Hydrolysis of Pure and Sodium Substituted Calcium Aluminates and Cement Clinker Components Investigated by in Situ Synchrotron X-ray Powder Diffraction

The hydrolysis of pure and sodium-substituted calcium aluminates and cement clinker phases was investigated in situ in the temperature range 25°–170°C, using the angle dispersive powder synchrotron powder X-ray diffraction technique. The final hydrolysis product in all cases was Ca₃Al₂(OH)₁₂. The intermediate phase Ca₄Al₂O₇·19H₂O was formed from the pure calcium aluminates, and the intermediate phases Ca₄Al₂O₇· x H₂O, x = 11, 13, or 19, were formed from the cement clinker phases.     

Chemistry and Morphology of Hydrogarnets Formed in Cement-Based CASH Hydroceramics Cured at 200° to 350°C

We have studied the chemistry and the morphology of hydrogarnet crystals produced in cement-based hydroceramic materials at elevated temperatures (200°–350°C) with silica and alumina additions. Such materials lie within the hydrothermal CaO–Al₂O₃–SiO₂–H₂O (CASH) system. Hydrogarnet Ca₃Al₂(SiO₄)_{3− y} (OH)_{4 y} is the dominant aluminum bearing phase formed and its composition is influenced mainly by the curing temperature and to a lesser degree by the addition of silica. The composition parameter y was estimated by Rietveld refinement of X-ray diffraction (XRD) data. Electron probe microanalysis (EPMA) shows that the hydrogarnets incorporate minor elements such as Fe, Mg, and S. EPMA data confirmed the hydrogarnet composition estimated from XRD. Both octahedral and icositetrahedral forms are observed. The icositetrahedral form is associated with higher minor element content.     

Microstructural and Microchemical Characterization of a Calcium Aluminate—Polymer Composite (MDF Cement)

The microstructure of a macrodefect-free (MDF) cement has been characterized by transmission electron microscopy (TEM), scanning electron microscopy (SEM), and high-resolution electron microscopy (HREM). The microchemistry of ultramicrotomed samples has been studied by energy dispersive spectrometry (EDS) and parallel electron energy loss spectrometry (PEELS). MDF cement consists of CaAl₂O₄ and CaAl₄O₇ grains randomly distributed in a polymer matrix. The ceramic/polymer interface contains an amorphous interphase inside of which are distributed very fine crystallites of the metastable hydration product Ca₂Al₂O₅·8H₂O. PEELS analyses of the interphase revealed the presence of carbon, indicating that Ca₂Al₂O₅·8H₂O was most likely stabilized by the intercalation of polymeric chains into its basal interlayers. The polymer phase preferably cross-links with Al. In situ environmental cell electron microscopy showed that moisture uptake of MDF cements occurred by polymer swelling and interphase dissolution. The role of the interfacial interphase in dry and wet mechanical properties is discussed.     

Phase Equilibria in High-Alumina Part of the System CaO–MgO–Al2O3–SiO2

Results are presented of a study of phase equilibria among crystalline and liquid phases in the quaternary system CaO–MgO-Al₂O₃–SiO₂ at Al₂O₃ contents greater than 35%. Equilibrium diagrams shown are for the five triangular joins CaAl₂Si₂O₃-Ca₂Al₂SiO₇-MgAl₂O₄, Ca₂Al₂SiO₇-MgAl₂O₄-Al₂O₃, CaAl₂Si₂O₈-MgO-Al₂O₃, CaAl₂Si₂O₈-Mg₂SiO₄-MgAl₂O₄, and CaAl₂Si₂O₈-MgO-Mg₂SiO₄. The composition and nature of the four quaternary peritectic points and the relationships of univariant lines and primary phase volumes are discussed.     

Determination of Positions of Zeolitic Calcium Atoms and Water Molecules in Hydrothermally Formed Aluminum-Substiqtuted Tobermorite-1.1nm Using Synchrotron Radiation Powder Diffraction Data

The crystal structure of hydrothermally formed Al-substituted tobermorite-1.1nm (Ca_4.9Si_5.5Al_0.5O_16.3(OH)_0.7·5H₂O) has been analyzed using synchrotron radiation powder diffraction data. Crystallographic positions of a zeolitic Ca atom and three water molecules in the channel of the framework were determined by the Monte Carlo method and subsequent Rietveld refinement. The Ca atom splits into two sites at a distance of 0.161 nm apart, and it is coordinated with the three water molecules and the three oxygen atoms belonging to the framework. Al atoms preferably substitute a part of the Si atoms at the "bridging SiO₄" tetrahedra rather than at those of the "chain middle group SiO₄" tetrahedra.     

