Improvement on characteristics of porous alumina from platelets using a TEOS treatment

A porous alumina body was synthesized from anisotropic alumina particles, namely platelets. When green compacts, which had been uniaxially pressed at 1 MPa, were heated at 1200 and 1500 °C for 1 h, the average porosity of the resulting alumina bodies was 75.5 and 71.0%, respectively. The thermal conductivity of the porous alumina fabricated at 1400 °C for 1 h with 72.3% in porosity was 0.8 W m^?1 K^?1. In an attempt to increase the compressive strength of the porous alumina bodies, TEOS (tetraethyl orthosilicate) solution treatment was carried out, followed by reheating to 1400 °C for 1 h. The compressive strength of the porous alumina body increased from 3.8 MPa (without TEOS solution treatment) to 10.2 MPa (with three rounds of TEOS treatment), with the porosity decreasing to 65.5% and the thermal conductivity increasing to1.2 W m^?1 K^?1.     

Synthesis and mechanical properties of porous alumina from anisotropic alumina particles

A porous alumina body was synthesized from anisotropic alumina particles (platelets). The uniaxial pressure in fabricating the green compact body had an influence on the relative density of the alumina body after heating. When green compacts, which had been uniaxially pressed at 1 and 3 MPa, were heated at 1400 °C for 1 h, the relative densities of the resulting alumina bodies were 25.0% and 35.5%, respectively. The compressive strength of compacts that were uniaxially pressed at 1 and 3 MPa were 0.8 and 4.3 MPa, respectively. In an attempt to increase the compressive strength of these porous alumina bodies, aluminum nitrate and magnesium nitrate solution treatments were performed, followed by reheating to 1400 °C for 1 h. When a 0.5 mol/l aluminum nitrate solution was used, the compressive strength of the porous alumina body uniaxially pressed at 1 MPa changed from 0.8 MPa (without solution treatment) to 1.5 MPa. Furthermore, when 0.1 mol/l magnesium nitrate solution was used, the compressive strength of the porous alumina increased to 1.7 MPa. Thus, solution treatment of the porous alumina body had a strong positive effect on its mechanical strength.     

Characterization of porous alumina bodies fabricated by high-temperature evaporation of boric acid with sodium impurity

For steel-making refractories, porous alumina bodies fabricated by the evaporation of chemical impurities at high temperatures was studied. Boron hydroxide and sodium carbonate were added in different proportions as impurities into the starting aluminum hydroxide powder compacts, which were heated at various temperatures for 1 h to form porous alumina bodies. During heating, the borate compounds that reacted with sodium seems to be formed in the liquid phase, so that all alumina particles were able to grow into platelets. Although the sodium inside the compacts was completely evaporated by 1400 °C, the boron melt was maintained above 1400 °C. Hence, alumina platelets grew with a card-house structure, which preserved the high porosity of the alumina body. After heating at 1600 °C for 1 h, the remaining boron oxide was completely evaporated and sintering between the alumina particles began to decrease the porosity. The compressive strength and porosity of the alumina bodies obtained by heating at 1700 °C for 1 h were 0.8 MPa and 64%, respectively. It is expected that the resulting porous alumina bodies can be used as castable porous clinkers.     

Effects of PMMA on porous structure of pollucite

The effects of PMMA as a pore-forming reagent and the powder for Cs-deficient pollucite, Cs₉Al_0.9Si_2.1O₆, calcined at 1073 K, on the microstructure of the porous body of Cs_0.9Al_0.9Si_2.1O₆ were investigated. The Cs_0.9Al_0.9Si_2.1O₆ porous bodies were fabricated by sintering the green compacts of the calcined powder and PMMA adding 35 mass% to the calcined powder. When the green compact was heated at 873 K in air for 20 h, pores <1 μm were observed in the porous body, suggesting that the PMMA previously dissolved in acetone was uniformly distributed in the calcined powder by the ball milling. The pore size of the obtained porous structure increased with increasing the size of the aggregated particles and the pore size distribution was significantly related to the size of Al₂O₃ balls and the time for the ball milling for mixing the calcined powders and PMMA.     

