Effect of Yb2SiO5 addition on the physical and mechanical properties of sintered mullite ceramic as an environmental barrier coating material

In this study, ytterbium monosilicate (Yb₂SiO₅)-added sintered mullite ceramics are prepared as candidate materials for environmental barrier coatings (EBCs). The effect of adding Yb₂SiO₅ on the physical and mechanical properties of the sintered mullite ceramics is investigated. The Yb₂O₃–SiO₂–Al₂O₃ ternary phase diagram indicates that adding Yb₂SiO₅ to the mullite goes beyond simply mixing; instead, liquid sintering occurs. Therefore, when we add Yb₂SiO₅ to the mullite, the sintered body possesses a denser microstructure and faster densification rate than does pure mullite. The density rapidly increases with the addition of 6 wt% Yb₂SiO₅ in the mullite, and almost full densifications are achieved with the addition of 12 wt% and 18 wt% Yb₂SiO₅. In this study, mullite ceramic that contains 12 wt% Yb₂SiO₅ exhibits the smallest plastic deformation and the highest elastic modulus among ceramics containing 6, 12, and 18 wt% Yb₂SiO₅, according to Hertzian indentation results. The results suggest that 12 wt% Yb₂SiO₅-doped mullite may be expected to act as a potential EBC material based on its excellent elastic properties, dense microstructure, and appropriate coefficient of thermal expansion.     

Crystal structure,mechanical and thermal properties of Yb4Al2O9: A combination of experimental and theoretical investigations

The key requirements for a successful thermal and environmental barrier coating (T/EBC) material include stability in high temperature water vapor, low Young's modulus, close thermal expansion coefficient (TEC) with mullite, low thermal conductivity and weak mechanical anisotropy. The current prime candidates for top coat are ytterbium silicates (Yb₂SiO₅ and Yb₂Si₂O₇). A major weakness of these two silicates is the severe anisotropy in mechanical properties and thermal expansion that would lead to cracking of the coating. Thus, searching for new materials with weak mechanical and thermal anisotropy is of signification. In this work, the crystal structure, mechanical and thermal properties of a promising T/EBC candidate, Yb₄Al₂O₉, are investigated theoretically and experimentally. Good ductility, low shear deformation resistance, low Young's modulus (151 GPa) and low thermal conductivity (0.78 W m⁻¹ K⁻¹) is underpinned by heterogeneous bonding characteristic and distortion of the structure. Close TEC (6.27 × 10⁻⁶ K⁻¹) with mullite and weak mechanical anisotropy highlight the suitability of Yb₄Al₂O₉ as a prospective T/EBC.     

Crystallisation of amorphous spray-dried precursors in the Al2O3–SiO2 system

The crystallisation of amorphous precursors has been studied in the whole range of composition in the Al₂O₃–SiO₂ system. The amorphous precursors have been obtained by hydrolysing TEOS directly in a diluted aqueous solution of aluminium nitrate, spray drying the clear solution and heating the resulting powder. Up to 70 mol % Al₂O₃, only mullite crystallises around 980–1000 °C; between 70 and 80 mol % Al₂O₃ mullite and spinel crystallise together; and for more than 80 mol % Al₂O₃ only spinel is formed. In the 70–80 mol % Al₂O₃ range of composition, when both mullite and spinel crystallise, low heating favours the crystallisation of mullite and it is nearly possible to crystallise only mullite from a 75 mol % Al₂O₃ sample. By rapid heating it is also possible to crystallise only spinel from the same 75 mol % Al₂O₃ precursor. The enthalpy and the activation energy for crystallisation are maximum for 60–80 mol % Al₂O₃. Heating the samples up to 1700 °C for 1 h, the phase equilibrium is not reached, particularly when both mullite and spinel crystallise together, and θ-Al₂O₃ is still present.     

