Pressureless sintering of dual-phase,high-entropy boride–carbide ceramics

Dual-phase, high-entropy boride–carbide ceramics were densified by pressureless sintering. Relative densities up to approximately 96% were obtained for ceramics containing about 30 vol% high-entropy boride and 70 vol% high-entropy carbide. Isostatic pressing at 200 MPa resulted in higher relative densities of both the green bodies and final ceramics compared to uniaxial pressing. The highest relative density of 96.3% was achieved for a ceramic that was isostatically pressed at 200 MPa and sintered at 2300°C for 2 h. Grain sizes of the resulting ceramics were approximately 2 µm. This is the first report of pressureless sintering of dual-phase, high-entropy boride–carbide ceramics.     

Microstructure and mechanical properties of WB2–B4C composites fabricated by boro/carbothermal reduction and SPS

The phase composition, microstructure, and mechanical properties of the WB₂–B₄C composites fabricated by a combination of boro/carbothermal reduction and spark plasma sintering (SPS) method with WO₃, B₄C, and graphite as raw materials were investigated in this study. The experimental results showed that the relative density of the as-sintered WB₂–B₄C composites was ∼93.1% and ∼99.5%, respectively, after being SPS sintered at 1600°C under the applied load of 30 MPa for 10 min. Scanning electron microscope analysis showed that a network structure with WB₂ grains surrounded by B₄C grains was observed after sintering. Analyses of high-resolution TEM showed semi-coherent interface and lattice distortion transition region between WB₂ and B₄C grains. The Vickers hardness of WB₂–B₄C composite increased to 22.3 ± 0.9 GPa at 9.8 N owing to the fully dense, solid solution of C, and three-dimensional network structure. Moreover, the fracture toughness and flexural strength of WB₂–B₄C composite reach 6.04 ± 0.81 MPa m^1/2 and 750 ± 80 MPa, respectively, which could be attributed to the semi-coherent interface between WB₂ and B₄C grains.     

Preparation and characterization of ultrafine ZrB2–SiC composite powders by a combined sol–gel and microwave boro/carbothermal reduction method

A combined sol–gel and microwave boro/carbothermal reduction technique was investigated and used to synthesize ultrafine ZrB₂–SiC composite powders from raw starting materials of zirconium oxychloride, boric acid, tetraethoxysilane and glucose. The effects of reaction temperature, molar ratios of n(B)/n(Zr) and n(C)/n(Zr+Si) on the synthesis of ultrafine ZrB₂–SiC composite powders were studied. The results showed that the optimum molar ratios of n(B)/n(Zr) and n(C)/n(Zr+Si) for the preparation of phase pure ultrafine ZrB₂–SiC composite powders were 2.5 and 8.0, respectively, and the firing temperature required was 1300 °C. This temperature was 200 °C lower than that require by using the conventional boro/carbothermal reduction method. Microstructures and phase morphologies of as-prepared ultrafine ZrB₂–SiC composite powders were examined by field emission-scanning electron microscopy (FE-SEM) and transmission electron microscope (TEM), showing that SiC grains were formed evenly among the ZrB₂ grains, and the grain sizes of ZrB₂ in the samples prepared at 1300 °C for 3 h were about 1–2 μm. The average crystalline sizes of these two phases in the as-prepared samples were calculated by using the Scherrer equation as about 58 and 27 nm, respectively.     

Comparison of PdCo/SBA-15 prepared by co-impregnation and sequential impregnation for Fischer–Tropsch synthesis

Properties and catalytic performance of bimetallic Pd–Co/SBA-15 prepared by co-impregnation (0.2Pd–10Co-CIP) and sequential impregnation (0.2Pd–10Co-SIP) for Fischer–Tropsch synthesis (FTS) were investigated. After calcination, Co₃O₄ was formed and located inside the channels of SBA-15 and on external surface. Compared to 0.2Pd–10Co-SIP, 0.2Pd–10Co-CIP had a smaller surface area, pore size, lower reduction temperature and less active sites due to larger particle sizes of Co₃O₄. From FTS testing, 0.2Pd–10Co-SIP provided higher and steadier conversions of CO and H₂ as well as higher yield of C₅–C₉ products.     

Carbon-containing droplet combustion–carbothermal synthesis of well-distributed AlN nanometer powders

A novel three-step technique was employed to synthesize the well-distributed AlN nanopowders. First, the hollow spherical precursor particles with an average diameter of 2–5 μm, consisting of an amorphous structure mixture of Al₂O₃ and C, was prepared by carbon-containing droplet combustion method by using glucose, urea, and aluminum nitrate as starting materials. The carbothermal reduction and nitridation (CRN) was carried out at 1500°C under N₂ flow for 2 h and subsequently the CRN product was calcined at 700°C in air for 1 h to remove residual carbon and transform the CRN product to high-purity AlN powders consisting of nanostructured hollow spheres. The formation mechanism of precursor and AlN hollow spheres was discussed in detail. The AlN powder exhibited well-distributed spherical particles with a size of 30–50 nm and good sinterability. After additive-free and pressureless sintering at 1800°C for 2 h, the relative density of the sintered AlN sample was measured to be 99.02%.     

