喷雾造粒对固相烧结SiC陶瓷的影响

采用离心式喷雾造粒技术对SiC浆料进行造粒,研究了喷雾造粒对SiC粉体的流动特性、成型行为、烧结性能、力学性能及显微结构的影响机制。研究结果表明:喷雾造粒后,碳化硅粉体流动性得到较大改善,素坯密度增加,微观结构致密;固相烧结后,碳化硅陶瓷的烧结性能提高,陶瓷显微结构得到改善。     

表面预处理对燃烧合成β-SiC粉体水基浆料流动性的影响

以燃烧合成工艺制备的β-SiC粉体为原料,系统研究了煅烧、酸洗、碱洗3种预处理工艺对燃烧合成SiC粉体表面特性和水基浆料流动性的影响。SiC粉体中的杂质,即可溶性金属离子和粉体表面的SiO2的含量是影响粉体zeta电位和浆料流动性的关键因素。这3种预处理工艺均能有效降低SiC粉体中的杂质含量,从而改善浆料的流动性,其中碱洗处理的效果最为显著。     

水基SiC料浆的分散稳定机制及喷雾造粒

以去离子水为液体介质,引入有机添加剂,配制水基SiC悬浮料浆,研究了水基料浆的分散稳定机制及其喷雾造粒行为,分析了有机添加剂和固相含量对料浆流变性能、造粒粉粒径分布及成型性能的影响机制.结果表明:当料浆pH≥10时,水基碳化硅料浆的分散性和稳定性较好,料浆具有剪切稀化的非Newton体特性:当加入0.2%(质量分数,下同)四甲基氢氧化铵、2.0%聚乙烯醇和1.0%聚乙二醇时,料浆黏度较小:固相含量为50%水基料浆喷雾造粒后,造粒粉的流动性、填充性能及成型性能明显提高,但球状造粒粉需要在一定成型压力下才能完全破碎.     

TMAH表面吸附对SiC粉体及浆料流变性能研究

采用固相球磨工艺,研究四甲基氢氧化铵(TMAH)添加量及球磨过程对TMAH在SiC粉体表面吸附效果及浆料流变性的影响。TMAH在SiC粉体表面的吸附状况,采用总有机碳(TOC)间接测定粉体洗涤液中的有机物含量。实验结果表明:固相球磨工艺可有效提高TMAH在SiC粉体表面的吸附率,所制备浆料的固相含量高。TMAH添加量为2.0‰、球磨时间为4 h时所处理的SiC粉体Zeta电位最大(70.6 mV),浆料流变性、稳定性最好。     

TiB2/Al2O3复合粉体的喷雾干燥造粒与特性研究

利用喷雾干燥技术对TiB_2/Al_2O_3复合粉体进行造粒,研究了浆料固相含量及粘结剂含量对喷雾干燥粉体颗粒形貌、结构、松装密度、流动性等的影响。结果表明：当浆料固相含量为47．6%,分散剂和粘结剂分别为固相质量的0．4%和1．0%时,浆料具有合适的粘度和最佳的分散稳定性,喷雾造粒得到的粉体为球形或近球形,具有较高的松装密度和流动性,能满足各种压制成型的需要。     

冷冻铸造法制备仿生梯度层状结构SiC多孔陶瓷

采用单向恒温冷冻铸造法制备出仿生梯度层状结构SiC多孔陶瓷.研究了水基SiC陶瓷浆料的初始固相含量和冷冻温度对SiC多孔陶瓷的微观结构(包括孔隙率、片层厚度和结构波长)及抗压强度的影响.随着离冷端距离的增加,层状多孔SiC骨架的片层厚度和结构波长均沿着冷冻方向增大.随着浆料初始固相含量的提高(20 vol.％～40 v...     

堆积法制造青瓷用胎体陶瓷粉料体制备及表征

针对堆积法制造龙泉青瓷,采用水基料浆与流态化喷雾造粒相结合制备青瓷胎体陶瓷粉料,研究了水基料浆的分散稳定机制及其喷雾造粒行为,分析了固相含量对料浆流变性能、造粒粉粒径分布及成型性能的影响机制。研究表明:水基料浆具有宾汉型流体特性,固相含量为40%的料浆具有较低粘度和剪切应力,而固相含量为50%的料浆的稳定性和分散性更好;喷雾造粒后,固相含量为50%料浆喷雾造粒颗粒呈规则球形,粒径分布较宽,具有较好的填充性能和成型性能。     

甘氨酸钠对SiC粉体的表面改性及其浆料流变性研究

以强电解质甘氨酸钠(SG)为改性剂,考察其在SiC粉体表面的吸附状况,制备高分散SiC粉体,同时研究其浆料流变性。结果表明,采用固相球磨和恒温处理工艺,0.15%甘氨酸钠改性后的SiC粉体Zeta电位绝对值明显高于改性前,pH值为10.0时,从38.9 mV增加到62.2 mV。TOC(总有机碳)对粉体洗涤液中有机物含量的测试表明,微量甘氨酸钠的平衡吸附可有效降低SiC浆料粘度,提高其固含量和稳定性。     