Investigation of high-temperature reactions within the ZrSiO4–Al2O3 system

Solid state reactions between ZrSiO₄ and αAl₂O₃ in powders of stoichiometric composition 3Al₂O₃·2SiO₂ were studied by X-ray diffraction and electron scanning microscopy with energy dispersive X-ray analysis (SEM + EDX). Data were obtained at temperature ranging from 1400 °C to 1600 °C for a period of time ranging from 30 min to 60 h. The results indicate that ZrSiO₄ and αAl₂O₃ react and form crystalline ZrO₂, crystalline mullite (almost 3Al₂O₃·2SiO₂ composition) and non-crystalline silicon–alumina phase (pre-mullite). At the temperature of 1600 °C the fastest stage of reaction is dissociation of ZrSiO₄. Obtained results show that dissociation of zircon is a first-order reaction. The dissolution of Al₂O₃ particles and diffusion of Al into non-crystalline phase seem to be the slowest step of the reaction.     

Structural-phase state and lasing of 5–15 at% Yb3+:Y3Al5O12 optical ceramics

Yttrium aluminum garnet (Yb³⁺:Y₃Al₅O₁₂) laser ceramics doped by 5, 10 and 15 at% of ytterbium ions were obtained by reactive sintering. Optimal sintering temperature range for the formation of highly-dense transparent Yb³⁺:Y₃Al₅O₁₂ ceramics under normal recrystallization conditions was found to be T = 1750–1800 °C. The influence of Yb³⁺ ions on structural-phase state, phase composition, microstructure, optical and luminescent properties of sintered samples was experimentally investigated. It was shown that lattice parameter a of Yb³⁺:Y₃Al₅O₁₂ ceramics decreases linearly with increasing of Yb³⁺ concentration in a good agreement with L. Vegard’s rule, that indicates to the formation of (Y_1−xYb_x)₃Al₅O₁₂ (х = 0.05–0.15) substitutional solid solutions. No concentration quenching of Yb³⁺ luminescence was observed in Yb³⁺:Y₃Al₅O₁₂ within the 5–15 at% doping range. Quasi-CW lasing of Yb³⁺:Y₃Al₅O₁₂ ceramics was studied under diode-pumping at 970 nm. A highest slope efficiency of about 50% was obtained for 15 at%-doped Yb³⁺:Y₃Al₅O₁₂ ceramics sintered at T = 1800 °C for 10 h.     

Solubility and microstructural development of TiO2-containing 3Al2O3·2SiO2 and 2Al2O3·SiO2 mullites obtained from single-phase gels

The interdependence of the titanium oxide amount and the anisotropic growth of mullites prepared from single-phase gels were investigated. Gels with stoichiometries 3(Al_2−xTi_xO₃)·2(SiO₂) and 2(Al_2−xTi_xO₃)·(SiO₂), with 0 ≤ x ≤ 0.15 were prepared by the semialkoxide method. Gels and specimens heated at temperatures between 1200 and 1600 °C were characterized by using infrared spectroscopy (IR), X-ray diffraction (XRD) and transmission and field emission scanning electron microscopies (TEM and FESEM). Al₂TiO₅ as minor impurity was detected in both series of mullites for gel precursor compositions x = 0.10 and x = 0.15, obtained at temperatures between 1200 and 1600 °C. Variations of lattice parameters of mullite, processed at temperatures from the range between 1400 and 1600 °C, with the starting nominal amount of titanium oxide indicated that the solubility limit of titanium oxide was in ranges 3.8–4.1 and 4.1–4.4 wt% TiO₂ for 3:2 and 2:1 mullites series, respectively. The anisotropic growth of titanium-doped mullite crystalline grains was significant only when the nominal amount of titanium oxide exceeded the limit of solubility into the mullite structure (for both mullite series). Stronger anisotropy occurred for the 3:2 series specimens, i.e. for the SiO₂-richer mullites. In both series of mullites, the anisotropic grain growth was observed for the process temperatures higher than 1400 °C; the crystalline grains of mullites processed at lower temperatures were equiaxials and of almost the same size.     