In situ synthesis of vanadium carbide–copper nanocomposite by a modified mechanochemical combustion method

Synthesis of vanadium carbide–copper nanocomposite was achieved via mechanochemical combustion method from reactant mixture of V₂O₅, CuO, C and Mg powders. The obtained samples were characterized by X-ray diffraction (XRD), transmission electron microscopy (TEM) and scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS). X-ray diffraction investigations indicated that the combustion products were V₄C₃, V₂C and Cu phases. Microstructural studies showed that a nanostructured powder with a mean particle size of about 100 nm was procured in the samples milled for 90 min.     

Effect of SiC nanoparticles on in-situ synthesis of SiC whiskers in corundum–mullite–SiC composites obtained by carbothermal reduction

Corundum–mullite–SiC composites were synthesised using a carbothermal reduction method. The effects of SiC nanoparticles and sintering temperatures on the phase transformation of the composites and the synthesis of SiC whiskers were studied by X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Results indicated that corundum, mullite, and SiC whiskers were produced as final products at 1600–1650 °C. SiC whiskers were formed through the vapor–solid mechanism. The added SiC nanoparticles worked as nucleating agents to facilitate the carbothermal reduction of aluminosilicates and formation of SiC whiskers. The sample with the added SiC nanoparticles exhibited a high yield of β-SiC of 17.1%. Furthermore, the SiC nanoparticles decreased the formation temperature of SiC whiskers from the original 1600 °C to 1500 °C, and the porosity of the composites was increased from 56.7% to 64.7% by increasing the partial pressure of SiO gas. This study provides an insight into the more efficient synthesis of composites with SiC whiskers through the carbothermal reduction of aluminosilicates.     

Mechanical and thermal properties of silicon carbide ceramics with yttria–scandia–magnesia

Two different SiC ceramics with a new additive composition (1.87 wt% Y₂O₃–Sc₂O₃–MgO) were developed as matrix materials for fully ceramic microencapsulated fuels. The mechanical and thermal properties of the newly developed SiC ceramics with the new additive system were investigated. Powder mixtures prepared from the additives were sintered at 1850 °C under an applied pressure of 30 MPa for 2 h in an argon or nitrogen atmosphere. We observed that both samples could be sintered to ≥99.9% of the theoretical density. The SiC ceramic sintered in argon exhibited higher toughness and thermal conductivity and lower flexural strength than the sample sintered in nitrogen. The flexural strength, fracture toughness, Vickers hardness, and thermal conductivity values of the SiC ceramics sintered in nitrogen were 1077 ± 46 MPa, 4.3 ± 0.3 MPa·m^1/2, 25.4 ± 1.2 GPa, and 99 Wm⁻¹ K⁻¹ at room temperature, respectively.     

Effects of excess boron on combustion synthesis of alumina–tantalum boride composites

TaB- and TaB₂–Al₂O₃ in situ composites were fabricated by thermite-incorporated combustion synthesis from the powder mixtures of different combinations, including Ta₂O₅–Al–B, Ta₂O₅–Al–B₂O₃–B, and Ta₂O₅–B₂O₃–Al. Effects of excess boron were studied on the combustion dynamics and phase constituents of final products. For the B₂O₃-containing samples, the reaction was less exothermic and aluminothermic reduction of Ta₂O₅ and B₂O₃ was less complete, resulting in the deficiency of boron and the presence of TaO₂ and Ta. For the samples containing elemental boron, the occurrence of borothermic reduction of Ta₂O₅ also caused the loss of boron. Experimental evidence showed that boron in excess of the stoichiometric amount substantially enhanced the formation of tantalum borides, which in turn facilitated the reduction of Ta₂O₅ by Al. Consequently, the samples rich with boron in the molar proportions of Ta₂O₅:Al:B=3:10:9 and 3:10:16 (i.e., B/Ta=1.5 and 2.67) were found to be the optimum stoichiometries of producing TaB- and TaB₂–Al₂O₃ composites through a self-sustaining combustion process.     

