with ixiolite structure, with particle sizes ranging from 10 nm to 30 nm, were synthesized by thermal decomposition at 950 °C. The precursors were obtained by aqueous sol–gel and the compacted and sintered ceramics with nearly full density were obtained through subsequent heat treatment. The microstructure and electrical performance were characterized by field emission scanning electron microscopy, x-ray diffraction, and microwave dielectric measurements. All the samples prepared in the range 950–1150 °C exhibit single ixiolite phase and relative density between ~87% and ~94%. The variation of permittivity and Q·ƒ value agreed with that of the relative density. Pure ZnTiTa₂O₈ ceramic sintered at 1050 °C for 4 h exhibited good microwave dielectric properties with a permittivity of 35.7, Q·ƒ value of 57,550 GHz, and the temperature coefficient of resonant frequency of about −24.7 ppm/°C. The relatively low sintering temperature and excellent dielectric properties in the microwave range would make these ceramics promising for applications in electronics.     

Far infrared and microstructural studies of mechanically activated nickel manganite

Nickel manganite powder synthesized by calcination of a stoichiometric mixture of manganese (MnO Aldrich 99.9%) and nickel oxide (NiO Merck, 99.5%) containing 0.5 wt% CoO and Fe₂O₃, was additionally mechanically activated in a high energy planetary ball mill for 5–60 min. The resulting powders were uniaxially pressed into disc shape pellets and then sintered for 60 min at 900 °C, 1050 °C and 1200 °C. Morphological changes of the obtained nickel manganite ceramics induced by mechanical activation were monitored using scanning electron microscopy, while changes in structural characteristics were followed using X-ray powder diffraction. Room temperature far infrared reflectivity spectra for all sintered samples were recorded in the frequency range between 50 cm^?1and 1200 cm^?1. The observed spectra for all samples showed the presence of the same oscillators, but their intensities depended on the sintering temperature and the time of mechanical acivation. Transversal and longitudinal optical modes were calculated for six ionic oscillators (four strong, and two shoulders) belonging to the nickel manganite partially inverse spinel structure.     

Charge–discharge curves and discharge capacities of LiNi1−yCoyO2 synthesized from lithium carbonate and nickel and cobalt oxides

LiNi_1?yCo_yO₂ (y=0.1, 0.3, and 0.5) were synthesized by a solid-state reaction method at 800 °C and 850 °C using Li₂CO₃, NiO, and Co₃O₄ as the starting materials. The electrochemical properties of the synthesized LiNi_1?yCo_yO₂ were then investigated. For samples with the same composition, the particles synthesized at 850 °C were larger than those synthesized at 800 °C. The particles of all the samples synthesized at 850 °C were larger than those synthesized at 800 °C. LiNi_0.5Co_0.5O₂ synthesized at 850 °C had the largest first discharge capacity (159 mA h/g), followed in order by LiNi_0.7Co_0.3O₂ synthesized at 800 °C (158 mA h/g) and LiNi_0.9Co_0.1O₂ synthesized at 850 °C (151 mA h/g). LiNi_0.9Co_0.1O₂ synthesized at 850 °C had the best cycling performance with discharge capacities of 151 mA h/g at n=1 and 156 mA h/g at n=5.     

Densification and Properties of Fe2O3 Nanoparticles added CaO Refractories

Up to 8 wt. % of Nano-iron oxide was added to CaO refractory matrix. The crystalline phases and microstructure characteristics of specimens sintered at 1650 °C for 5 h in an electric furnace were studied by X-ray diffraction (XRD) and scanning electron microscopy (SEM), respectively. The physical properties are reported in terms of bulk density, apparent porosity and hydration resistance. The mechanical behavior was studied by a cold crushing strength (CCS) and flexural strength at 1200 °C test. As a result, it was found that the presence of Nano-iron oxide in the CaO refractory matrix induced 2CaO.Fe₂O₃ (C₂F), CaO.Fe₂O₃ (CF) and 3CaO.Al₂O₃ (C₃A) phase’s formation, which improved the sintering process. Nano-iron oxide also influenced the bonding structure through a direct bonding enhancement. On the Other hand, the presence of Nano-iron oxide resulting in improvement properties of CaO refractory matrix refractories such as bulk density, hydration resistance and cold crushing strength. The maximum flexural strength at 1200 °C is achieved by the samples containing 4 wt. % nano-Fe₂O₃.     

Spark plasma sintering of silicon nitride/barium aluminum silicate composite

Si₃N₄ based composites were successfully sintered by spark plasma sintering using low cost BaCO₃, SiO₂ and Al₂O₃ as additives. Powder mixtures were sintered at 1600–1800 °C for 5 and 10 min. Displacement-temperature-time (DTT) diagrams were used to evaluate the sintering behavior. Shrinkage curve revealed that densification was performed between 1100 and 1700 °C. The specimen sintered at 1700 °C showed the maximum relative density (99.8±0.1%), flexural strength (352±16 MPa), Vickers harness (11±0.1 GPa) and toughness (5.6±0.05 MPa m^1/2).     