Alumina porous nanomaterials obtained by colloidal processing using d-fructose as dispersant and porosity promoter

Recently, great effort has been devoted to obtain porous materials with customized pore size distribution, high surface area and submicrometer sized microstructures or nanostructures. In this work, the viability of colloidal processing routes to obtain porous bulk ceramics using alumina nanopowders and d-fructose as a dispersant and a porosity former has been explored.The rheological behaviour of nanosuspensions was studied in order to assure their stability and to analyse the influence of different parameters (solids loading, fructose content, pH, sonication time). Mesoporous green bodies were obtained by slip casting with d-fructose in concentrations ranging from 5 to 50 wt%. The drying and burning-out conditions were determined by DTA-TG measurements and the sintering cycles were selected from the dynamic sintering curve. Sintered alumina materials with high porosity (>60%), open microstructures, submicrometer sized porosity (d_p = 140–210 nm) and grain size lower than 500 nm, were obtained for pieces sintered at temperatures of 1300 and 1400 °C. The influence of different processing parameters on the porosity and the microstructure of the sintered materials is discussed.     

Thermal conductivity of ceramic/metal composites from preforms produced by freeze casting

Porous alumina and zirconia preforms, processed by ice templating, have been used to manufacture ceramic/metal composites by aluminium alloy infiltration. The aim of the present work is to study the influence of the ceramic material nature and of the initial porous structure on the thermal conductivity anisotropy of the composite in order to assess potential applications in the field of thermal management. The materials are characterised in terms of pore volume fraction and pore size before and after metal infiltration. The freeze casted preforms exhibit anisotropic lamellar structures with ellipsoidal pores ranging from 35 µm to 40 µm and porosity fractions from 64 to 67%. After metal infiltration, composite parts present the same anisotropic morphology, which correspond to alternating ceramic and metal layers. Thermal conductivities have been determined, with an average of 80 W m⁻¹ K⁻¹ and 13 W m⁻¹ K⁻¹ parallel and perpendicular to the freezing direction respectively, for zirconia/metal composites. Theoretical values of thermal conductivity can be calculated using the Maxwell-Eucken relation, to handle the residual porosity, in combination with series and parallel resistance models to describe the overall anisotropic character. These give good agreement to experiment.     

Preparation and properties of porous alumina ceramics with oriented cylindrical pores produced by an extrusion method

Porous alumina ceramics with unidirectionally-oriented pores were prepared by extrusion. Carbon fibers of 14 μm diameter and 600 μm length to be used as the pore-forming agent were kneaded with alumina, binder and dispersing agent. The resulting paste was extruded, dried at 110 °C, degreased at 1000 °C and fired at 1600 °C for 2 h. SEM showed a microstructure of dispersed highly oriented pores in a dense alumina matrix. The pore area in the cross section was 25.3% with about 1700 pores/mm². The pore size distribution of the fired body measured by Hg porosimetry showed a sharp peak corresponding to the diameter of the burnt-out carbon fibers. The resulting porous alumina ceramics with 38% total porosity showed a fracture strength of 171 MPa and a Young's modulus of 132 GPa. This strength is significantly higher than the reported value for other porous alumina ceramics even though the present pore size is much larger.     

Preparation and properties of porous alumina ceramics with uni-directionally oriented pores by extrusion method using a plastic substance as a pore former

Porous alumina ceramics with uni-directionally aligned pores were prepared by an extrusion method using 0–40 vol.% poly (vinyl acetate) (PVAC) as the pore former. A paste was prepared by mixing 25 mass% distilled water, 4 mass% methylcellulose, 8 mass% oleic acid and 0.8 mass% ammonium poly (carboxylic acid). This paste was molded into a 10 mm Ø body using a ram-type extruder, dried at room temperature for 24 h, calcined at 600 °C for 1 h and sintered at 1500 °C for 2 h in air. The PVAC added to the paste was homogeneously dispersed and formed particles 0.1–150 μm in size which extended in the extrusion direction and were converted to through-hole pores after sintering. The resulting pore size distribution in the samples was bimodal, centered at about 0.4 μm with a broad peak at about 70 μm dia. The resulting porous alumina ceramics showed high gas permeability because of their uni-directionally oriented through-hole pore structure.     