Effect of boron oxide on the microstructure of mullite-based glass-ceramic glazes for floor-tiles in the CaO–MgO–Al2O3–SiO2 system

The effect of increasing replacement of Al₂O₃ by B₂O₃ in a parent glass on the sintering and further crystallization of mullite was investigated. The composition of the parent glass was chosen in the mullite primary phase field of the CaO–MgO–Al₂O₃–SiO₂ quaternary system. Glass powder pellets were heated under standard (10 °C/min and 2 h of hold time) and fast heatings (25 °C/min and 5 min of hold time) at different temperatures from 700 to 1190 °C. Sintering of B₂O₃-containing glasses took place in the range between 850 and 1050 °C. X-ray diffraction results showed that mullite formed as unique crystalline phase for glasses containing amounts of B₂O₃ larger than 6 wt%. For lower amounts of boron oxide cordierite was formed as secondary crystalline phase. Quantitative determination of mullite by Rietveld analysis indicated that the higher amount of mullite present in the glass-ceramic fast heated at 1160 °C was 19.5 wt% for the glass containing 9 wt% of B₂O₃. The final microstructure of the glass-ceramic glazes showed the presence of well shaped, long acicular mullite crystals dispersed within the residual glassy phase. Results of glass-ceramic glazes when applied as slurry and under industrial heating conditions pointed out promising mechanical properties.     

In-situ synthesis and textural evolution of the novel carbonaceous SiC/mullite aerogel via polymer-derived ceramics route

A novel carbonaceous SiC/mullite composite aerogel is derived from catechol-formaldehyde/silica/alumina hybrid aerogel (CF/SiO₂/AlOOH) via polymer-derived ceramics route (PDCR). The effects of the reactants concentrations on the physicochemical properties of the carbonaceous SiO₂/Al₂O₃ aerogel and SiC/mullite aerogel are investigated. The mechanism of the textural and structural evolution for the novel carbonaceous SiC/mullite is further discussed based on the experimental results. Smaller reactants concentration is favorable to formation of mullite. Reactants concentration of 25% is selected as the optimal condition in considering of the mullite formation and bulk densities of the preceramic aerogels. Spherical large silica particles are also produced during heat treatment, and amorphous silica is remained after this reaction. With further heat treatment at 1400 °C, silicon carbide and mullite coexist in the aerogel matrix. The mullite addition decreases the temperature of SiC formation, when compared with the conventional methods. However, after heat treatment at 1450 °C, the amount of mullite begins to decrease due to the further reaction between carbon and mullite, forming more silicon carbide and alumina. The carbonaceous SiC/mullite can be transferred to SiC/mullite binary aerogel after carbon combustion under air atmosphere. The carbonaceous SiC/mullite has a composition of SiC (31%), mullite (19.1%), SiO₂ (14.4%), and carbon (35%). It also possesses a 6.531 nm average pore diameter, high surface area (69.61 m²/g), and BJH desorption pore volume (0.1744 cm³/g). The oxidation resistance of the carbonaceous SiC/mullite is improved for 85 °C when compared with the carbon based aerogel.     

Selective gas-phase conversion of maleic anhydride to propionic acid on Pt-based catalysts

Pt-based catalysts, supported on Al₂O₃, SiO₂ and SiO₂–Al₂O₃, were prepared by incipient wetness impregnation and tested in the gas phase hydrogenation of maleic anhydride at atmospheric pressure and 240 °C. In these conditions, the hydrogenolytic activity pattern was: Pt/SiO₂ > Pt/Al₂O₃ > Pt/SiO₂–Al₂O₃, which is just the opposite of the support acidity trend. These metal Pt-based catalysts showed high selectivity to propionic acid, which was always higher than 80%. The selectivity pattern to this product was: Pt/Al₂O₃ > Pt/SiO₂ > Pt/SiO₂–Al₂O₃. Both activity and selectivity patterns may be explained on the basis of metal-support interaction and support acidity.     

