Effect of starch addition on microstructure and properties of highly porous alumina ceramics

Porous alumina ceramics with ultra-high porosity were prepared through combining the gel-casting process with the pore-forming agent technique. Porosity and pore size distribution of the sintered bulks were evaluated with and without adding starch, respectively. In particular, the influences of starch addition on the properties, including thermal conductivity and compressive strength were studied. It was found that the incorporation of starch increased the nominal solid loading in the suspension and subsequently promoted the particle packing efficiency. The porosity is raised with increasing starch content from 0 to 30 vol%, which brings the decrease in thermal conductivity, whereas the compressive strength isn't seriously degraded. The further higher starch addition (40 vol%), however, would deteriorate the performance of the alumina porous ceramics. It is believed that the appropriate starch amount (lower than 30 vol%), working as a pore-forming agent, suppresses the driving force of densification without affecting the connections of neighboring grains while excessive starch amount would lead to the collapse of the porous structure.     

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.     

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.     

Microstructure and electrical properties of relaxor (1 − x)[(K0.5Na0.5)0.95Li0.05](Nb0.95Sb0.05)O3–xBaTiO3 piezoelectric ceramics

In order to solve the low temperature stability of electrical properties in KNN-based ceramics, (1 ? x)[(K_0.5Na_0.5)_0.95Li_0.05](Nb_0.95Sb_0.05)O₃–xBaTiO₃ [(1 ? x)KNLNS–xBT] lead-free piezoelectric ceramics were prepared by the conventional solid-state sintering method. The introduction of BT stabilizes the tetragonal phase of KNLNS ceramics at room temperature, results in a typical ferroelectric relaxor behavior, and shifts the polymorphic phase transition to below room temperature. Moreover, there is a strong BaTiO₃ concentration dependence of relaxor behavior and electrical properties, and the ceramic with x = 0.005 exhibits optimum electrical properties and typical relaxor behavior (d₃₃ = 269 pC/N, k_p = 0.50, ?_r = 1371, tan δ = 0.03, T_C ～ 349 °C and γ = 1.88024). These results indicate that the BT is an effective way to improve the temperature stability as well as the electrical properties of KNN-based ceramics.     

Preparation of porous Y2SiO5 ceramics with relatively high compressive strength and ultra-low thermal conductivity by a TBA-based gel-casting method

Porous Y₂SiO₅ ceramics with relative high compressive strength (as high as 24.45 MPa) and ultra-low thermal conductivity (～0.08 W/m K) were successfully fabricated by a tert-butyl alcohol based gel-casting method. The formation mechanism of the 3D interconnected pores and the properties of the green body are discussed. The porosity, pore size, compressive strength and thermal conductivity could be controlled by varying the initial solid loading and the sintering temperature. When regulating the initial solid loading (from 20 to 50 wt%) and sintering temperature (from 1200 to 1500 °C), the porosity can be controlled between 47.74% and 73.93%, and the compressive strength and the thermal conductivity of porous Y₂SiO₅ ceramics varied from 3.34 to 24.45 MPa and from 0.08 to 0.55 W/m K, respectively. It should be noted that the porous Y₂SiO₅ ceramics with 30 wt% solid loading and sintering at 1400 °C had an open porosity of 61.80%, a pore size of 2.24 μm, a low room-temperature thermal conductivity of 0.17 W/m K and a relatively high compressive strength of 13.91 MPa, which make this porous Y₂SiO₅ ceramics suitable for applications in high-temperature thermal insulators.     

Low-temperature sintering and electrical properties of (K,Na)NbO3 based lead-free ceramics with high Curie temperature

Lead-free ceramics (1 ? x)(K_0.48Na_0.52)NbO₃–(x/5.15)K_2.9Li_1.95Nb_5.15O_15.3 (x = 0.3–0.6, KNN–KLN100x) were prepared by conventional sintering technique at a low temperature of 960 °C. The effects of KLN contents on microstructure, dielectric, and piezoelectric properties were investigated. After the addition of KLN, the sintering performance and Curie temperature of the ceramics were markedly improved. The ceramics with x = 0.3 exhibited very good piezoelectric properties: d₃₃ = 138 pC/N, k_p = 45.03%, T_c = 495 °C, the dielectric constant at room temperature ?_r (RT) = 478 and the maximum dielectric constant ?_r (max) = 5067. These results indicated that the KNN–KLN100x lead-free ceramics sintered at low temperatures are promising for high temperature piezoelectric applications.     

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.     

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.     

Isothermal and adiabatic Young's moduli of alumina and zirconia ceramics at elevated temperatures

The elastic moduli (Young's moduli) of alumina and zirconia ceramics with porosities ranging from almost dense (2–3%) to highly porous (46–52%), the latter prepared with starch as a pore-forming agent, have been measured via impulse excitation and four-point bending tests from room temperature up to more than 1200 °C. It is shown that, independent of the temperature and the material, the porosity dependence of the Young's modulus is well predicted by our exponential relation and that, irrespective of porosity, the temperature dependence follows a master curve that is characteristic of the material (for alumina exhibiting a decrease with a gradually growing tangent slope and for zirconia exhibiting a steep decrease with an inflection point at moderately elevated temperatures below 400 °C). Differences between isothermal (static) and adiabatic (dynamic) values are negligible as long as the materials are purely elastic (i.e. at temperatures below approximately 1000 °C).     