Reactions between Hot-Pressed Calcium Hexaluminate and Silicon Carbide in the Presence of Oxygen

The reactions between hot-pressed calcium hexaluminate (CaAl₁₂O₁₉, hibonite) and silicon carbide (SiC) at 1100°-1400°C in air and nominal argon atmospheres were investigated. In inert atmospheres, there was no evidence of reaction at temperatures up to at least 1400°C. In air, the oxidation of SiC produced a layer of silica or a multicomponent amorphous silicate (depending on impurities) that reacted with CaAl₁₂O₁₉. At temperatures below 1300°C, the reaction resulted in the stratification of two distinct interfacial layers: a partially devitrified CaO-Al₂O₃-SiO₂ glass adjacent to SiC and a CaAl₂Si₂O₈ (anorthite) layer adjacent to hibonite. At 1400°C, a large amount of liquid was formed, the majority of which was squeezed out from between the reaction couple. No distinct layer of anorthite was present; instead, the anorthite was replaced by a layer of alumina between the glass-rich layer and hibonite. An activation energy of 290 kJ/mol was determined for the reaction, which is consistant with oxygen diffusion through a calcium aluminosilicate glass. The reaction between rare-earth hexaluminates and SiO₂ was predicted to produce a more-viscous glass than CaAl₁₂O₁₉ and SiO₂ and, therefore, have slower reaction kinetics, because of lower mass transport in the glass.     

Hydration Study of the System Ca3Al2O6–CaSO4· 2H2O–Ca(OH)2–H2O with and without Citric Acid

Hydration occurring in the system Ca₃Al₂O₆–CaSO₄· 2H₂O–Ca(OH)₂–H₂O has been studied at different temperatures and it was found that the reactions are diffusion controlled. The kinetic data obeyed Jander's equation and the rate of reaction increased with increasing temperature. X-ray diffraction studies and calorimetric measurements show that when gypsum is consumed, ettringite is converted into monosulfate. The rate of this conversion also increased with the increasing temperature and decreased in the presence of citric acid. Spectroscopic studies showed that there was some interaction between citric acid and the cement and that the product of hydration is of colloidal nature. Zeta potential measurements show that retardation of Ca₃Al₂O₆ hydration in the presence of gypsum and Ca(OH)₂ is not due to SO²⁻₄ adsorption. Electrical conductivity and thermoelectric potential measurements of solid Ca₃Al₂O₆ show that Ca₃Al₂O₆ is an n -type semiconductor and contains defects. The retardation of Ca₃Al₂O₆ may be due to poisoning of reaction sites by gypsum and Ca(OH)_2.     

29Si and 27Al MASNMR Study of Stratlingite

Strätlingite (2CaO·Al₂O₃·SiO₂·8H₂O) is a complex calcium aluminosilicate hydrate commonly associated with the hydration of slag-containing cements or other cements enriched in alumina. Strätlingite can coexist with the hydrogarnet solid solution [hydrogarnet (3CaO·Al₂O₃·6H₂O)-katoite (3CaO·Al₂O₃·SiO₂·4H₂O)] and calcium silicate hydrate (C-S-H). Since Strätlingite is present in many blended cements, the knowledge of strätlingite's characteristic silicate anion structure and how aluminum is accommodated by the structure is important. Phase pure Strätlingite samples have been synthesized from oxides in the presence of excess water and from metakaolinite, calcium aluminate cement, CaO, NaOH, and water. The samples were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), and thermogravimetric analysis (TGA) and then further examined using ²⁹Si, with and without cross-polarization (CP), and ²⁷Al solid-state magic angle nuclear magnetic resonance spectroscopy (MASNMR). For the most part, NMR data for these strätlingites corroborate structural information available in the literature. The aluminum atoms are both tetrahedrally and octahedrally coordinated, and the silicon atoms exist predominantly as Q₂, Q₂(1Al), and Q₂(2Al) species. The presence of alkali affects the structure of strätlingite in subtle ways, significantly reducing the Al^IV/A1^VI ratio.     

