Innovative carbon-bonded filters based on a new environmental-friendly binder system for steel melt filtration

New carbon-bonded alumina filters for steel melt filtration were developed. The carbonaceous matrix was based on a new, environmental friendly binder system based on lactose and tannin. The filter preparation was analogous to the production of conventional foam filters according to the Schwartzwalder process. The processing as well as the rheology of the slurries was investigated. An addition of n-Si increased the carbon yield and the cold crushing strength (CCS) of the samples. Higher values of CCS were obtained after coating of the filters with alumina. The material was characterized by scanning electron microscopy, X-ray diffraction and Raman spectroscopy. The applicability of these new filters was assessed in impingement tests with a steel melt, in which three out of four recipes survived the thermal shock.     

Nano-functionalization of carbon-bonded alumina using graphene oxide and MWCNTs

This paper focused on the nano-functionalization of carbon-bonded alumina using graphene oxide (GO) and multi-walled carbon nanotubes (MWCNTs). GO was prepared according to the modified Tour's method. The rheology of suspensions containing GO, CNTs and both substances were analyzed and discussed. Xanthan proved to be a suitable stabilizer for the three systems. The spraying process of the suspensions was investigated with the aid of a high-speed camera. Al₂O₃-C filters and flat samples were spray coated, for investigations in contact with steel. The ceramic foam filters as well as the starting suspensions were analyzed by several analytic techniques to investigate the microstructure and other properties. Moreover, the hot stage microscope was used to study the steel/coating wetting behavior during operation at high temperatures. The results showed that the formulation containing both GO and CNTs delivered the best performance in contact with the melt. Similar coatings based on these nano-sized materials may offer an innovative route to improve purification of steel melts by filtration.     

Mechanical and physical characterization of Al2O3–C foam filters produced by distinct processing routes: The importance of the ceramic strut morphology

In this work the influence of the production route and filter dimensions on the mechanical properties of carbon-bonded alumina foam filters was investigated. Features like cold crushing strength and fracture behavior were analyzed and used to compare them. Microfocus computer tomography (μCT) was applied to characterize the geometry of the filters, providing a deep correlation with their fracture behavior. Furthermore, computer-generated filter geometries were used as reference. The results indicated that the centrifugation process is better suited for the production of carbon-bonded alumina filters, and is even more effective when the foam dimensions are increased in the range of those analyzed in this research. Finite element simulations showed the influence of the relative density and strut tapering on the cold crushing strength of filters, providing a correlation between filter structure and its failure mechanism. The attained results provided further insights towards the production of inclusions-free metal parts.     

Carbon-bonded alumina foam filters produced by centrifugation: A route towards improved homogeneity

An alternative route for producing carbon-bonded alumina filters was analyzed and compared with the state of the art, both based on the replica method. The latter comprises a dip coating and subsequent rolling and spraying steps (R+S). The proposed route is based on dip coating and centrifugation (CF-T1). Aiming to investigate the influence of an additional thermal treatment on the ceramic coating homogeneity, a modified centrifugation route was analyzed (CF-T2). Computer tomography (CT) analyses provided a targeted evaluation of the spatial material distribution after each processing step. It was found that log-normal functions fitted well the wall thickness values attained for all investigated filters. Qualitative surface evaluation was conducted using a digital (optical) microscope. The R+S and CF-T1 filters exhibited surface macro-cracks and hollow struts, due to the release of the polyurethane foam template during firing. The CF-T2 presented partly filled struts with a high amount of micro-cracks on the surface, being a potential alternative to increase the filtration efficiency, as the filter surface area was raised. However, in preliminary mechanical tests, the surface micro-cracks seemed to considerably reduce the cold crushing strength of the CF-T2 filters. Based on the CT data, it was possible to conclude that the centrifuged filters presented a more homogeneous material distribution, as a consequence of higher automation level of the process.     

Impact of spinel forming systems (Fe-/Mg-/Mn-Al-O) as functional coating materials for carbon-bonded alumina filters on steel melt filtration

Since solid, non-metallic inclusions influence considerably the quality of casted steel products, carbon-bonded alumina foam filters are used in secondary metallurgical treatments to remove these particles from steel melts. In order to attain a significant improvement of the filtration process, five different carbonaceous spinel compounds from the Fe-/Mg-/Mn-Al-O systems are applied on carbon-bonded alumina filters in this study and investigated with regard of their filtration efficiency. However, these spinel compounds decompose partially during sintering at 1400?°C under reducing atmosphere, wherefore the resulting coatings contain not only spinel compounds, but also oxidic and metallic components. The subsequent interaction with molten steel leads to the development of multicrystal structures on the filter surface, which stem from interfacial reactions between coating materials, molten steel, and inclusions. As a result of this procedure, a reduction of almost 60% alumina inclusions is measured with the aid of an automatic SEM, whereby spinel compounds from the Fe-Mn-Al-O system achieve highest filtration efficiencies.     