金属过滤器用高性能碳化硅泡沫陶瓷的制备

介绍了一种适用于大规模工业化生产高强度金属过滤用碳化硅泡沫陶瓷的方法。采用商用SiC粉体和聚氨酯泡沫通过2次挂浆工艺可以制备出最大平均抗弯强度达到2．87 MPa,平均孔径在3 mm左右,同时具备优良的抗热震性能和高达1700℃耐火度的碳化硅泡沫陶瓷。探讨了浆料的牯度、流变性能对挂浆性能的影响及第2次挂浆对强度的增强机理,说明1次浆料的触变性能和适当固相含量的2次浆料是高强度泡沫陶瓷制备的关键,而2次挂浆工艺对强度提高的主要贡献来源于第2次浆料对1次挂浆烧结后留下空洞的有效弥补。     

碳化硅浓悬浮体的分散特性和流变性研究

通过对碳化硅粉体在有机单体介质中的Zeta电位，分散剂用量和浓悬浮体的粘度等的测试及其沉降试验，详细研究了粒径分布较宽的碳化硅粉体（0.2-250μm)的胶体分散特性，沉降行为以及浓悬浮体的流变行为。结果表明，选用适量的分散剂四甲基氢氧化铵可使SiC颗粒的Zeta电位绝对值提高近20mV，调整浆料pH至11．9附近可制备出固相体积分数高达70％的SiC浓悬浮体。该浓悬浮体中粗细SiC颗粒间能达到一稳定的分数，悬浮粒子不会产生明显地沉降，其流变行为符合Quemada模型。     

水基改性碳化硅陶瓷料浆流变性的研究

用有机硅偶联剂处理SiC粉体，在适合的上，经聚合反应再将有机的单体接枝于SiC颗粒表面上，在SiC颗粒表面上形成聚电解质包覆层，以改善SiC粒子在水介质中的分散性质。同时研究了改性SiC粉在水介质中的稳定条件，荷电性及在高固体含量下，用改性SiC粉所制备的陶瓷料浆的流变性。研究结果表明：改性后碳化硅粉在水中的分散稳定性能大大优于未改性碳化硅粉，所制备料浆体系的固体含量，分散稳定性能，粘度等参数有满足注浆成型工艺的要求。     

氨基硅烷偶联剂表面改性SiC微粉的研究

采用3种氨基硅烷偶联剂WD-50、WD-52和WD-57对SiC微粉进行表面改性,制备出高固相含量、低粘度的SiC料浆,并通过红外光谱分析了SiC微粉改性前后的表面特性.结果表明,采用偶联剂WD-52改性的SiC微粉固相体积含量达到54.5%、料浆稳定性显著提高且粘度降低,与偶联剂WD-50和WD-57相比,WD-52的改性效果最好.     

Highly concentrated aqueous SiC slurry containing fine SiC powder: A new approach for ultra-dense green body

SiC slurry with ultra-high concentration up to 70 vol% was prepared using oxidized fine and coarse SiC powder mixture, and dense SiC green body with a relative density of 76% was fabricated by drying the slurry at ambient condition. Three approaches were performed to prepare highly concentrated SiC slurry; preparation of SiC powder having good dispersion behavior, optimization of the oxidation condition, and optimization of bi-modal particle size distribution. An aqueous slurry with the solid loading up to 62 vol% could be prepared using fine (150 nm) SiC powder prepared by the mechanical alloying of Si and carbon. The surface property of the fine and coarse (10 μm) SiC powders was optimized using an oxidation treatment. The maximum solid loading of the fine SiC slurry prepared using oxidized powder was 66 vol%. By optimizing the mixing ratio of the oxidized fine and coarse SiC powder to 75:25, the solid loading of the SiC slurry could increase up to 70 vol%. The relative densities of the green bodies after drying 66, 68, and 70 vol% slurries were 69, 75.7, and 76.1%, respectively, which values were higher than those (58%) prepared by cold isostatic pressing under 200 MPa.     

Preparation of photosensitive SiO2/SiC ceramic slurry with high solid content for stereolithography

Stereolithography is a popular three-dimensional (3D) printing technology, which is widely used for manufacturing ceramic components owing to its high efficiency and precision. However, it is a big challenge to prepare SiC ceramic slurry with high solid content for stereolithography due to the strong light absorption and high refractive index of dark SiC powders. Here, we propose a novel strategy to develop photosensitive SiO₂/SiC ceramic slurry with high solid content of 50–65 vol% by adding spherical silica with low light absorbance and applying a stacking flow model to improve the solid content of the slurry. The as-prepared slurry exhibits excellent stereolithography properties with a dynamic viscosity lower than 20 Pa s and curing thickness more than 120 μm. Therefore, it can be successfully applied for stereolithography-based additive manufacturing of SiC green bodies with large size (100 mm), sub-millimeter accuracy (0.2 mm), and complex structure. The stacking flow model also shows immense potential for the stereolithography of other dark-color ceramics with high solid content.     