Diphasic aluminosilicate gels with two stage mullitization in temperature range of 1200–1300 °C

The crystallization of mullite in amorphous diphasic gel aged for 6 months has been studied using non-isothermal differential scanning calorimetry (DSC) and powder X-ray diffraction with Rietveld structure refinement analysis. The diphasic premullite gels undergo structural changes by aging even when they are calcined at 700 °C. These changes imply segregation of the sample to Al₂O₃-rich and SiO₂-rich regions. From the Al₂O₃-rich region crystallizes poorly defined AlSi spinel at 977 °C followed by two-step mullite crystallization in the temperature interval of 1200–1300 °C. Two overlapped exothermic peaks on DSC scan of aged gel were observed; the first at 1233 °C and the second at 1261 °C. The former is attributed to mullite crystallization by transformation of AlSi spinel, by which excess alumina occurs, which in the second step of mullitization reacts with amorphous SiO₂-rich phase. The activation energy for mullite crystallization in the first step was E_a=935±14 kJ mol⁻¹ and the Avrami exponent n=2.5. The values E_a=1119±25 kJ mol⁻¹ and n=1.2 were obtained for mullite formation in the second step. If amorphous SiO₂-rich phase is extracted from the sample, the value E_a=805±26 kJ mol⁻¹ is obtained. Mullite crystallizing from AlSi spinel (when SiO₂-rich phase has been extracted) differentiates compositionally from that formed by both reactions. Smaller unit cell parameters and higher amount of oxygen vacancies are incorporated into tetrahedral positions of mullite structure, as was determined by Rietveld structure refinement method.     

The effect of BaO and Al2O3 addition on the crystallization behaviour of cordierite glass ceramics in the presence of V2O5 nucleant

The effect of V₂O₅ nucleant on crystallization of stoichiometric cordierite glass ceramics in the presence of various amounts of BaO and Al₂O₃ additives were investigated by DTA, XRD and SEM. It was shown that 3 wt.% V₂O₅ and 1.5 wt.% BaO were the optimum amounts of the additives effective in inducing both surface and bulk crystallization in the above glass ceramics.This resulted in ～90 wt.% cordierite after a 3 h heat treatment at 1020 °C. The specimens possessing 4–5 wt.% Al₂O₃ in excess of the stoichiometric cordierite composition, developed mullite along with cordierite in the temperature range of 1045–1055 °C, whereas in the specimen containing 6 wt.% excess Al₂O₃, mullite was detected as the sole crystallization product.     

Effect of physical vapor deposited Al2O3 film on TGO growth in YSZ/CoNiCrAlY coatings

Thermal barrier coatings (TBCs) comprising of yttria stabilized zirconia (YSZ) ceramic top coat and CoNiCrAlY metallic bond coat have been widely used in gas turbines. However, the developed oxides layer in the interface of the top and bond coats during thermal exposure of the TBCs always results in the destruction of the system. In order to restrain the growth of oxides layer and improve the thermal shock resistance of TBCs, a thin Al₂O₃ film was pre-deposited on CoNiCrAlY bond coat by physical vapor deposition (PVD) technology. After thermal exposure, morphologies and phase compositions of the thermal growth oxides (TGO) layer in the conventional and pre-deposited Al₂O₃ film TBCs were examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The residual stresses in the coatings were analyzed using micro-Raman spectroscopy (LabRam-1B). It was found that TGO layer formed in the conventional TBCs was mainly composed of Al₂O₃, (Cr,Al)₂O₃ + (Co,Ni)(Cr,Al)₂O₄ + NiO (CSN), and (Cr,Al)₂O₃ + (Co,Ni)(Cr,Al)₂O₄ (CS), while in the treated TBCs, the formed TGO layer appeared more uniform and compact. The CSN and CS clusters, which are normally considered as a weakness for TBCs, were greatly limited. The residual stresses in the TBCs after thermal shock were also reduced by the deposition of Al₂O₃ film.     