Homogeneous doping of ceramics by infiltration–gelation

Advanced ceramics require small amounts of cation dopants to improve the sintering process or achieve certain properties. Dopant precursors are often dissolved in initial processing liquids, which may adversely affect ceramic colloidal stability, and dopant transport during drying. This would lead to chemical and microstructural inhomogeniety in the eventual ceramics. Here we present a method that circumvents these problems using the example of Al³⁺-doped TiO₂ ceramics. Homogeneous TiO₂ compacts with 34% porosity are first prepared by colloidal casting and calcined at 700 °C. The obtained compacts are infiltrated with an aqueous solution of Al(NO₃)₃, citric acid and ethylene glycol. The solution composition is adjusted such that during drying, a gel forms that covers the internal pore surface. Subsequent decomposition of organics results in a homogeneous dopant distribution in the porous and then dense-sintered TiO₂ compacts. This is verified with SEM-EDX, and laser ablation coupled ICP-MS on dense compacts sintered at 1100 °C.     

Preparation of boron carbide–aluminum composites by non-aqueous gelcasting

Gelcasting is an attractive forming process to fabricate ceramic parts with near-net-shape. In the present work, non-aqueous gelcasting of boron carbide (B₄C)–aluminum (Al) composites was studied. A stable B₄C–Al slurry with solids loading up to 55 vol.% for gelcasting was prepared. The slurry was solidified in situ to green body with the mean value of relative density of 64% and flexural strength of 21 MPa. The SEM images showed that powders in green body compact closely by the connection of polymer networks. B₄C–Al samples were also obtained by the process of gelcasting and sintering at 1300 °C for 1 h in 0.1 MPa Ar atmosphere. The average bulk density of sintered body was 2.05 g cm⁻³.     

In situ synthesis of Al2O3–SiC powders via molten-salt-assisted aluminum/carbothermal reduction method

Al₂O₃–SiC composite powder (ASCP) was successfully synthesized using a novel molten-salt-assisted aluminum/carbothermal reduction (MS-ACTR) method with silica fume, aluminum powder, and carbon black as raw materials; NaCl–KCl was used as the molten salt medium. The effects of the synthesis temperature and salt-reactant ratio on the phase composition and microstructure were investigated. The results showed that the Al₂O₃–SiC content increased with an increase in molten salt temperature, and the salt–reactant ratio in the range of 1.5:1–2.5:1 had an impact on the fabrication of ASCP. The optimum condition for synthesizing ASCP from NaCl–KCl molten salt consisted of maintaining the temperature at 1573 K for 4 h. The chemical reaction thermodynamics and growth mechanism indicate that the molten salt plays an important role in the formation of SiC whiskers by following the vapor-solid growth mode in the MS-ACTR treatment. This study demonstrates that the addition of molten salt as a reaction medium is a promising approach for synthesizing high-melting-point composite powders at low temperatures.     

Pyrolysis synthesis of Si–B–C–N ceramics and their thermal stability

Si–B–C–N ceramics were synthesized by co-pyrolyzing hybrid polymeric precursors of polycarbosilane (PCS) and polyborazine (PBN). The pyrolysis behavior and structural evolution of the hybrid precursor, the microstructure and composition of the prepared Si–B–C–N ceramics were fully investigated. It was found that the copyrolysis of hybrid polymeric precursors in Ar led to the release of CH₄, CH₃NH₂ and CH₃CN gases at temperatures ranging from 200 to 1100 °C, and finally resulted in the formation of amorphous Si–B–C–N ceramics. In particular, the Si–B–C–N ceramics formed from the hybrid precursor with PBN/PCS mass ratio of 1 could keep amorphous state up to the annealing temperature of 1800 °C with weight change of only 2.08%. But this amorphous ceramics would decompose to form crystalline SiC, BN and Si₃N₄ at 2000 °C. Additionally, compared with PCS-derived SiC ceramics, the Si–B–C–N ceramics showed improved anti-oxidation performance up to 1300 °C due to the formation of borosilicate layers covering the ceramics.     

Mechanical behavior of zirconium diboride–silicon carbide ceramics at elevated temperature in air

The mechanical properties of zirconium diboride–silicon carbide (ZrB₂–SiC) ceramics were characterized from room temperature up to 1600 °C in air. ZrB₂ containing nominally 30 vol% SiC was hot pressed to full density at 1950 °C using B₄C as a sintering aid. After hot pressing, the composition was determined to be 68.5 vol% ZrB₂, 29.5 vol% SiC, and 2.0 vol% B₄C using image analysis. The average ZrB₂ grain size was 1.9 μm. The average SiC particles size was 1.2 μm, but the SiC particles formed larger clusters. The room temperature flexural strength was 680 MPa and strength increased to 750 MPa at 800 °C. Strength decreased to ～360 MPa at 1500 °C and 1600 °C. The elastic modulus at room temperature was 510 GPa. Modulus decreased nearly linearly with temperature to 210 GPa at 1500 °C, with a more rapid decrease to 110 GPa at 1600 °C. The fracture toughness was 3.6 MPa·m^½ at room temperature, increased to 4.8 MPa·m^½ at 800 °C, and then decreased linearly to 3.3 MPa·m^½ at 1600 °C. The strength was controlled by the SiC cluster size up to 1000 °C, and oxidation damage above 1200 °C.     