Effects of pore structure on thermal conductivity and strength of alumina porous ceramics using carbon black as pore-forming agent

In the present work, carbon black (CB) works as a pore-forming agent in the preparation of alumina porous ceramics. The pore structures (i.e. mean pore size, pore size distribution and various pores size proportions) were characterized by means of Micro-image Analysis and Process System (MIAPS) software and mercury intrusion porosimetry. Then their correlation and thermal conductivity as well as strength were determined using grey relation theory. The results showed that the porosity and mean pore size increased against the amount of CB, whereas the thermal conductivity, cold crushing strength and cold modulus of rupture reduced. The <2 μm pores were helpful for enhancing the strength and decreasing the thermal conductivity whereas the >14 μm pores had the opposite effects.     

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.     

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.     

Low cost foam-gelcasting preparation and characterization of porous magnesium aluminate spinel (MgAl2O4) ceramics

Porous MgAl₂O₄ ceramics were prepared via a low cost foam-gelcasting route using MgAl₂O₄ powders as the main raw material, ammonium polyacrylate as a dispersant, a small amount of modified carboxymethyl cellulose as a gelling agent, and TH-IV polymer as a foaming agent. The effects of additive's content, solid loading and gelling temperature on slurry's rheological behavior were investigated, and microstructures and properties of as-prepared porous MgAl₂O₄ ceramics examined. Based on the results, the roles played by the foaming agent in the cases of porosity, pore structure, pore size, mechanical properties and thermal conductivity were clarified. Porosity and pore sizes of as-prepared porous MgAl₂O₄ ceramics increased with increasing the foaming agent from 0.05 to 0.6 vol%. Porous MgAl₂O₄ ceramics with porosity of 75.1% and average pore size of 266 µm exhibited a compressive strength as high as 12.5±0.8 MPa and thermal conductivity as low as 0.24 W/(m K) (at 473 K).     

Morphotropic phase boundary in the BNT–BT–BKT system

Lead-free x Bi_0.5Na_0.5TiO₃–y BaTiO₃–z Bi_0.5K_0.5TiO₃ piezoelectric ceramics were synthesized by a conventional solid state reaction method. The microstructure, ferroelectric and piezoelectric properties of the ceramics were investigated. Structure measurements by X-ray diffraction with Rietveld refinement have allowed us to specify more precisely the morphotropic phase boundary (MPB) in this system. For (1 ? x) BNT–x BT solid solution ceramics, the 0.94 BNT–0.06 BT morphotropic composition shows the higher values with d₃₃ = 170 pC/N, k_p = 0.35 and k_t = 0.53. In the case of (1 ? x) BNT–x BKT compositions, the d₃₃, k_p and k_t are, respectively, 137 pC/N, 0.39 and 0.54 for the 0.80 BNT–0.20 BKT ceramic. On the other hand, the ternary 0.865 BNT–0.035 BT–0.100 BKT morphotropic composition shows high piezoelectric constant and electromechanical coupling factors (d₃₃ = 133 pC/N, k_p = 0.26 and k_t = 0.57).     

Assessment of thermal conductivity as a function of porosity in bread dough during proving

During the proving process, yeast fermentation in the aqueous phase of dough produces carbon dioxide which diffuses through the aqueous phase to the gas cell nuclei entrapped during dough mixing. CO₂ evaporates to generate within gas cell nuclei an excess pressure that provides the driving force for dough expansion. As a result, the void fraction of the dough increases and thermal conductivity decreases. These two properties are of considerable interest because of their technological significance in breadmaking (specific volume and processing times). The aim of the present study was therefore to investigate experimentally the thermal conductivity and porosity evolutions of bread dough during the proving process. Apparent density and thermal conductivity of fermenting dough were experimentally determined as a function of fermentation time using the line-heat source probe and image analysis methods, respectively. Thermal conductivity values were observed in the range of 0.36–0.12 W m^?1 K^?1 and values of void fraction air between 6 and 78% at proving conditions of 35 °C and 95% HR for 100 min of fermentation time. According to experimental data, relationship between thermal conductivity λ and porosity ? could be adequately described by a nonlinear equation: λ(?) = 0.421–0.134?–0.219?^0.5.     