Influence of Fluorine Content in Apatite–Mullite Glass-Ceramics

The nucleation and crystallization of a series of glasses based on 4.5SiO₂·3Al₂O₃·1.5P₂O₅·(5 − z )CaO · z CaF₂ with a Ca:P ratio corresponding to apatite were studied. In these glasses, the objective was to investigate the influence of fluorine content and z was varied from 3 to 0. All the glasses studied crystallized to fluorapatite (FAP) and mullite with the exception of the glass containing no fluorine, which crystallized to β-tricalcium phosphate (Ca₃(PO₄)₂) and anorthite (CaAl₂Si₂O₈). Glasses that contained sufficient fluorine to form FAP bulk nucleated to give FAP without a nucleation hold. Thermal gravimetric analysis demonstrated a significant weight loss corresponding to the crystallization of mullite, which increased with the fluorine content of the glass and also with decreased particle size. The loss was attributed to volatile SiF₄. The glass transition temperature decreased with increased fluorine content of the glass.     

Microstructural Characterization of Cofired Tungsten-Metallized High-Alumina Electronic Substrates

Microstructural characterization of a high-Al₂O₃ substrate containing cofired thick-film tungsten metallization, with particular emphasis on the metal/ceramic interface, was conducted. The substrate contained tabular Al₂O₃ grains surrounded by a continuous calcium magnesium aluminum silicate glass containing particles of monoclinic ZrO₂ and reduced rutile (TiO_{2- x} ). The metal/ceramic adhesion was caused by mechanical interlocking between the W and Al₂O₃ grains by the glass phase which penetrated the porous W layers during sintering; there was no interfacial reaction or diffusion zone. The mechanical properties of the W metallization did not limit interfacial strength. Heat treatments of the substrate at 1400 K in air and under vacuum resulted in the devitrification of the intergranular glass. The most abundant devitrification product was anorthite (CaAl₂Si₂O₈), accompanied by magnesium aluminate titanate, magnesium aluminate spinel, α-cristobalite (SiO₂), and α-cordierite (Mg₂Al₄Si₅O₁₈). In addition, small rutile particles precipitated within the Al₂O₃ grains.     

Ternary System Al2O3—MgO—CaO: Part II, Phase Relationships in the Subsystem Al2O3—MgAl2O4—CaAl4O7

Solid-state compatibility and melting relationships in the subsystem Al₂O₃—MgAl₂O₄—CaAl₄O₇ were studied by firing and quenching selected samples located in the isopletal section (CaO·MgO)—Al₂O₃. The samples then were examined using X-ray diffractomtery, optical microscopy, and scanning and transmission electron microscopies with wavelength- and energy-dispersive spectroscopies, respectively. The temperature, composition, and character of the ternary invariant points of the subsystem were established. The existence of two new ternary phases (Ca₂Mg₂Al₂₈O₄₆ and CaMg₂Al₁₆O₂₇) was confirmed, and the composition, temperature, and peritectic character of their melting points were determined. The isothermal sections at 1650°, 1750°, and 1840°C of this subsystem were plotted, and the solid-solution ranges of CaAl₄O₇, CaAl₁₂O₁₉, MgAl₂O₄, Ca₂Mg₂Al₂₈O₄₆, and CaMg₂Al₁₆O₂₇ were determined at various temperatures. The experimental data obtained in this investigation, those reported in Part I of this work, and those found in the literature were used to establish the projection of the liquidus surface of the ternary system Al₂O₃—MgO—CaO.     

The System CaO-Al2O3-P2O5-H2O at 200°C

The phase relations were established experimentally for the system CaO-Al₂O₃-P₂O₅-H₂O at 200°C and 1710 kPa. The quaternary compound, crandallite, CaAl₃(PO₄)₂(OH)₅· H₂O, was found to be stable. Compatibility joins in the system were determined. The phase relations are presented on the isothermal-isobaric 90 wt% water plane and by projecting the primary fields of the liquidus surface onto the same plane.     