Sol–emulsion–gel synthesis of cordierite ceramics for high-frequency multilayer chip inductors

Nano-Cordierite powders used for high frequency chip inductors (MLCIs) were prepared by sol–emulsion–gel method. Effects of precursor concentration and [H₂O]/[Si] molar ratio on this material were studied. The sol–emulsion–gel processing of Mg₂Al₄Si₅O₁₈ as well as its dielectric property were investigated. Owing to the better packing efficiency and therefore higher surface energy of the freestanding nano-powder, the pressed pellets made by cordierite powder showed 98.6% theoretical density at 900 °C for 2 h. The additive Bi₂O₃ was utilized to promote the crystallization or transformation to α-cordierite and sintering. The sol–emulsion–gel-derived cordierite ceramics have low dielectric constant (ε=3.0～4.0; 18 GHz) and low dielectric loss (tgδ<0.001; 18 GHz) and can be co-fired with high conductivity metals such as Au, Ag/Pd internal electrode at low temperature (900 °C), suggesting that it was an ideal dielectric material for high-frequency multilayer chip inductors.     

Improved adhesion of TiN coatings on Al2O3–carbide composites by DFT calculations and experimental arc-PVD synthesis

Electronic and atomic structures of interfaces between TiN coatings and Al₂O₃–WC composites were investigated by Density functional theory (DFT) calculations. As typical examples, interfacial orientation relationships of TiN(001)/Al₂O₃(0001), TiN(001)/WC(0001), TiN(111)/Al₂O₃(0001), and TiN(111)/WC(0001) were chosen. It was found that the TiN(111)/Al₂O₃(0001) and TiN(111)/WC(0001) interfaces have interfacial structural units of six-fold coordinated triangular prisms centered on Ti atoms. In contrast, those of the interfaces with TiN(001) tend to have more distorted structure units due to their larger lattice misfits. Theoretical works of separation showed that interfacial strength is much more increased at the TiN(111) interfaces, as compared to those at the TiN(001) interfaces. Accordingly, experimental controls of TiN-coating orientations on Al₂O₃–WC composites were attempted by using the cathodic arc ion plating method. It was found that orientations of (111) in the TiN coatings can be more enhanced and then interfacial mechanical strengths and hardnesses of the TiN coatings can increase more with rising bias voltages.     

Synthesis of nano-phase ZrC by carbothermal reduction using a ZrO2–carbon nano-composite

Carbothermal reduction of Zr-sucrose gels powders into nano-phase ZrC, or ZrC-Zr(C,O) core-shell powders, via a composite of 2–4 nm sized ZrO₂ and amorphous carbon, is described. Samples with 1.7–20 sucrose-carbon:Zr ratio gels heated to 1495 °C at 10 °Cmin^?1, with 3 and 30 min hold time were studied in detail using; TG, XRD, SEM, TEM, STEM-EDX, and XPS with Ar⁺-ion etching. After 1495 °C, 3 min, the samples with 12-20C:Zr ratios yielded weakly agglomerated 30 to 40 nm sized ZrC particles, surrounded by a dense 5 nm thick shell of Zr(C,O). With 5C:Zr significant amounts of ZrO₂ was present after heating at 1495 °C for 3 min, while after 30 min annealing, ZrC particles without residual amorphous carbon was obtained. Minor amounts of zirconia was found in most samples, which in similarity with the 5 nm Zr(C,O) shell, is believed to stem from post synthesis oxidation.     

Low-temperature synthesis and microwave dielectric properties of trirutile-structure MgTa2O6 ceramics by aqueous sol–gel process

Trirutile-structure MgTa₂O₆ ceramics were prepared by aqueous sol–gel method and microwave dielectric properties were investigated. Highly reactive nanosized MgTa₂O₆ powders were successfully synthesized at 500 °C in oxygen atmosphere with particle sizes of 20–40 nm. The evolution of phase formation was detected by DTA–TG and XRD. Sintering characteristic and microwave dielectric properties of MgTa₂O₆ ceramics were studied at different temperatures ranging from 1100 to 1300 °C. With the increase of sintering temperature, density, ?_r and Q · f values increased and saturated at 1200 °C with excellent microwave properties of ?_r ～ 30.1, Q · f ～ 57,300 GHz and τ_f ～ 29 ppm/°C. The sintering temperature of MgTa₂O₆ ceramics was significantly reduced by aqueous sol–gel process compared to conventional solid-state method.