Composite Ni/Al2O3 coatings and their corrosion resistance

Composite coatings Ni/Al₂O₃ were electrochemically deposited from a Watts bath. Al₂O₃ powder with particle diameter below 1 μm was codeposited with the metal. The obtained Ni/Al₂O₃ coatings contained 5-6% by weight of corundum. The structure of the coatings was examined by scanning electron microscopy (SEM). It has been found that the codeposition of Al₂O₃ particles with nickel disturbs the nickel coating's regular surface structure, increasing its microcrystallinity and surface roughness. DC and AC electrochemical tests were carried out on such coatings in a 0.5 M solution of Na₂SO₄ in order to evaluate their corrosion resistance. The potentiodynamic tests showed that the corrosion resistance of composite coating Ni/Al₂O₃ is better than that of the standard nickel coating. After 14 days of exposure the nickel coating corrodes three times faster than the Ni/Al₂O₃ coating. The electrochemical behaviour of the coatings in the corrosive solution was investigated by electrochemical impedance spectroscopy (EIS). An equivalent circuit diagram consisting of two RC electric circuits: one for electrode, nickel corrosion processes and the other for processes causing coating surface blockage, were adopted for the analysis of the impedance spectra. The changes in the charge transfer resistance determined from the impedance measurements are comparable with the changes in corrosion resistance determined from potentiodynamic measurements.     

Corrosion mechanisms of Al2O3/MgAl2O4 by V2O5, NiO, Fe2O3 and vanadium slag

The effects of V₂O₅, NiO, Fe₂O₃ and vanadium slag on the corrosion of Al₂O₃ and MgAl₂O₄ have been investigated. The specimens of Al₂O₃ and MgAl₂O₄ with the respective oxides above mentioned were heated at 10 °C/min from room temperature up to three different temperatures: 1400, 1450 and 1500 °C. The corrosion mechanisms of each system were followed by XRD and SEM analyses. The results obtained showed that Al₂O₃ was less affected by the studied oxides than MgAl₂O₄. Alumina was only attacked by NiO forming NiAl₂O₄ spinel, while the MgAl₂O₄ spinel was attacked by V₂O₅ forming MgV₂O₆. It was also observed that Fe₂O₃ and Mg, Ni, V and Fe present in the vanadium slag diffused into Al₂O₃. On the other hand, the Fe₂O₃ and Ca, S, Si, Na, Mg, V and Fe diffused into the MgAl₂O₄ structure. Finally, the results obtained were compared with those predicted by the FactSage software.     

Dynamic corrosion of Al2O3-ZrO2-SiO2 and Cr2O3-containing refractories by molten frits. Part I: Macroscopic analysis

Manufacturing of enamels and frits has undergone dramatic changes since the 1980s. This has required significant efforts in research and development. Typical compositions of frits for ceramic tiles are silica-based with fluxing agents; some of the components are highly corrosive. Improvements in the production of frits would imply the selection of the most adequate refractories as a function of the chemical composition of the considered frit and the fabrication procedure.The refractories currently used in frit furnaces are Al₂O₃-ZrO₂-SiO₂ (AZS) fused cast materials and Cr₂O₃-based materials. In this work, results on dynamic corrosion studies of AZS and Cr₂O₃-based materials by two ZnO-containing frits are described. Experiments have been performed using the “Merry Go Round” test at ≅1500 °C. Macroscopic results are analysed in terms of the remaining volume after the tests, as usually done in the glass industry. The significance and limits of such an approach are discussed.     

Dynamic corrosion of Al2O3-ZrO2-SiO2 and Cr2O3-containing refractories by molten frits. Part II: Microstructural study

In this work results on dynamic corrosion studies of fused cast Al₂O₃-SiO₂-ZrO₂ and isostatically pressed and sintered Cr₂O₃-based refractories by two crystalline (transparent) frits are described. Experiments have been performed using the “Merry Go Round” test at ≅1500 °C.Microstructural and mineralogical analyses of selected areas from the corroded regions of the studied refractories were performed by reflected light optical microscopy and scanning electron microscopy with analysis by X-ray dispersive energy.Significant differences between the corrosion mechanisms acting in the two types of materials were found. In the fused cast Al₂O₃-SiO₂-ZrO₂ specimens corrosion took place by the dissolution of alumina and zirconia in the frit and in the glass formed by the reaction between the frit and the refractory. In the Cr₂O₃-based materials the corrosion process was controlled by the capillar penetration of the molten frit through the open pores. The reaction between the ZnO from the frits and Cr₂O₃ led to the formation of spinel (ZnCr₂O₄), a high-melting point bonding phase that retarded the frit penetration. Results are discussed using the relevant phase equilibrium diagrams.     