Preparation and characterization of porous alumina ceramics through starch consolidation casting technique

This work aims at studying the influence of thermal treatment on the microstructure, resistivity and technological properties of porous alumina ceramics prepared via starch consolidation casting (SCC) technique. Colloidal suspensions were prepared with three different contents of alumina solid loading (55, 60 and 65 mass%) and corn starch (3, 8 and 13 mass%). The sintered samples at 1400, 1500, 1600 and 1700 °C, show open porosity between 46 and 64%, depending on the starch content in the precursor suspensions and sintering temperature. The pore structures were analyzed by SEM. The effect of corn starch content on the apparent porosity, pore size distribution, linear shrinkage and electrical resistivity as well as cold crushing strength of the sintered porous alumina ceramics was also measured. These porous alumina ceramics are promising porous ceramic materials for using in a wide range of thermal, electrical and bioceramics applications as well as filters/membranes and gas burners, due to their excellent combination properties.     

Al2O3–SiC composites prepared by warm pressing and sintering of an organosilicon polymer-coated alumina powder

Al₂O₃/SiC micro/nano composites were prepared by axial pressing of poly(allyl)carbosilane-coated submicrometre alumina powder at elevated temperature (called also warm pressing, or plastic forming) with subsequent pressureless sintering in the temperature interval between 1700 and 1850 °C. Warm pressing at 350 °C and 50 MPa resulted in green bodies with high mechanical strength and with markedly higher density than in green bodies prepared by cold isostatic pressing of the same powder at 1000 MPa. The sintering of warm pressed specimens moreover yielded the composites with higher final density (less than 4% of residual porosity) with the microstructure composed of micrometer-sized alumina grains (D₅₀ < 2 μm) with inter- and intragranular SiC precipitates. High sintering temperatures (>1800 °C) promoted the formation of intergranular platelets identified by TEM as 6H polytype of α-SiC. The maximum hardness (19.4 ± 0.5 GPa) and fracture toughness (4.8 ± 0.1 MPa m^1/2) were achieved in the composites containing 8 vol.% of SiC, and sintered for 3 h at 1850 °C. These values are within the limits reported for nanocomposites Al₂O₃/SiC by other authors and do not represent any significant improvement in comparison to monolithic alumina.     

Thermal properties of silicon carbide composites fabricated with chopped Tyranno® SiAlC fibres

Thermal diffusivity, a, and thermal conductivity, κ, between room temperature and 600 K were investigated for SiC composites containing 0–50 mass% of Tyranno^® SiAlC (SA) fibre (mean length: 394 μm) hot-pressed at 1800 °C for 30 min under a pressure of 31 MPa. The monolithic SiC specimen possessed κ of 32.1 W m⁻¹ K⁻¹ at room temperature; no significant changes were found for the SiC composite containing ≤20 mass% of SA fibre addition. However, further increases in the amount of SA fibre to 50 mass% improved κ to a maximum of 56.3 W m⁻¹ K⁻¹. The value of a for the SiC composite containing 40 mass% of SA fibre was 0.185 cm² s⁻¹ at room temperature and decreased to 0.120 cm² s⁻¹ at 600 K. In addition, SiC composites using 40 mass% of SA fibre with a carbon interface of approximately 100 nm were fabricated. The effect of this interface on a and κ was marginal.     

Influence of anionic stabilization of alumina particles in 2-propanol medium on the electrophoretic deposition and mechanical properties of deposits

The ceramic dispersions were prepared using 0.85, 1.70, 4.25, 12.75 or 21.25 wt.% of monochloroacetic, dichloroacetic or trichoroacetic acid, 15 wt.% alumina and 2-propanol. The mechanism of anionic stabilization in 2-propanolic media was described. Alumina green bodies were prepared from the stable dispersion via electrophoretic deposition (EPD). It was found that increasing dispersion conductivity significantly influenced the EPD yields. The most effective electrophoretic depositions were performed from dispersions with conductivity in range 4.0–5.3 × 10⁻⁴ S m⁻¹. Deposits with the highest green density were prepared from the dispersion stabilized by trichloroacetic acid. This behavior was explained by low voltage drop during deposition. The surface roughness was high at low dispersion conductivity and with increasing acid concentration in dispersion the surface of deposits was smoother. The mechanism of particle arrangement in deposit was discussed. Influence of stabilizer amount in the dispersion on the hardness and fracture toughness was described.     