Investigations of reticulated porous alumina foam ceramics based on different coating techniques with the aid of μCT and statistical characteristics

Alumina foam ceramic filters were prepared due to the “replica technique”. The parameters of the two coating steps were varied to find the optimal processing route to prepare ceramic foam filters with a good homogeneous distribution of the strut thickness. Different additives for the slurry for the impregnation (first coating) step were investigated with the aid of rheological measurements. For the second coating step spraying as well as centrifuging techniques with different processing parameters were studied. The sintered foam structure (strut diameter, pore size and porosity) was characterized with the aid of CT-images and described with an image analysis software and statistical tools.     

二次挂浆工艺对铸造用SiC基泡沫陶瓷性能的影响

采用有机前驱体浸渍法制备SiC基泡沫陶瓷过滤器。研究了一次挂浆后的坯体分别经烘干和预烧后进行二次挂浆,制备的泡沫陶瓷在质量增加和抗热震性方面的差异,以及预烧温度对质量增加和抗热震性的影响。结果表明:1)二次挂浆制备工艺制备的SiC基泡沫陶瓷的室温抗压强度明显高于一次挂浆工艺制备的,但抗热震性又明显低于一次挂浆的。2)对二次挂浆制备的泡沫陶瓷,无论是相同的浆料二次挂浆还是不同浆料同样挂浆量挂浆,烘干后直接进行二次挂浆制得的SiC基试样的热震次数要远高于经预烧后进行二次挂浆制得试样的。3)对预烧后二次挂浆制备的泡沫陶瓷,预烧温度越高,其抗热震性越差。     

Production of ceramic foam filters for molten metal filtration using expanded polystyrene

Filtration of molten metals with ceramic foam filters is a proven method in order to remove the inclusions. This paper develops a new approach for the production of ceramic foam filters. In the conventional method of ceramic foam filter production, polyurethane sponges are used.In this work, ceramic foam filter was produced by using expanded polystyrene. Polystyrene is expanded in a specially designed mold by steam to form polystyrene patterns. Various ceramic slurries are then poured into the polystyrene cell and allowed to air dry. After the shaping operation, filters are subjected to sintering process under various conditions. By this new method, filter channel sizes can be controlled and traps with desired configurations can be formed. Some tests were applied to the produced filters. Thermal shock tests ensured that the filters could withstand temperatures of 1450 °C. Water absorption test showed that bauxide based material absorbed water more than the others.     

Investigation of Strut Crack Formation in Open Cell Alumina Ceramics

An investigation was made into the source of strut cracking during the fabrication process of open cell ceramics that are produced by coating a polymeric foam. Several sources for the stress that produces these cracks were considered, viz., differential drying, thermal expansion mismatch between the polymer and the green ceramic coating, and the gas pressure produced by pyrolysis of the organic skeleton. Thermogravimetric analysis of the polymeric foam was used to estimate the gas evolution rate associated with the pyrolysis process, but this was found to be very low compared to the pressures required to cause strut damage. SEM observations on samples taken by interrupting the fabrication procedure showed the cracks were not produced during drying but rather at a temperature near the melting/decomposition point of the polymer and prior to pyrolysis. It was then deduced that the differential thermal expansion between the polymer and the ceramic coating was the source of the stress. The strut cracking is observed to occur primarily in the region of the highly curved strut edges of the polymer foam, at which the ceramic coating is often rather thin. Techniques to change the processing procedure to overcome the strut cracking are discussed.     

Manufacturing of nano mullite-silicon carbide filters by in situ reaction bonding

In the present study, the effect of silica nanoparticles on the formation of nano-mullite phase for use in the manufacture of silicon carbide based ceramic foam filters has been investigated. Polyurethane foam filters were impregnated with nanosilica particles by slip casting. In this method, the effect of different percentages of nanosilica particles in the slurry on compressive strength, density and porosity of ceramic foam filters was investigated. The effect of silica nanoparticles on viscosity of slurry was studied using rheometric test. So, sample S₁₅ was selected to proceed. For thermal treatment of ceramic foams, different sintering temperatures were investigated and the best temperature was reported at 1250 °C. Compressive strength results showed that with increasing nano-silica content, CCS increased. XRD results from the samples showed that the nano-mullite phase was formed at 1250 °C along with silicon carbide and alumina phases. Scanning electron microscope images (SEM) showed that the mullite phase was formed in nano-dimensions in ceramic foam bodies. The formation of mullite phase in the microstructure of the filters is one of the factors of strengthening and increased refractory characteristics. EDS analysis by the scanning electron microscopy of the filter which passed ductile iron melt showed that cast iron inclusions and impurities were mostly consisted from FeO, MnO, SiO₂, Al₂O₃, MgO and CO, which were trapped inside the ceramic filter.     