Laser machining of Al2O3-ZrO2 (3%Y2O3) eutectic composite

In this work we present the study of the interaction between NIR pulsed laser and Al₂O₃-ZrO₂ (3%Y₂O₃) eutectic composite. The effect produced by modifying the reference position as well as the working conditions and laser beam features has been studied when the samples are processed by means of pulse bursts.The samples were obtained by the laser floating zone technique using a CO₂ laser system. The laser machining was carried out with a Q-switched Nd:YAG laser at its fundamental wavelength of 1064 nm with pulse-widths in the nanosecond range.Geometric dimensions, i.e. ablated depth, machined width and removed volume as well as ablation yield of the resulting holes have been studied. We have described and discussed the morphology, composition and microstructure of the processed samples.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Accommodation of impurities in α-Al2O3, α-Cr2O3 and α-Fe2O3

Atomic scale computer simulation was used to predict the mechanisms and energies associated with the accommodation of aliovalent and isovalent dopants in three host oxides with the corundum structure. Here we consider a much more extensive range of dopant ions than has previously been the case. This enables a rigorous comparison of calculated mechanism energetics. From this we predict that divalent ions are charge compensated by oxygen vacancies and tetravalent ions by cation vacancies over the full range of dopant radii. When defect associations are included in the model these conclusions remain valid. At equilibrium, defects resulting from extrinsic dopant solution dominate intrinsic processes, except for the largest dopant cations. Solution reaction energies increase markedly with increasing dopant radius. The behaviour of cluster binding energies is more complex.     

A novel solid superbase of Eu2O3/Al2O3 and its catalytic performance for the transesterification of soybean oil to biodiesel

A novel solid superbase catalyst of Eu₂O₃/Al₂O₃ was prepared and its basic strength reached 26.5 measured by indicators according to Hammett scale. The catalytic activity of Eu₂O₃/Al₂O₃ was evaluated for the transesterification of soybean oil with methanol to biodiesel in the fixed bed reactor and under atmospheric pressure. The results show that Eu₂O₃/Al₂O₃ is an excellent catalyst for the transesterification of soybean oil, and the conversion of soybean oil can reach 63.2% at 70 °C for 8 h.     

Improvement of coke resistance of Ni/Al2O3 catalyst in CH4/CO2 reforming by ZrO2 addition

This work investigates the improvement of Ni/Al₂O₃ catalyst stability by ZrO₂ addition for H₂ gas production from CH₄/CO₂ reforming reactions. The initial effect of Ni addition was followed by the effect of increasing operating temperature to 500–700 °C as well as the effect of ZrO₂ loading and the promoted catalyst preparation methods by using a feed gas mixture at a CH₄:CO₂ ratio of 1:1.25. The experimental results showed that a high reaction temperature of 700 °C was favored by an endothermic dry reforming reaction. In this reaction the deactivation of Ni/Al₂O₃ was mainly due to coke deposition. This deactivation was evidently inhibited by ZrO₂, as it enhances dissociation of CO₂ forming oxygen intermediates near the contact between ZrO₂ and nickel where the deposited coke is gasified afterwards. The texture of the catalyst or BET surface area was affected by the catalyst preparation method. The change of the catalyst texture resulted from the formation of ZrO₂–Al₂O₃ composite and the plugging of Al₂O₃ pore by ZrO₂. The 15% Ni/10% ZrO₂/Al₂O₃ co-impregnated catalyst showed a higher BET surface area and catalytic activity than the sequentially impregnated catalyst whereas coke inhibition capability of the promoted catalysts prepared by either method was comparable. Further study on long-term catalyst stability should be made.     

Surface modification of Cr2O3 nanoparticles with 3-amino propyl trimethoxy silane (APTMS). Part 1: Studying the mechanical properties of polyurethane/Cr2O3 nanocomposites

The surface of Cr₂O₃ nanoparticles was modified with various amounts of 3-amino propyl trimethoxy silane (APTMS). Thermal gravimetric analysis (TGA), turbidimeter and Fourier transform infrared (FTIR) spectroscopy were utilized in order to investigate APTMS grafting on the nanoparticles. Then, polyurethane nanocomposites were prepared using various loadings of silane modified Cr₂O₃ nanoparticles. The nanoparticles dispersion in the coating matrix was studied by a field emission scanning electron microscopy (FESEM). Dynamic mechanical thermal analysis (DMTA) and tensile test were utilized in order to investigate the mechanical properties of the nanocomposites. Results obtained from FTIR, TGA and turbidimeter measurements revealed that the organic functional groups of the silane were successfully grafted on the surface of the nanoparticles. The mechanical properties of the polyurethane were significantly enhanced using 2 wt% Cr₂O₃ nanoparticles modified with 0.43 g silane/5 g pigment compared with other samples.     