Formation of porous aggregations composed of Al2O3 platelets using potassium sulfate flux

Porous aggregations, with about 10 μm diameter, composed of Al₂O₃ platelet crystals were formed by heating a powder mixture consisting of Al₂(SO₄)₃+2K₂SO₄ (mol ratio) in an alumina crucible at temperatures 1000–1300°C for 3 h and removing the flux component with hot hydrochloric acid after heating. The specific surface area of the aggregations obtained by heating at 1000°C for 3 h was maximum and its value was 5·2 m² g⁻¹. Since the size of Al₂O₃ platelets increased and the number of Al₂O₃ platelets decreased, the specific surface area decreased to 0·7 m² g⁻¹ at 1100°C. When heated at 1300°C, the size of the Al₂O₃ platelets increased with increasing amount of K₂SO₄ in the starting powder mixture. ©     

Investigating the effect of SPRM on mechanical strength and thermal conductivity of highly porous alumina ceramics

For recycling waste refractory materials in metallurgical industry, porous alumina ceramics were prepared via pore forming agent method from α-Al₂O₃ powder and slide plate renewable material. Effects of slide plate renewable material (SPRM) on densification, mechanical strength, thermal conductivity, phase composition and microstructure of the porous alumina ceramics were investigated. The results showed that SPRM effectively affected physical and thermal properties of the porous ceramics. With the increase of SPRM, apparent porosity of the ceramic materials firstly increased and then decreased, which brought an opposite change for the bulk density and thermal conductivity values, whereas the bending strength didn’t decrease obviously. The optimum sample A2 with 50 wt% SPRM introducing sintered at 1500 °C obtained the best properties. The water absorption, apparent porosity, bulk density, bending strength and thermal conductivity of the sample were 31.7%, 62.8%, 1.71 g/cm³, 47.1 ± 3.7 MPa and 1.73 W/m K, respectively. XRD analysis indicated that a small quantity of silicon carbide and graphite in SPRM have been oxidized to SiO₂ during the firing process, resulting in rising the porous microstructures. SEM micrographs illustrated that rod-like mullite grains combined with plate-like corundum grains to endow the samples with high bending strength. This study was intended to confirm the preparation of porous alumina ceramics with high porosity, good mechanical properties and low thermal conductivity by using SPRM as pore forming additive.     

Preparation and properties of bimodal porous apatite ceramics through slip casting using different hydroxyapatite powders

A bimodal porous hydroxyapatite (HAp) body with high flexural strength was prepared through slip casting. The effect of different particle sizes on the flexural strength and microstructure of three different types of hydroxyapatite (HAp) powders was studied. The powder characteristic of laboratory-synthesized HAp powder (L-HAp) was obtained through a wet-milling method, drying and heating of a mixture of calcium hydrogen phosphate di-hydrate and calcium carbonate. The median particle size of L-HAp was 0.34 μm, and the specific surface area was 38.01 m²/g. The commercial HAp had median particle sizes for the K-HAp (Kishida chemical Co. Ltd., K-HAp) and T-HAp (Taihei chemical Co. Ltd., T-HAp) of 1.13 and 3.65 μm, and specific surface areas of 11.62 and 6.23 m²/g, respectively. The different powder characteristics affected the slip characteristics, and the flexural strength and microstructure of the sintered porous HAp bodies were also different. The flexural strengths of the porous HAp ceramics prepared by heating at 1200 °C for 3 h in air were 17.59 MPa for L-HAp with a porosity of 60.48%, 3.92 MPa for commercial K-HAp with a porosity of 79.37%, and 4.55 MPa for commercial T-HAp with a porosity of 76.46%.     

Fabrication of porous SiO2/C composite from rice husks

Porous SiO₂/carbon composites were fabricated by heating pellets composed of rice husk (RH) powders in small (<74 μm), medium(74–175 μm) and large(150–300 μm) sizes. The contents of the small RH were fixed at 30 mass% and the RH pellets molded at 10, 15, and 30 MPa were heated at 800–1150 °C in an inert atmosphere. The weight loss due to the thermal decomposition of the organic materials in the pellet peaked at 1000 °C, whereas the specimen heated at 1000 °C showed the lowest carbon content and density, 29 mass% and 0.40 g cm⁻³, respectively. The SiO₂ phase of the specimens were amorphous at 800 and 1150 °C, but a cristobalite phase was visible at 1000 °C. The specimen fire at 1000 °C showed a higher compressive strength than the others, and the large RH particles were seen to increase the strength of the product while an increase in molding pressure decreased the medium pore size, from 17 to 7 μm, and increased the strength, from 0.25 to 3.52 MPa. The specific surface area (SSA) of the specimen peaked at 450 m² g⁻¹, at 1000 °C and finally, the mesopore size of the specimens was similar throughout, at ∼2 nm.     

