Cellular glass obtained from non-powder preforms by foaming with steam

Cellular glass, or foamed glass, has been obtained as a result of the heating (to 700–800 °C) of heavy and strong preforms formed due to the binding properties of the silicate additives. Durability of the preforms reached 6 MPa at the density of 1.8 g/cm³. The main expanding agent in the composition is steam, which can also be a carbon oxidizer and increase the amount of the evolved gases and decrease the density of the foamed glass obtained. As a result of changing the initial composition structure, the density of the obtained foamed glass varied from 0.14 to 0.6 g/cm³, its breaking strength - from 0.6 to 5.0 MPa. and heat conductivity – from 0.045 to 0.15 W/(m·К), respectively. The speed of expansion of the preforms had an extreme character with the induction period typical for topochemical reactions. The obtained cellular materials possessed a distinct crystalline structure. The experiments showed the possibility of obtaining cellular materials with acceptable properties from different types of glass for the solution of environmental tasks. Various technological methods of obtaining cellular material blocks from preforms of various forms were tested to use them for thermal insulation and facing materials.     

Processing and in vitro bioactivity of high-strength 45S5 glass-ceramic scaffolds for bone regeneration

In this paper, the compressive strength and in vitro bioactivity of sintered 45S5 bioactive glass scaffolds produced by powder technology and polymer foaming were investigated. The sintering temperature of scaffolds was 975 °C. The characterization of scaffolds before immersion in SBF was performed by scanning electron microscopy (SEM) and microtomography (μCT). The scaffolds were also tested for compression, and their density and porosity were measured. After immersion, the samples were observed through SEM and analyzed using EDS, X-ray diffraction (XRD), and infrared spectroscopy (FT-IR). Mass variation was also estimated. The glass-ceramic scaffolds showed a 61.44±3.13% interconnected porosity and an average compressive strength of 13.78±2.43 MPa. They also showed the formation of a hydroxyapatite layer after seven days of immersion in SBF, demonstrating that partial crystallization during sintering did not suppress their bioactivity.     

Effects of sintering temperature and holding time on porosity and shrinkage of glass tubes

The influences of sintering temperature and holding time on porosity and shrinkage of glass tubes have been studied by optical microscope. It is evident that there exists three stages for the sintering process of glass. At the first stage, both increasing temperature and prolonging the holding time contribute to lowering the porosity and to intensifying the shrinkage greatly. At the second stage, the glass further densifies and the voids among particles become smaller and less. Finally, at the third stage the shrinkage rate almost keeps unchanged to sintering temperature and holding time.     

The use of egg shells to produce Cathode Ray Tube (CRT) glass foams

Cleaned Cathode Ray Tube (CRT) (panel and funnel) waste glasses produced from dismantling TV and PC colour kinescopes were used to prepare glass foams by a simple and economic processing route, consisting of a direct heating of glass powders at relatively low temperatures (600–800 °C). This study reports on the feasibility of producing glass foams using waste egg shells as an alternative calcium carbonate-based (95 wt%) foaming agent derived from food industry. The foaming process was found to depend on a combination of composition, processing temperature and mixture of raw materials (glass wastes). Hot stage microscopy (HSM), X-ray diffraction (XRD) and scanning electron microscopy (SEM) were used to characterize foams and evaluate the foaming ability and the sintering process. The experimental compositions allowed producing well sintered glass foams with suitable properties for some functional applications with environmental benefits such as: (1) reduced energy consumption because of the low heat treatment temperatures used; and (2) materials produced exclusively from residues.     

Effect of sintering temperature on compressive strength of porous yttria-stabilized zirconia ceramics

Porous yttria-stabilized zirconia (YSZ) ceramics were fabricated by tert-butyl alcohol (TBA)-based gel-casting method for potential applications in heat-insulation materials. The effect of sintering temperature on compressive strength of porous YSZ ceramics was investigated on the basis of measurements linear shrinkage, porosity and pore size. As the sintering temperature increased from 1350 to 1550 °C, a decrease of porosity from 77 to 65%, a decrease of average pore size from and an increase of linear shrinkage from 15.4 to 31.8% were observed. The compressive strength increased remarkably from 3 to 27 MPa with increasing sintering temperature from 1350 to 1550 °C, which was related to the corresponding change of linear shrinkage, porosity, pore size and microstructure. A remarkable decrease of compressive strength with increasing porosity was observed. The compressive strength decreased also with increasing pore size.     