Ni4Nb2O9 ceramics prepared by the reaction-sintering process

Fabrication of Ni₄Nb₂O₉ ceramics via a reaction-sintering process was investigated. A mixture of raw materials was sintered into ceramics by bypassing calcination and subsequent pulverization stages. Ni₄Nb₂O₉ phase appeared at 1300 °C and increased with increasing soak time. Ni₄Nb₂O₉ content was found >96% in 1350 °C/2 h sintering pellets. A density of 5.71 g/cm³ was obtained for pellets sintered at 1350 °C for 2 h. This reaches 96.5% of the theoretical density. As the sintering temperature increased to 1350 °C, an abnormal grain growth occurred and grains >100 μm could be found. ?_r of 15.4–16.9 are found in pellets sintered at 1200–1300 °C. Q × f increased from 9380 GHz in pellets sintered at 1200 °C to 14,650 GHz in pellets sintered at 1250 °C.     

Fabrication and properties of Y2O3 transparent ceramic by sintering aid combinations

Transparent Y₂O₃ ceramics were fabricated by the solid-state reaction and vacuum sintering method using La₂O₃, ZrO₂ and Al₂O₃ as sintering aids. The microstructure of the Y₂O₃ ceramics sintered from 1550 °C to 1800 °C for 8 h were analyzed by SEM. The sintering process of the Y₂O₃ transparent ceramics was optimized. The results showed that when the samples were sintered at 1800 °C for 8 h under vacuum, the average grain sizes of the ceramics were about 3.5 µm. Furthermore, the transmittance of Y₂O₃ ceramic sintered at 1800 °C for 8 h was 82.1% at the wavelength around the 1100 nm (1 mm thickness), which was close to its theoretical value. Moreover, the refractive index of the Y₂O₃ transparent ceramic in the temperature range from 30 °C to 400 °C were measured by the spectroscopic ellipsometry method.     

Poly(N-isopropylacrylamide) assisted microwave synthesis of magnesium aluminate spinel oxide for production of highly transparent films by hot compression

Magnesium aluminate spinel oxides have been prepared via poly(N-isopropylacrylamide) assisted microwave technique. The prepared MgAl₂O₄ powders showed a crystalline cubic structure with spinel phase after calcination at 600 °C only. The poly(N-isopropylacrylamide) amount showed a high effect on the crystallite size and the densification behavior of MgAl₂O₄. The increase of the amount of poly(N-isopropylacrylamide) reduced the sintering temperature of MgAl₂O₄ from 1400 °C to 1050 °C. The hot-pressed of MgAl₂O₄ powders in the presence of 3 wt% of poly(N-isopropylacrylamide) exhibited a full density at sintering temperature 1100 °C in 15 min only. The sintered films showed high transparency (81 ± 2%) in the wavelength range 500–1000 nm.     

Synthesis of glass–ceramics in the CaO–MgO–SiO2 system with B2O3, P2O5, Na2O and CaF2 additives

Glass–ceramics based on the CaO–MgO–SiO₂ system with limited amount of additives (B₂O₃, P₂O₅, Na₂O and CaF₂) were prepared. All the investigated compositions were melted at 1400 °C for 1 h and quenched in air or water to obtain transparent bulk or frit glass, respectively. Raman spectroscopy revealed that the main constituents of the glass network are the silicates Q¹ and Q² units. Scanning electron microscopy (SEM) analysis confirmed liquid–liquid phase separation and that the glasses are prone to surface crystallization. Glass–ceramics were produced via sintering and crystallization of glass-powder compacts made of milled glass-frit (mean particle size 11–15 μm). Densification started at 620–625 °C and was almost complete at 700 °C. Crystallization occurred at temperatures >700 °C. Highly dense and crystalline materials, predominantly composed of diopisde and wollastonite together with small amounts of akermanite and residual glassy phase, were obtained after heat treatment at 750 °C and 800 °C. The glass–ceramics prepared at 800 °C exhibited bending strength of 116–141 MPa, Vickers microhardness of 4.53–4.65 GPa and thermal expansion coefficient (100–500 °C) of 9.4–10.8 × 10⁻⁶ K⁻¹.     

Structural,electromagnetic, and dielectric properties of lithium-zinc ferrite ceramics sintered by pulsed electron beam heating

Structural, electromagnetic, and dielectric properties of Li_0.4Fe_2.4Zn_0.2O₄ lithium-zinc ferrite sintered by 2.4 MeV pulsed electron beam heating at 1050 °С for 2 h were investigated. The formation of ferrite with a single-phase cubic spinel structure was confirmed by X-ray diffraction analysis. The average grain size of ferrite ceramic was determined by SEM analysis and its value was 1.7 µm. The radiation-thermal sintered samples are characterized by a saturation magnetization of 67.8 emu/g, the Curie temperature of 508 °C, AC electrical resistivity of 2.4×10⁴ Ω cm (at 25 °C). The frequency dependences of permittivity and the loss tangent were obtained in (20 – 2×10⁶) Hz frequency range. The behavior of ε′ is characterized by high dispersion caused by relaxation polarization in the investigated frequency range. The results were compared to the LiZn ferrite characteristics sintered by traditional thermal heating.     