Evaluation of the pore morphology formation of the Freeze Foaming process by in situ computed tomography

The so-called Freeze Foaming method aims at manufacturing ceramic cellular scaffolds for diverse applications. One application is dedicated to potential bone replacement material featuring open, micro and interconnected porosity. However, the main challenges of this foaming method is to achieve a homogeneous pore morphology. In a current project, the authors throw light on the bubble/pore and strut formation of this process by in situ computed tomography. This allows for evaluating varying process parameter’s effects on the growth of the ceramic foam during the foaming process. As first result and basis for CT analysis, a stable and reproducible model suspension was developed which resulted in reproducible foam structures. In dependence of selected process parameters like pressure reduction rate or air content in the ceramic suspension resulting Freeze Foams became adjustable with regard to their pore morphology. Pore size and distribution data as well as the porosity were characterized and evaluated accordingly.     

Additive manufactured polyamide foams with periodic grid as templates for the production of functional coated carbon-bonded alumina foam filters

For the industrial production of metal melt filters, the replica technique is established since several decades. The polyurethane foams used as templates show a rather random structure with several defects which are transferred into the final filter structure after the replication. In order to generate filters with periodic structure and low amount of defects, a periodic foam model was used and open cell foams were produced by selective laser sintering of aged polyamide 12 (PA12). The PA12 foams were then used as sacrificial templates for the replica technique in the production route of Al₂O₃-C filters with functional coatings based on a cold sprayed Al₂O₃-C coating or a flame sprayed coating based on Al₂O₃. The differences in geometry between the computer-generated model foam, the sacrificial PA12 foam, the foam after carbonization, and the additional functionalized filters with the cold and hot coating were analyzed by computed tomography. Based on CT-data isosurfaces of the foams were generated to virtualize and distinguish the differences. Preliminary mechanical tests showed a higher cold crushing strength for the filters coated via flame-spray technique than the cold coating.     

A novel method based on ultrastable foam and improved gelcasting for fabricating porous mullite ceramics with thermal insulation–mechanical property trade-off

Foam instability and long drying cycle limits the widespread use of foaming method. In this paper, a kind of porous mullite ceramic with thermal insulation–mechanical property trade-off were fabricated via novel ultrastable foam and improved gelcasting procedure. The solidification process and stability of foam slurry, as well as the thermal, mechanical property and pore structure of the porous mullite ceramics were investigated. The results showed that porous mullite ceramics with different bulk densities could be prepared via varying volume of foam which was stable enough to be maintained in slurry for a long time. The accelerated gelation rate as well as the gelation degree resulted in the improved gelcasting method led to a shortened period of drying and demould. The obtained pores, which were small, smooth, and unimodal distributed in size in porous mullite ceramics, contributed to achieving the trade-off between thermal insulation and mechanical property.     

Validation of an experimental-numerical approach for the high temperature behaviour of open-cell ceramic foams

Open-cell ceramic foams are used as filters in casting processes of molten metal to reduce the amount of non-metallic inclusions. These filters are exposed to high temperatures and loadings, sometimes for a longer time. Therefore, the dimensional stability has to be considered, which suffers from inelastic deformations, in particular creep deformations.A recent work of the authors describes the creep deformation behaviour of such foam structures using an experimental-numerical approach based on bulk material creep tests. Now, the results of this prediction are validated by creep curves of real foam samples. This comparison shows a good accordance for the considered parameters (load, temperature, time, and creep phase).Moreover, the influences of different structural parameters on the elastic foam stiffness and foam creep resistance are investigated. The relative foam density has the greatest impact, followed by uniaxial pore stretching in one direction and strut shape, whereas polydispersity has only a very small effect.     