Suppressing the effect of cullet composition on the formation and properties of foamed glass

The process of foaming glass is very dependent on the chemical composition of the glass. In this study we used a foaming-agent/oxidizing-agent couple and a crystallization inhibitor to foam cullets of flat, container and CRT-panel glass. Foamed glass with a density of 110–120?kg?m^–3, a thermal conductivity of 50–52?mW?m^–1 K^–1 and a homogeneous pore structure was obtained from a mixture of panel glass, 0.33?wt% carbon and 4.45?wt% Fe₂O₃. We also showed that it is possible to fabricate foamed glass with the same density or pore structure as mentioned above by adding up to 50?wt% container cullet or 70?wt% flat glass to the mixture. In the foamed samples with a low content of panel glass, crystals form, resulting in an increased open porosity, density and inhomogeneous pore structure. The crystallization can, however, be inhibited by adding calcium phosphate, so enabling the preparation of high-quality foamed glass from flat glass or flat/container-glass mixture. The pore gas is predominantly CO₂ and the pressure inside the pores is 0.36–0.47?bar. The reduced effect of the composition on the foaming process suggests that there is a great potential for stabilizing the production of foamed glass and ensuring the product's quality.     

Fabrication and microstructure of porous SiC ceramics with Al2O3 and CeO2 as sintering additives

In the present study, porous silicon carbide ceramics were prepared via spark plasma sintering at relatively low temperatures using Al₂O₃ and CeO₂ as sintering additives. Sacrificial template was selected as the pore forming mechanism, and gelcasting was used to fix the slurry in a short time. The evolution process of the microstructures during different steps was observed by SEM. The influence of the sintering temperature and sintering additives on the shrinkage and porosity of the samples was studied. The microstructures of different samples were characterized, and the mechanical properties were also evaluated.     

Processing of porous glass ceramics from highly crystallisable industrial wastes

This study was carried out to gain understanding about the sintering behaviour of highly crystallisable industrial waste derived silicate mixtures under direct heating and rapid cooling conditions. The materials used in this study were plasma vitrified air pollution control waste and rejected pharmaceutical borosilicate glass. Powder compacts sintered under direct heating conditions were highly porous; compacts with particle size <?38?μm reached a maximum density of 2.74 g?cm^??3 at 850°C, whereas compacts with particles of size <?100?and <?250?μm reached maximum densities of 2.69 and 2.72 g?cm^??3 at 875 and 900°C respectively. Further increase in sintering temperature resulted in a rapid decrease in density of the glass ceramics. Image analysis results were used to link the sudden drop in density to the increase in volume of microsized pores formed in the samples during sintering. In particular, compacts made from <?38 μm particles sintered at 950°C resulted in 65 vol.-% porosity with a pore size of ～20?μm. Such materials can be used for sound and thermal insulation purposes.     

Sintering and crystallization of plates prepared from coarse glass ceramic frits

The focus of this study was the development of a CAS glass-ceramic (14.0CaO·5.5Al₂O₃.80·5SiO₂) for use in civil engineering as a decorative material. This glass-ceramic system was chosen because it can be used to produce plates with a similar appearance to those of marble and granite materials. Ceramic plates were produced by the Grain Glass Sintering process from frits with a coarse grain size (2.1 mm average particle size). Powder frit samples (5.3-μm average particle size) were prepared and characterized. The results were compared with those obtained with coarse particles. Thermal treatment was performed in one stage, with the heating rate varying from 2 to 25 °C min^?1. Temperatures were defined by differential thermal analysis and heating microscopy. With these results, it was possible to establish correlations among the esthetic effects, the microstructure, and the heat treatment conditions (temperature, heating rate, and holding time). The relative density ranged from 0.92 to 0.96. The formation of wollastonite and pseudowollastonite was observed. An esthetic effect similar to that of natural marble was more apparent in those samples in which the microstructure presented a visual contrast between the bulk and the coarse frit. Lower heating rates intensified the visual contrast and reduced porosity near the surface regions.     

Elaboration and characterization of porous granules based on waste glass

The evolutions of the world today and the population increase have resulted in pollution and human wastes, which contaminate the environment and adversely affect the human's quality of life.All forms of food and drink packages, made of paper, plastic foam, aluminum and glass, are designed for the consumers' convenience. After being used, these packages are discarded as garbage and have today become a social problem.It is in this context that our work for obtaining a building material (foam glass granules) that is much lighter is registered with the properties of heat insulation and acoustic improved based on cullet in order to recycle it and for improving the present laws about the waste products in closed circuit (finished products → waste products → finished products).Investigations have shown that grinding waste glass to particle size less than 0.1 mm and adding 1% of Ca CO₃ content provide the production of material with the following properties: particle density of 0.5 g/cm³, strength of 17.50 MPa and water adsorption of 95%, with the temperature for foaming ranges determined at 850 °C. The microstructures are homogenous, with pore sizes of up to 2 mm. The foam glass is counted among the new glass products meeting certain requirements on comfort, in particular in the building industry (thermal and acoustic insulation). The product obtained presents excellent thermal (λ = 0,031 W/m°C) and acoustic (R = 15 dB) properties.     