Preparation and properties of mullite-bonded porous fibrous mullite ceramics by an epoxy resin gel-casting process

Porous fibrous mullite ceramics with a narrow range of pore size distribution have been successfully prepared utilizing a near net-shape epoxy resin gel-casting process by using mullite fibers, Al₂O₃ and SiC as raw materials. The effects of sintering temperatures, different amounts of fibers and Y₂O₃ additive on the phase compositions, linear shrinkage, apparent porosity, bulk density, microstructure, compressive strength and thermal conductivity were investigated. The results indicated that mullite-bonded among fibers were formed in the porous fibrous mullite ceramics with a bird nest pore structure. After determining the sintering temperatures and the amount of fibers, the tailored porous fibrous mullite ceramics had a low linear shrinkage (1.36–3.08%), a high apparent porosity (61.1–71.7%), a relatively high compressive strength (4.4–7.6 MPa), a low thermal conductivity (0.378–0.467 W/m K) and a narrow range of pore size distribution (around 5 µm). The excellent properties will enable the porous ceramics as a promising candidate for the applications of hot gas filters, thermal insulation materials at high temperatures.     

Effects of mono-dispersed PMMA micro-balls as pore-forming agent on the properties of porous YSZ ceramics

Porous yttria-stabilized zirconia (YSZ) ceramics were successfully fabricated by the dry pressing method with different size (1.8–20 μm) and amount (2–60 vol.%) of mono-dispersed poly methyl methacrylate (PMMA) micro-balls. Different PMMA additions with different size and amount were investigated to achieve optimal thermal and mechanical properties. With increases of the amount of PMMA, the porosity of porous YSZ ceramics ranges from 7.29% to 51.6%, the flexural strength increases firstly and then decreases, and the thermal conductivity decreases continuously. With decreases of the diameter of PMMA micro-balls, the mean pore size and thermal conductivity of porous YSZ ceramics decrease, and the flexural strength of porous YSZ ceramics with same porosity increases firstly and then decreases. The porous YSZ ceramics with a higher porosity (18.44 ± 1.24%), the highest flexural strength (106.88 ± 3.2179 MPa) and low thermal conductivity (1.105 ± 0.15 W/m K) can be obtained when the particle diameter and the amount of PMMA are 5 μm and 20 vol.%, respectively.     

New multifunctional porous Yb2SiO5 ceramics prepared by freeze casting

New porous Yb₂SiO₅ ceramics were prepared by a water-based freeze casting technique using synthesized Yb₂SiO₅ powders. The prepared porous Yb₂SiO₅ ceramics exhibit multiple pore structures, including lamellar channel pores and small pores, in its skeleton. The effects of the solid content and sintering temperature on the pore structure, porosity, dielectric and mechanical properties of the porous Yb₂SiO₅ ceramics were investigated. The sample with 20 vol% solids content prepared at 1550 °C exhibited an ultra-low linear shrinkage (i.e. 4.5%), a high porosity (i.e. 79.1%), a high compressive strength (i.e. 4.9 MPa), a low dielectric constant (i.e. 2.38) and low thermal conductivity (i.e. 0.168 W/(m K)). These results indicate that porous Yb₂SiO₅ ceramics are good candidates for ultra-high temperature broadband radome structures and thermal insulator materials.     

Fabrication of textured Sr2Na0.9K0.1Nb5O15 ceramics: Anisotropy in structures and electrical properties

Highly textured Sr₂Na_0.9K_0.1Nb₅O₁₅ (SKNN) ceramics were fabricated by reactive templated grain growth method using acicular Sr₂KNb₅O₁₅ (SKN) templates. CuO (1 wt.%) was used as sintering additive. SKN templates were aligned in matrix powders of SrNb₂O₆ and NaNbO₃ via tape casting and sintered at higher temperatures to obtain texture morphology. Through carefully controlling the processing conditions, a texture fraction of 86% was obtained. The structure evolution was explained by liquid-phase-assisted growth mechanism, in which the whole process was divided into 3 steps according to priority: phase formation stage, densification stage, and texture development stage. The textured ceramics exhibited anisotropic properties with the highest electrical properties obtained in c-axis direction: ?_r = 2212, ?_m = 4869, P_r = 15.92 μC cm^?2 and d₃₃ = 82 pC N^?1, showing that reactive templated grain growth method is very effective to improve the physical properties of SKNN ceramics.     

Microstructure and electrical properties of (Ba0.98Ca0.02)(Ti0.94Sn0.06)O3-modified Bi0.51Na0.50TiO3 lead-free ceramics

(Ba_0.98Ca_0.02)(Ti_0.94Sn_0.06)O₃-modified Bi_0.51Na_0.5TiO₃ [(1 ? x)BNT–xBCTS] ceramics were prepared by the normal sintering. A stable solid solution is well formed between BNT and BCTS, and the morphotropic phase boundary of (1 ? x)BNT–xBCTS ceramics is identified in the compositional range of 0.05 ≤ x ≤0.06. The temperature dependence of the dielectric loss and the poling temperature dependence of the d₃₃ value are used to determine the depolarization value (T_d). The T_d value of these ceramics gradually decreases with increasing BCTS content, together with the gradual increase of the dielectric constant. An enhanced electrical behavior of d₃₃ ～ 170 pC/N, k_p ～ 32.8%, P_r ～ 38.5 μC/cm², and E_c ～ 34.3 kV/cm is demonstrated for the ceramic with x = 0.06, which is double than that of pure BNT ceramic.