Surface modification of superfine SiC powders by ternary modifiers-KH560/sodium humate/SDS and its mechanism

SiC is a promising functional ceramic material with many great properties. High concentrated SiC slurry with excellent rheology and stability is required in some processes of ceramic forming. In this work, the dispersion of SiC powders was obviously improved by ternary modifiers: γ-(2,3-epoxypropoxy) propytrimethoxysilane (KH560), sodium humate and sodium dodecyl sulfate (SDS). Modified SiC slurry showed the lowest viscosity of 0.168 Pa s at a solid content of 50 vol%. The maximum absolute value of zeta potential of SiC increased from 47.3 to 61.6 mV by modification. Sedimentation experiments showed that a highly stable suspension of modified SiC was obtained at pH 10. SiC green body with high density of 2.643 g/cm³ was prepared with modified powders by slip casting. X-ray photoelectron spectra (XPS) and thermogravimetry (TG) measurements indicated the adsorption of modifiers on SiC surface. Therefore, modified SiC powders could stably disperse in aqueous media due to the increase of electrosteric repulsion between particles. The novel strategy used in this study could further improve the dispersion of SiC powders.     

Reply to the Comment by K. Jorgensen et al. to “Analysis of constant rate period of spray drying of slurry”

Previously developed model for spray drying of slurry droplets with high solid content (Liang, 2001) was revised to describe correctly a boundary condition on the outer surface of droplet on basis of the rate of liquid evaporation.     

Spray-dried ceramic powders: A quantitative correlation between slurry characteristics and shapes of the granules

The characteristics and consequently the properties of ceramic coatings performed using plasma spraying means depend not only on the operating conditions but also on the powder feedstock. Oxide powders are commonly prepared in one stage or in a combination of stages of fusing, crushing, agglomerating and sintering. The spray drying process (which corresponds to the agglomerating route) is a technique in which small constituent particles dispersed in water (which is called slurry) are sprayed in hot air and granulated thanks to a binder (latex or PVA). Spray drying is carried out for a variety of reasons, two major motivations being the production of composite and shape controlled powders for thermal spray applications. The aim of the present work was to establish a correlation between the slurry formulation and the characteristics of the spray dried granules for two oxide ceramics: Al₂O₃ and Y₂O₃-ZrO₂. Detailed studies on the dispersion and stability of the slurries were performed using sedimentation tests, electrophoretic mobility measurements as well as adsorption isotherms experiments. Then, a drying experimental test based on the drying of a suspended droplet was developed to assess the drying mechanisms, identify the correlation between the slurry characteristics and the morphology of the dried granules and finally to predict the shapes of the spray-dried powders. It was shown that there is a qualitative relation between the sedimentation behaviour (as measured by the sediment ratio) and the granule shape (solid or hollow) and a quantitative relation between the thickness of the shell (for hollow granule) and the state of dispersion and the nature of the binder used. Finally, several powder batches were prepared in the spray-dryer which confirm the reliability of the drying simulation test.     

Relationship analysis on particle-coating-ablation property of UHTC coatings fabricated by plasma spray technique

The relative high porosity of plasma spray ultra-high temperature ceramic (UHTC) coatings has been an important limiting factor for the ablation property and one of the reasons is the original pores of feedstocks. In this work, dense and spherical ZrC–SiC powders were fabricated by induction plasma spheroidization (IPS) and were used to prepare ZrC–SiC coating by vacuum plasma spray. The effect of microstructure of feedstock particles on the microstructure and ablation property of coating was studied. The results showed that the spherodized particles were composed of eutectic-like phase and ZrC granules, exhibiting high degree of compactness and sphericity, which had higher deposition rate and generated splats with flattened structure to overlap compactly then produce highly dense coating compared with those of spray drying (SD) particles. The deposition rate was doubled and the porosity of the coating was reduced by half. The ablation resistance of ZrC–SiC coating was greatly improved due to the formation of dense oxide scale.     

Dispersibility of pretreated polyacrylic acid-modified SiC powder

A slurry with high dispersibility is crucial for slip casting technology. The weakly acidic SiC powder with high dispersibility was prepared with polyacrylic acid pretreated by the sodium hydroxide (adjusted pH = 5). The pretreated polyacrylic acid can be effectively adsorbed on the surface of SiC powder, and its utilization efficiency (37%) was better than the unpretreated one (21%). The modified SiC powder with pH = 6 was obtained by polyacrylic acid modification, and the maximum solid content was 61.2 Vol%. The optimum of the pretreated polyacrylic acid addition amount was 1 wt% based on Zeta potential, solid content, and viscosity analysis data. Compared with the unmodified SiC, the Zeta potential absolute value of the modified (−63 mV) was higher due to a large amount of anionic modifier adsorbed on particle surfaces. The modified SiC slurry was more stable because the modification increases the electrostatic repulsion among the SiC molecules.