Fabrication of porous silicon carbide ceramics with high porosity and high strength

Unique porous SiC ceramics with a honeycomb structure were fabricated by a sintering-decarburization process. In this new process, first a SiC ceramic bonded carbon (SiC/CBC) is sintered in vacuum by spark plasma sintering, and then carbon particles in SiC/CBC are volatized by heating in air at 1000 °C without shrinkage. The honeycomb structure has at least two different sizes of pores; ∼20 μm in size resulting from carbon removal; and smaller open pores of 2.1 μm remaining in the sintered SiC shell. The total porosity is around 70% and the bulk density is 0.93 mg/m³. The bending and compressive strengths are 26 MPa, and 105 MPa, respectively.     

Characterization of basaltic tuffs and their applications for the production of ceramic and glass–ceramic materials

Alkaline basaltic tuffs, from Southern Turkey were characterized and employed to obtain ceramic and glass–ceramic materials by combined sintering and crystallization process. The chemical and mineralogical compositions were analyzed by X-ray fluorescence spectrometry and X-ray diffraction analyses, respectively. The phase formation and the sintering behaviour were investigated by DTA, differential dilatometer and hot-stage microscopy. The micro-structure and residual porosity of the sintered samples were observed by SEM and evaluated by pycnometric techniques. Ceramic material, based on 50% basaltic tuff and 50% clay, was obtained at 1150 °C with 13% total porosity and 4% water absorption. Glass–ceramic materials were synthesized directly using the milled basaltic tuff by mean of the sinter-crystallization technique, in the range 900–1150 °C. The investigation has showed that, due to the high porosity and low crystallinity, alkaline tuffs could be a suitable raw material for ceramic application.     

TBA-based freeze/gel casting of porous hydroxyapatite scaffolds

Porous ceramic scaffolds with a controlled “designer” pore structure have been prepared by the freeze/gel casting route using a TBA-based hydroxyapatite slurry system with 20–40 wt.% solid content. The products were characterized in terms of sintered microstructure, together with physical and mechanical properties. After sintering at 1050–1250 °C, the advantages of freeze casting and gel casting appeared in the pore structure and compressive strength of the ceramics, i.e., unidirectional aligned macro-pore channels developed by controlling the solidification direction of the TBA solvent used in the freeze casting together with small diameter (micron sized) isolated pores formed in the dense outer walls of the pore channels when processed by gel casting. The sintered porosity and pore size generally resulted in a high solid loading giving low porosity and small pore size, this leading to higher compressive strengths. The scaffolds obtained exhibited an average porosity and compressive strength in the range 41.9–79.3% and 35.1–2.7 MPa, respectively, depending on the processing conditions used.     

Potassium based bioactive glass for bone tissue engineering

A fundamental issue for the restoration of bone defects according to a tissue engineering approach is the development of highly porous bioactive scaffolds. The polymer burning out method is widely employed to fabricate bioceramic scaffolds because of its versatility, simplicity and low cost. However, the resulting scaffolds may suffer low porosity and non-interconnected pores. In the present contribution a new fabrication method is presented. Thanks to a recently developed potassium-based bioactive glass, which has the peculiarity to be sintered at a relatively low temperature (i.e. ∼750 °C), it was possible to use sodium chloride particles as pore generating agents, which helped to maintain the shape of the struts during the entire sintering process. The salt particles can be easily removed by immersing the scaffold in water, giving place to a structure that combines high porosity (in the 70–80 vol.% range) with interconnected pores and an appreciable mechanical behaviour (Young's modulus in the 3.4–3.7 MPa range according to compression tests).     

Preparation and characterisation of porous composite biomaterials based on silicon nitride and bioglass

The combination of bioinert and bioactive material offers new potentialities in bone tissue engineering. The present paper deals with preparation of novel biomaterial composite based on silicon nitride (Si₃N₄) and bioglass (in amount of 10 and 30 wt%) by free sintering at 980 °C for 1 h in nitrogen atmosphere. The obtained material was characterised by differential thermal analysis (DTA) and X-ray powder diffraction (XRD), porosity and pore size distribution were evaluated by means of mercury intrusion porosimetry (MIP). The bioactivity was examined in vitro with respect to the ability of hydroxyapatite layer formation on the surface of materials as a result of contact with simulated body fluid (SBF). All composites were studied by Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) before and after immersion in SBF. The bioglass-free sample was prepared as a reference material to compare the microstructure and bioactivity to the composites.     