Densification and ablation behavior of ZrB2 ceramic with SiC and/or Fe additives fabricated at 1600 and 1800 °C

The effects of Fe and SiC additions on the densification, microstructure, and ablation properties of ZrB₂-based ceramics were investigated in this study. The sample powders were conventionally mixed by cemented carbide ball then sintered by spark plasma sintering. The ablation rates and behavior of the ceramics were investigated under an oxyacetylene torch environment at about 3000 °C. A sample with high relative density (96.3%), high flexural strength (415.6 MPa), and low linear ablation rate (−0.4 µm/s) was obtained via SPS at 1600 °C. Adding 4 vol% Fe was more beneficial to the density of ZrB₂ sintered at 1600 °C as compared to ZrB₂ sintered at 1800 °C. The ablation behavior and rates were similar among samples sintered at 1600 °C and 1800 °C.     

Development of a new glass–ceramic by means of controlled vitrification and crystallisation of inorganic wastes from urban incineration

This paper reports the results of a study of the feasibility of recycling the solid residues from domiciliary waste incineration by producing a glass-ceramic. The major components of the raw material (TIRME F+L), which was from a Spanish domiciliary incinerator, were CaO, SiO₂ and Al₂O₃ but nucleating agents, such as TiO₂, P₂O₅, and Fe₂O₃ were also present in reasonable amounts. It was found that a relatively stable glass with suitable viscosity could be obtained by mixing 65 wt% TIRME F+L with 35 wt% glass cullet. The heat treatment required to crystallise the glass produced from this mixture, designated TIR65, was nucleation at 560°C for 35 min followed by crystal growth at 100°C for 120 min. The resulting glass-ceramic contained a number of crystalline phases, the most stable being clinoenstatite (MgSiO₃), or perhaps a pyroxenic phase which incorporates Ca, Mg and Al in its composition, and åkermanite (Ca₂MgSi₂O₇). The microstructure contained both fibre-like and dendritic crystals. The mechanical properties were acceptable for applications such as tiles for the building industry. ©     

Densification and biocompatibility of sintering 3.0 mol% yttria-tetragonal ZrO2 polycrystal ceramics with x wt% Fe2O3 and 5.0 wt% mica powders additive

The densification and biocompatibility of sintered 3.0 mol% yttria-tetragonal zirconia polycrystal (3Y-TZP) ceramics, with X wt% Fe₂O₃ and 5.0 wt% mica powders (denoted by 3Y-TZP: X-5.0 wt% mica) have been studied. When the pellets of 3Y-TZP: X-5.0 wt% mica were sintered at 1300 °C for 1 h, the relative shrinkage increases from 19.20–19.43% with the X increased from 0.3 to 1.0. The relative shrinkage of pellets containing 1.0 wt% Fe₂O₃ (X=1.0) increased from 19.43–19.59% when sintering temperatures were raised from 1300 °C to 1450 °C. X-ray diffraction results show that the pellets of 3Y-TZP: X-5.0 wt% mica sintered at 1400 °C for 1 h only contained single phase of tetragonal ZrO₂ (t-ZrO₂). When the sintering temperature was higher than 1400 °C, the Vickers microhardness was greatest in the pellets with X=0.5. Within pellets with the same Fe₂O₃ content, the dominant wavelength (λ_d) was only slightly different for pellets sintered at 1300 °C and those sintered at 1450 °C. The results of the materials were evaluated in vitro cytotoxicity tests reveals that the powders and sintered pellets are safe materials. The oral mucosa irritation tests did not find erythema or histopathological change including normal epithelium, and was free from leucocyte infiltration, vascular congestion and oedema.     

Fabrication and negative thermal expansion properties of P-substituted ZrV2O7 sintered bodies

Calcined powders of ZrV_1.2P_0.8O₇ (ZVP) and ZrV₂O₇ (ZV) were synthesized by heating gels prepared from NH₄H₂PO₄, NH₄VO₃, and ZrOCl₂ solutions at 500 and 400 °C, respectively. Dense ZV-added ZVP sintered bodies were subsequently fabricated through heating at 850 °C for 20 h, with the addition of ZrV₂O₇ as a sintering additive. The resulting material had a relative density of ca. 92%, while the relative density of pure sintered ZVP was ca. 72%. NH₄H₂PO₄ (NHP) was also added to ZVP along with ZV to obtain a molar ratio of P in NHP for V in ZV = 1. Subsequently, a single phase (NHP, ZV)-added ZVP sintered body was obtained by heating at 850 °C. Thermomechanical analysis showed that the dense ZV-added ZVP sintered body exhibited a positive thermal expansion from 25 to 150 °C and a negative thermal expansion from 150 to 500 °C.