A new and economic approach to fabricate resistant porous membrane supports using kaolin and CaCO3

This new and economic approach to fabricate resistant porous membrane supports consists of Algerian kaolin and calcite (CaCO₃) instead of Al₂O₃. The porous mullite (3Al₂O₃·2SiO₂) and anorthite (CaO·Al₂O₃·2SiO₂) based ceramics were obtained by solid state reaction. Different calcite amounts (10–28 wt%) have been added into kaolin halloysite type (Al₂O₃·2SiO₂·4H₂O) in order to control pores forming with appropriate distribution and sizes. Based on a pore distribution and formed phases, a kaolin + 15 wt% calcite (K15C) mixture was selected for flat and tubular configurations. A porosity of 45–52% was also obtained when K15C compacts were sintered at 1100–1250 °C. For example, porosity, average pore size (APS) and 3 point flexural strength were 49%, 3 μm and 87 MPa (same as Al₂O₃ value), respectively when K15C compacts were sintered at 1250 °C for 1 h. Finally, a correlation between microstructure and mechanical properties of elaborated supports has been discussed.     

High temperature single crystal properties of mullite

Extensive neutron diffraction and Rietveld studies of dense, hot pressed mullite (3Al₂O₃·2SiO₂) have been conducted up to 1650 °C in air, yielding a complete set of lattice parameters and axial thermal expansion coefficients. Unconstrained powders of the same stoichiometric composition were also analyzed by X-ray diffraction and Rietveld techniques up to 900 °C in air, from which lattice parameters and thermal expansion coefficients were obtained. An earlier reported structural discontinuity was confirmed by XRD to lie in the temperature range 425 to 450 °C. Single-crystalline mullite fibers of composition 2·5Al₂O₃·SiO₂ were grown from the melt by a laser-heated, float zone method. A partial set of the single-crystal elastic moduli were determined from various sections of fiber, by Brillouin spectroscopy, from room temperature up to 1400 °C. They indicated a roughly 10% reduction in stiffness over that temperature range.     

Phase equilibria in the CaO·SiO2Na2O·SiO2Na2O·Al2O3·6SiO2 system

Equilibrium phase relations in the system CaO·SiO₂Na₂O·SiO₂Na₂O·Al₂O₃·6SiO₂ at 40–80 wt% Na₂O·Al₂O₃·6SiO₂ composition range have been experimentally studied at temperatures between 800 °C and 1200 °C. The liquidus temperature was determined with differential scanning calorimetry. The equilibrated samples were quenched with pressurized nitrogen, and examined with electron probe X-ray microanalysis and X-ray diffraction for identification of microstructure and phase relations. Five primary phase fields, CaO·SiO₂, Na₂O·SiO₂, Na₂O·2CaO·3SiO₂, 2Na₂O·CaO·3SiO₂ and Na₂O·Al₂O₃·6SiO₂ were established. The ternary eutectic point of CaO·SiO₂, Na₂O·2CaO·3SiO₂ and Na₂O·Al₂O₃·6SiO₂ was determined to be at 1030 °C with the composition of 29.0 wt% CaO·SiO₂, 12.0 wt% Na₂O·SiO₂ and 59.0 wt% Na₂O·Al₂O₃·6SiO₂. Peritectic reaction of Na₂O·2CaO·3SiO₂, 2Na₂O·CaO·3SiO₂ and Na₂O·Al₂O₃·6SiO₂ occurred at 930 °C with the composition of 13.0 wt% CaO·SiO₂, 29.0 wt% Na₂O·SiO₂ and 58.0 wt% Na₂O·Al₂O₃·6SiO₂. The liquidus surface projection of the ternary system has been constructed in the composition region important for the bottom ash application.     

Development of mullite/zirconia composites from a mixture of aluminum dross and zircon

In order to obtain mullite/zirconia composites, mixtures of aluminum dross and zircon were sintered. Aluminum dross was collected and purified by a milling, sieving and washing process. Stoichiometric mixtures of aluminum dross and zircon were sintered at several temperatures (1400, 1450 and 1500 °C) for several periods of time (2, 4 and 6 h). After the purifying treatment the dross contained mainly Al₂O₃, AlN, MgAl₂O₄, SiO₂ and metallic Al. A homogeneous mullite matrix with small zirconia particles was obtained by sintering the aluminum dross–zircon samples at 1500 °C for 6 h.     