Wear behavior of graphene/alumina composite

In the present work, the dry sliding behavior of a graphene/alumina composite material was studied against alumina in air. The tests were carried out in a reciprocating wear tester with an applied load of 20 N, a sliding speed of 0.06 m s⁻¹ and a sliding distance of up to 10 km. Under the testing conditions, the graphene/ceramic composite showed approximately half the wear rate and a 10% lower friction coefficient than the monolithic alumina. It has been found that this behavior is related to the presence of graphene platelets adhered to the surface of friction that form a self-lubricating layer which provides enough lubrication in order to reduce both wear rate and friction coefficient, as compared to the alumina/alumina tribological system.     

Dense carbon monoliths for supercapacitors with outstanding volumetric capacitances

A commercially available dense carbon monolith (CM) and four carbon monoliths obtained from it have been studied as electrochemical capacitor electrodes in a two-electrode cell. CM has: (i) very high density (1.17 g cm⁻³), (ii) high electrical conductivity (9.3 S cm⁻¹), (iii) well-compacted and interconnected carbon spheres, (iv) homogeneous microporous structure and (v) apparent BET surface area of 957 m²g⁻¹. It presents interesting electrochemical behaviors (e.g., excellent gravimetric capacitance and outstanding volumetric capacitance). The textural characteristics of CM (porosity and surface chemistry) have been modified by means of different treatments. The electrochemical performances of the starting and treated monoliths have been analyzed as a function of their porous textures and surface chemistry, both on gravimetric and volumetric basis. The monoliths present high specific and volumetric capacitances (292 F g⁻¹ and 342 F cm⁻³), high energy densities (38 Wh kg⁻¹ and 44 Wh L⁻¹), and high power densities (176 W kg⁻¹ and 183 W L⁻¹). The specific and volumetric capacitances, especially the volumetric capacitance, are the highest ever reported for carbon monoliths. The high values are achieved due to a suitable combination of density, electrical conductivity, porosity and oxygen surface content.     

Investigating the effect of porosity level and pore former type on the mechanical and corrosion resistance properties of agro-waste shaped porous alumina ceramics

The strength integrity and chemical stability of porous alumina ceramics operating under extreme service conditions are of major importance in understanding their service behavior if they are to stand the test of time. In the present study, the effect of porosity and different pore former type on the mechanical strength and corrosion resistance properties of porous alumina ceramics have been studied. Given the potential of agricultural wastes as pore-forming agents (PFAs), a series of porous alumina ceramics (Al₂O₃-xPFA; x=5, 10, 15 and 20 wt%) were successfully prepared from rice husk (RH) and sugarcane bagasse (SCB) through the powder metallurgy technique. Experimental results showed that the porosity (44–67%) and the pore size (70–178 µm) of porous alumina samples maintained a linear relationship with the PFA loading. Comprehensive mechanical strength characterization of the porous alumina samples was conducted not just as a function of porosity but also as a function of the different PFA type used. Overall, the mechanical properties showed an inverse relationship with the porosity as the developed porous alumina samples exhibited tensile and compressive strengths of 20.4–1.5 MPa and 179.5–10.9 MPa respectively. Moreover, higher strengths were observed in the SCB shaped samples up to the 15 wt% PFA mark, while beyond this point, the silica peak observed in the XRD pattern of the RH shaped samples favored their relatively high strength. The corrosion resistance characterization of the porous alumina samples in hot 10 wt% NaOH and 20 wt% H₂SO₄ solutions was also investigated by considering sample formulations with 5–15 wt% PFA addition. With increasing porosity, the mass loss range in RH and SCB shaped samples after corrosion in NaOH solution for 8 h were 1.25–3.6% and 0.44–2.9% respectively; on the other hand, after corrosion in H₂SO₄ solution for 8 h, the mass loss range in RH and SCB shaped samples were 0.62–1.5% and 0.68–3.3% respectively.