Microstructure and mechanical properties of fine grained carbon-bonded Al2O3–C materials

Fine grained carbon-bonded Al₂O₃–C materials as used in ceramic filters have been manufactured by uniaxial and isostatic pressing, respectively. The variation in the microstructure over the cross section of the samples which in particular depends on the shaping technique plays an important role in the wetting of the material by liquid steel. Moreover, the amount and grain size of the binder has a decisive influence on the porosity and bulk density and therefore on the mechanical properties. For this, two different grain size distributions of Carbores^® P binder were used, and in addition the fraction of binder was varied from 5–30 wt%. Tests of the cold crushing strength and of the cold modulus of rupture were performed at room temperature. The adjusted bulk density, open porosity and shrinkage of the samples were determined and the microstructure was analyzed by means of scanning electron microscopy. For control of a homogeneous distribution of carbon in the samples, the residual carbon content was measured also within individual samples at different positions.     

陶瓷涂层结构优化及失效机理的研究现状

陶瓷涂层以其优异的耐磨损、耐高温、耐腐蚀等性能表现出巨大的工程应用前景。但是,在服役过程中因温度变化和受力诱发的裂纹产生、扩展,甚至导致涂层开裂、剥落及失效,这些因素限制了涂层的应用,因此通过结构优化改善陶瓷涂层的抗开裂、剥落性能较为重要。本文首先论述了纳米结构涂层、耐磨多层涂层、复合涂层的失效机理及其结构优化。提出了利用单次喷涂制备粘结层和陶瓷层的方法,通过该方法可以消除陶瓷层与粘结层间的界面形态,提高涂层的断裂韧性、粘结强度。最后展望了陶瓷涂层在材料组分设计和工艺优化研究中应重点关注的方面。     

Stability of catalytic foam diesel-soot filters based on Cs2O, MoO3, and Cs2SO4 molten-salt catalysts

The durability of catalytic alumina and zirconia-toughened mullite ceramic foam diesel-soot filters was tested by exposing them to severe, artificial exhaust conditions. The catalytic performance, composition, and mechanical strength were constantly monitored. It was concluded that the mechanical strength of the catalytic filters may be reduced by an interaction of the catalyst with certain compounds of ceramic filters. In practice, it should be possible to minimize the effect by carefully controlling the composition of the ceramic filter. For instance, the presence of phosphorous in alumina-based filters support should be avoided. The stability of the current catalyst phases, based on Cs₂O, MoO₃, and Cs₂SO₄, is too low for application. Due to partial evaporation, emission of catalyst compounds into the environment is likely and when that happens significant deactivation of the catalytic phase is unavoidable. The catalyst was also found to be soluble in water, which might be disastrous in the case of condensation occurring in the exhaust pipe.     

Simultaneous Filtration and Catalytic Oxidation of Carbonaceous Particulates

Two catalytic filters prepared by the deposition of Cu–V–K–Cl catalyst on different ceramic supports, foam and sintered aluminosilicate monolith, were employed for the removal of soot from the exhaust of a gas-oil burner. The foam filter was more suitable than the sintered filter for this application allowing better soot–catalyst contact, lower gas pressure drop and easier spontaneous filter regeneration.     

Effect of silica sol on performance and surface precision of alumina ceramic shell prepared by binder jetting

Using 3D printing technology to prepare ceramic shell used for precision investment casting can realize short process and efficient preparation of the ceramic shell, which has a great application potential in the casting field. However, the 3D printed ceramic shells often have the problems of low strength and accuracy. In this paper, a silica sol room temperature dip coating treatment combined with high temperature sintering method was proposed to improve the strength and surface precision of the ceramic shell prepared by the binder jetting. The effects of silica sol concentration and dip coating time on performance and surface precision of the alumina ceramic shell were studied. The mechanical properties and surface precision of the alumina ceramic shell prepared by the binder jetting were improved significantly with the increases of the sol concentration and dip coating time. With the dip coating time of 90 s and sol concentration of 30%, the maximum bending strength of the alumina ceramic reached 44.8 MPa, which was 18.9 times higher than that of the untreated alumina ceramic. The top surface roughness and side roughness of the alumina ceramic decreased from 6.87 μm to 5.70 μm and 7.55 μm–6.46 μm, respectively, compared to those of the untreated alumina ceramic.     

AS型泡沫陶瓷过滤器的研制

详细说明了用网状弹性聚氨基甲酸乙脂切片浸渍陶瓷料浆研制AS型泡沫陶瓷过滤器的工艺。采用非磷酸盐添加剂粘合,由碳化硅、氧化铝、硅胶及少量硅酸铝纤维制成的AS型泡沫陶瓷过滤器抗压强度可达1．65MPa而厚度仅为15mm,并且不会造成环境污染,完全可以满足过滤铁熔液的要求。