Influence of barium oxide on the crystallization, microstructure and mechanical properties of potassium fluorophlogopite glass-ceramics

The influence of barium oxide, heat treatment time and temperature on the crystallization, microstructure and mechanical behavior of the system Ba_x·K_1−2x·Mg₃·Al·Si₃O₁₀·F₂ (where x = 0.0, 0.3 and 0.5) was investigated in order to develop novel, high strength and machinable glass-ceramics. Three glasses were prepared and characterized by differential thermal analysis (DTA), X-ray diffraction (XRD), scanning electron microscope (SEM) techniques and some mechanical testing methods.The crystallization kinetics of glass-ceramics was also studied. Activation energy and Avrami exponent calculated for the crystallization peak temperature (T_p) of three different glass batches. The Vickers hardness decreased slightly on formation of the potassium fluorophlogopite and barium fluorophlogopite phases, but decreased significantly on formation of an interconnected ‘house of cards’ microstructure.     

A new potassium-based bioactive glass: Sintering behaviour and possible applications for bioceramic scaffolds

Providing structural support while maintaining bioactivity is one of the most important goals for bioceramic scaffolds, i.e. artificial templates which guide cells to grow in a 3D pattern, facilitating the formation of functional tissues. In the last few years, 45S5 Bioglass^® has been widely investigated as scaffolding material, mainly for its ability to bond to both hard and soft tissues. However, thermal treatments to improve the relatively poor mechanical properties of 45S5 Bioglass^® turn it into a glass-ceramic, decreasing its bioactivity. Therefore, the investigation of new materials as candidates for scaffold applications is necessary. Here a novel glass composition, recently obtained by substituting the sodium oxide with potassium oxide in the 45S5 Bioglass^® formulation, is employed in a feasibility study as scaffolding material. The new glass, named BioK, has the peculiarity to sinter at a relatively low temperature and shows a reduced tendency to crystallize. In this work, BioK has been employed to realize two types of scaffolds. The obtained samples have been fully characterized from a microstructural point of view and compared to each other. Additionally, their excellent bioactivity has been established by means of in vitro tests.     

Crystallization process and some properties of novel transparent machinable calcium-mica glass-ceramics

Bulk glass having a calcium-mica composition (Ca_0.5Mg₃AlSi₃O₁₀F₂) is homogeneous glass. The crystallization mechanism of the mica is surface crystallization and transparency is lost completely when crystallization occurs on the surface. In this study, by decreasing SiO₂ and increasing CaO and Al₂O₃ from the chemical composition of Ca_0.5Mg₃AlSi₃O₁₀F₂, and moreover by replacing a small amount of K₂O instead of CaO, the phase separation appears in the glasses. Because of this phase separation, the mica begins to be crystallized not only on the surface but also in the bulk at lower temperatures. Consequently, the novel transparent machinable mica glass-ceramic can be obtained by heating the glasses having the chemical composition of Ca_0.6Mg₃Al_1.2Si_2.8O₁₀F₂ and K_0.01Ca_0.595Mg₃Al_1.2Si_2.8O₁₀F₂. As a larger amount of calcium-mica is separated, the bending strength decreases and the fracture toughness increases. Furthermore, by replacing K⁺ ion instead of Ca²⁺ ion in the interlayer of calcium-mica, the interlayer bonding strength becomes high, resulting in the increase of the bending strength.     

Effect of soda-lime glass on sintering and technological properties of porcelain stoneware tiles

The feasibility of waste glass recycling in ceramic tile production was assessed with special reference to fully vitrified products (porcelain stoneware). Soda-lime float or container glass was introduced, in replacement of sodic feldspar, in typical porcelain stoneware bodies (up to 10 wt.%) that underwent a laboratory simulation of tilemaking process, with a technological and compositional characterization of both fired and unfired tiles. Soda-lime glass had no significant effect on semi-finished products, but it influenced remarkably the firing behaviour, increasing shrinkage and closed porosity, decreasing open porosity and bulk density, and lowering mechanical and tribological performances. Waste glass promotes a more effective melting of quartz and a partial dissolution of mullite, leading to a more abundant and less viscous liquid phase, which accelerates the sintering kinetics. In conclusion, soda-lime glass can be used in small amounts (5% or less) with tolerable modifications of technological behaviour and performances of porcelain stoneware tiles.     

Recycling of CRT panel glass as fluxing agent in the porcelain stoneware tile production

In the present work, the feasibility to substitute feldspar raw material in a porcelain stoneware body with Panel Cathode Ray Tube (CRT) glass was investigated. A standard batch and a composition, where 35 wt.% Na-feldspar was substituted by CRT glass, were sintered at different temperatures in the range of 1000–1250 °C. The degree of the densification was studied by evaluation of the closed and total porosity, while the sintering rate was estimated by non-isothermal dilatometric measures. The variation of the crystalline phase composition was evaluated by XRD analysis. From the preliminary study other ceramic samples with different percentages of CRT glass (i.e. 2.5, 5 and 10 wt.%) were prepared and fired in industrial kiln. The sintering parameters, the microstructure and the mechanical properties were measured and compared with the standard composition.