Hydrothermal Solidification of Kaolinite–Quartz–Lime Mixtures

The strength development of hydrothermally solidified kaolinite–quartz–lime systems with kaolinite as the aluminum source was studied. The starting materials were mixed so that the Ca/(Si + Al) atomic ratio was in the range 0.23 to 0.25, and the Al/(Si + Al) ratio was between 0 to 0.50. Specimens were formed by uniaxial pressing and hydrothermal treatment under saturated steam pressure at 200°C for 2 to 20 h. For quartz-rich systems with Al/(Si + Al) = 0 and 0.05, strength development by the formation of calcium silicate hydrates, such as C–S–H and tobermorite (Ca₅(Si₆O₁₈H₂)·(4H₂O), was observed. On the other hand, in the case of kaolinite-rich systems with Al/(Si + Al) = 0.24 to 0.50, strength development by the formation of hydrogarnet (Ca₃Al₂(SiO₄)(OH)₈) was recognized, resulting in flexural strengths between 15 to 20 MPa. It is proposed that strength development is related to the formation of mesopores (∼0.04 μm) that accompanied formation of the hydrogarnet.     

Sub-Solidus Synthesis and Microwave Dielectric Characterization of Plagioclase Feldspars

Na _x Ca_{1− x} Al_{2− x} Si_{2+ x} O₈ plagioclase solid solutions (0≤ x ≤1) were synthesized under sub-solidus conditions using a solid-state reaction technique. The plagioclase formation and the sintering temperature decreased with an increase in x from the anorthite (CaAl₂Si₂O₈; x =0) to the albite (NaAlSi₃O₈; x =1).
Microwave (MW) dielectric measurements revealed that slow-cooled ( P 1 ) anorthite exhibited higher Q × f values than fast-cooled ( I 1 ) anorthite. Slow cooling also considerably improved the Q × f values of the sodium-rich Na _x Ca_{1− x} Al_{2− x} Si_{2+ x} O₈ solid solutions (0.8≤ x ≤1), where the highest Q × f value of 17 600 GHz was obtained for slow-cooled Na_0.8Ca_0.2Al_1.2Si_2.8O₈. The temperature coefficient of resonant frequency (τ_f) approached zero for 0.8≤ x ≤1.     

Potassium Vapor Attack in Refractories of the Alumina–Silica System

A graphite chamber was used for the reaction between samples of 45 or 55 wt% alumina and a mixture of metallurgical coke and potassium carbonate. Thermal treatments were conducted at 1000°C. The results suggest that the potassium attack in silica-alumina bricks is controlled by the following reactions: K₂O + SiO₂→ K₂O → SiO₂ in the glassy matrix; 3(K₂O · 2SiO₂) + 3Al₂O₃→ 2SiO₂· 3(K₂O · Al₂O₃· 2SiO₂) + 2SiO₂ for short times; and K₂O → Al₂O₃· 2SiO₂+ 2SiO₂· K₂O · Al₂O₃· 4SiO₂ for long times. In 55 wt% alumina bricks containing corundum and tridymite, potassium also attacks those phases forming a glassy phase. The formation of kaliophilite at the matrix/mullite grain interface causes a volumetric expansion of 55.5%, resulting in cracks in the matrix. Because the kaliophilite phase is not in equilibrion with mullite, the former will react with free silica to form leucite that is more thermodynamically stable.     

Crystallization of Pseudo-orthorhombic Anorthite on Basal Sapphire

Anorthite-glass films were grown on basal Al₂O₃ substrates using pulsed-laser deposition. The substrates were cleaned and annealed in air at 1400°C to produce crystallographically flat (0001) terraces. The films were deposited in an oxidizing environment. X-ray microanalysis confirmed the composition of the glass films to be close to that of anorthite (CaO·Al₂O₃·2SiO₂). Although anorthite usually has triclinic symmetry, subsequent crystallization of these films in air at 1200°C resulted in the formation of pseudo-orthorhombic CaAl₂Si₂O₈ ( o -anorthite), a known metastable form of the mineral. Microstructural characterization was performed using visible-light microscopy, scanning electron microscopy, and transmission electron microscopy. The films dewetted the substrate either before or after crystallization to form o -anorthite islands which had strong orientation relationships to the Al₂O₃ substrate. The epitaxy of the o -anorthite islands was accompanied by a small lattice mismatch parallel to the substrate plane. The formation of three orientational variants is consistent with the symmetry of the basal Al₂O₃ surface. The dislocation network observed at the o -anorthite/Al₂O₃ interface indicates that nucleation and growth of the anorthite occurs directly on the substrate surface without an intervening interfacial amorphous layer. The study of anorthite-glass films is important because they are present in liquid-phase-sintered Al₂O₃, and may be devitrified by postsintering heat treatments.     