Thermal evolution and structural study of 2:1 mullite from monophasic gels

Single phase mullite gels with composition 2Al₂O₃·SiO₂ (2:1) were prepared by the slow hydrolysis method using aluminium nitrate nonahydrate and tetraethylorthosilicate as reagents. The evolution to mullite from gels was studied by infrared (IR) spectroscopy and X-ray diffraction (XRD). Gels thermally treated under fast schedules showed mullite formation below 900 °C. Compositional and microstructural changes in 2:1 mullites through the range of temperature from 900 to 1600 °C were determined by the measurement of lattice parameters and field emission scanning electron microscopy. The alumina-rich mullites formed at low temperatures become almost the nominal 2:1 at 1600 °C. This result is consistent with available thermodynamic data for mullite formation from alumina and silica. Microstructural examination indicated an almost constant grain size for mullite from 900 to 1600 °C.     

Mechanical properties and microstructure of Yb2SiO5 environmental barrier coatings under isothermal heat treatment

Yb₂SiO₅ (ytterbium monosilicate) top coatings and Si bond coat layer were deposited by air plasma spray method as a protection layer on SiC substrates for environmental barrier coatings (EBCs) application. The Yb₂SiO₅-coated specimens were subjected to isothermal heat treatment at 1400 °C on air for 0, 1, 10, and 50 h. The Yb₂SiO₅ phase of the top coat layer reacted with Si from the bonding layer and O₂ from atmosphere formed to the Yb₂Si₂O₇ phase upon heat treatment at 1400 °C. The oxygen penetrated into the cracks to form SiO₂ phase of thermally grown oxide (TGO) in the bond coat and the interface of specimens during heat treatment. Horizontal cracks were also observed, due to a mismatch of the coefficient of thermal expansion (CTE) between the top coat and bond coat. The isothermal heat treatment improves the hardness and elastic modulus of Yb₂SiO₅ coatings; however, these properties in the Si bond coat were a little bit decreased.     

An evaluation of plasma-sprayed coatings based on Al2O3 and Al2O3–13 wt.% TiO2 with bond coat on pure titanium substrate

In this study, the effects of bond coat on the properties of Al₂O₃ and Al₂O₃–13 wt.% TiO₂ coatings, which is plasma sprayed onto a commercial pure titanium substrate with and without Ni–5 wt.% Al (METCO 450 NS) as bond coating layer were investigated in terms of microhardness, bonding strength and surface roughness. Optical and scanning electron microscopy (SEM) examinations revealed that there is a uniform coating layer with no spalling and delamination. However, there is a little amount of porosity. The results indicated that the application of bond coat layer in the plasma spraying of Al₂O₃ and Al₂O₃–13 wt.% TiO₂ on pure titanium substrate has increased the hardness and bonding strength of coatings. While the adhesive bonding is dominant without bond coat, the cohesive bonding is dominant with the application of the bond coating layer. It has been observed that percentage of cohesion strength was about three times higher than that of adhesion strength.     

Porous acicular mullite ceramics fabricated with in situ formed soot oxidation catalyst obtained from waste MoSi2

Porous acicular mullite (3Al₂O₃·2SiO₂) ceramics containing Cu₃Mo₂O₉ as a soot oxidation catalyst was fabricated by a novel approach using commercial powders of Al₂O₃ and CuO, and powder obtained by controlled oxidation of ground waste MoSi₂. The obtained material consisted of elongated mullite grains which are known to be effective in carbon soot removal from diesel engine exhaust. The presence of in situ created Cu₃Mo₂O₉ was found to catalyze the carbon burnout which is an extremely important feature when it comes to filter regeneration, i.e., the captured soot removal. The carbon burnout temperature in the sample containing 12 wt% CuO was by 90 °C lower than that in the sample without CuO. Effect of sintering temperature as well as the effect of amount of CuO additive on mullite properties were studied. It was found that the increase in amount of CuO in samples sintered at 1300 °C decreased porosity and increased compressive strength of the porous mullite ceramics. The addition of 12 wt% CuO increased the strength of the porous mullite ceramics up to 70 MPa, whereas the porosity was reduced from 62% in the mullite without CuO to 44% in the mullite ceramics containing 12 wt% CuO. Although affected by the amount of CuO, the microstructure still consisted of elongated mullite grains.