Hydration of 3CaO·Al2O3 and 3CaO·Al2O3+] Gypsum With and Without CaCl2

Paste samples of tricalcium aluminate alone, with CaCl₂, with gypsum, and with gypsum and CaCl₂ were hydrated for up to 6 months and the hydration products characterized by SEM, XRD, and DTA. Tricalcium aluminate hydrated initially to a hexagonal hydroaluminate phase which then changed to the cubic form; the transformation rate depended on the size and shape of the sample and on temperature. The addition of CaCl₂ to tricalcium aluminate resulted in the formation of 3CaO · Al₂O₃· CaCl₂·10H₂O and 4CaO · Al₂O₃· 13H₂O, or a solid solution of the two. The chloride retarded the formation of the cubic phase 3CaO · Al₂O₃· 6H₂O; the addition of gypsum resulted in the formation of monosulfoaluminate with a minor amount of ettringite. When chloride was added to tricalcium aluminate and gypsum, more ettringite was formed, although 3CaO · Al₂O₃· CaSO₄· 12H₂O and 3CaO · Al₂O₃· CaCl₂· 10H₂O were the main hydration products.     

Chemical Preparation of the Binary Compounds in the Calcia-Alumina System by Self-Propagating Combustion Synthesis

The binary compounds Ca₃Al₂O₆ (C₃A), Ca₁₂Al₁₄O₃₃ (C₁₂A₇), CaAl₂O₄ (CA), CaAl₄O₇ (CA₂), and CaAl₁₂O₁₉ (CA₆) in the CaO-Al₂O₃ system have been synthesized as high-compound-purity ceramic powders by using the self-propagating combustion synthesis (SPCS) method. Materials characterization of the above-mentioned phases was performed via powder X-ray diffractometry (XRD), Fourier transform infrared spectroscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. The structural characterization of the C₁₂A₇ phase has been performed via Rietveld analysis on the powdered XRD samples. It has hereby been shown that, by using this synthesis procedure, it should be possible to manufacture high-purity ceramic powders of CA, CA₂, and C₁₂A₇ at 850°C, C₃A at 1050°C, and CA₆ at 1200°C in a dry-air atmosphere.     

Calcium Phosphate Cements Prepared by Acid–Base Reaction

We investigated the characteristics of calcium phosphate cements (CPC) prepared by an exothermic acid–base reaction between NH₄H₂PO₄-based fertilizer (Poly-N) and calcium aluminate compounds (CAC), such as 3CaO · Al₂O₃ (C₃A), CaO · Al₂O₃ (CA), and CaO · 2Al₂O₃ (CA₂), in a series of integrated studies of reaction kinetics, interfacial reactions, in-situ phase transformations, and microstructure development. Two groups were compared: untreated and hydrothermally treated CPC specimens. The extent of reactivity of CAC with Poly-N at 25°C was in the following order: CA > C₃A ≫ CA₂. The formation of a NH₄CaPO₄· x H₂O salt during this reaction was responsible for the development of strength in the CPC specimens. The in-situ phase transformation of amorphous NH₄CaPO₄· x H₂O into crystalline Ca₅(PO₄)₃(OH) and the conversion of hydrous Al₂O₃ gel →γ-AIOOH occur in cement bodies during exposure in an autoclave to temperatures up to 300°C. This phase transformation significantly improved mechanical strength.     

A Novel Way to Synthesize Yttrium Aluminum Garnet from Metal–Inorganic Precursors

Yttrium aluminum garnet (YAG, Y₃Al₅O₁₂) was synthesized by sol–gel processing from the stoichiometric amounts of aluminum pellets, Y(NO₃)₃·6H₂O, and Al(NO₃)₃·9H₂O or AlCl₃·6H₂O, with suitable kinds of acid (citric acid, acetic acid, etc.) as catalysts. Polycrystalline YAG powder was obtained by drying the YAG precursor followed by calcination at temperatures above 900°C. Thermogravimetry/differential thermal analysis and Fourier transform infrared specotrscopic analyses in air showed an exothermic peak at ∼900°C, attributed to the formation of a polycrystalline YAG phase and weight loss of 60% at 1000°C, caused by the decomposition of hydroxyl and NO₃⁻, etc. X-ray diffraction analysis showed that YAG can be formed at 900°C, and no other intermediate was observed. In particular, the YAG sol can be used for dry-spinning fibers with the aid of some organic polymer.