Electrolytic deposition of Ni-Co-Al2O3 composite coating on pipe steel for corrosion/erosion resistance in oil sand slurry

To improve the resistance of the hydrotransport pipe steel to corrosion and erosion in oil sand slurry, a Ni-Co-Al₂O₃ composite coating was fabricated by electrolytic deposition on X-65 pipe steel substrate. Potentiodynamic polarization curve and electrochemical impedance measurements show that the deposited coating significantly improves the corrosion resistance of the steel in water-oil-sand solution that simulates the chemistry of oil sand slurry. The corrosion resistance of the coating increases with the increasing Al₂O₃ particle concentration in electrolyte, cathodic current density, electrode rotating speed and temperature. However, a maximum value of corrosion resistance as a function of the depositing parameters is observed, indicating that the optimal electrodepositing parameters and operating conditions are essential to the maximization of the corrosion resistance of the coated steel in oil sand slurry. The optimal depositing conditions are suggested in the given system. The morphology, structure and composition of the coatings were characterized by scanning electron microscopy and energy-dispersive X-ray analysis. The Ni-Co-Al₂O₃ composite coating develops a compact, uniform, nodular structure with an average thickness of 50-200 microns. The Al₂O₃ amount in the coating increases with the increasing Al₂O₃ concentration in electrolyte, which also enhances the co-deposition of Ni and Co. The micro-hardness and wear resistance of the composite coatings are much higher than the steel substrate and increase with the increasing Al₂O₃ particle amount in the coating.     

Selective synthesis of mixed alcohols from syngas over catalyst Fe2O3/Al2O3 in slurry reactor

The Fe₂O₃/Al₂O₃ catalyst was studied to selectively synthesize mixed alcohols from syngas in a continuously stirred slurry reactor with the oxygenated solvent Polyethylene Glycol-400 (PEG-400). The selectivity of mixed alcohols in the products reached as high as 95 wt.% and the C₂₊ alcohols (mainly ethanol) was more than 40 wt.% in the total alcohol products at the reaction conditions of 250 °C, 3.0 MPa, H₂/CO = 2 and space velocity = 360 ml/g_cat h. The hydrogen temperature programmed reduction (H₂-TPR) and X-ray photoelectron spectroscopy (XPS) measurements of the catalyst confirmed that the FeO phase was responsible for the high selectivity to mixed alcohols in the process. And the oxygenated solvent PEG-400 was also necessary for the selective synthesis of mixed alcohols in the reaction system.     

Long-term degradation of Ta2O5-doped Bi2O3 systems

Bismuth oxide in δ-phase is a well-known high oxygen ion conductor and can be used as an electrolyte for intermediate temperature solid oxide fuel cells (IT-SOFCs). 5-10 mol% Ta₂O₅ are doped into Bi₂O₃ to stabilize δ-phase by solid state reaction process. One Bi₂O₃ sample (7.5TSB) was stabilized by 7.5 mol% Ta₂O₅ and exhibited single phase δ-Bi₂O₃-like (type I) phase. Thermo-mechanical analyzer (TMA), X-ray diffractometry (XRD), AC impedance and high-resolution transmission electron microscopy (HRTEM) were used to characterize the properties. The results showed that holding at 800-850 °C for 1 h was the appropriate sintering conditions to get dense samples. Obvious conductivity degradation phenomenon was obtained by 1000 h long-term treatment at 650 °C due to the formation of α-Bi₂O₃ phase and Bi₃TaO₇, and 〈1 1 1〉 vacancy ordering in Bi₃TaO₇ structure.     

Electrochemical anticorrosion performance evaluation of Al2O3 coatings deposited by MOCVD on an industrial brass substrate

Alumina (Al₂O₃) coatings of different thickness were deposited on OT59 brass substrate (BS) using the metal organic chemical vapour deposition (MOCVD) technique to evaluate the corrosion performance by EIS measurements. The used precursor was dimethyl-aluminium-isopropoxide. Electrochemical characterizations of the deposited films were performed in a standard very aggressive acidic solution (aerated 1N H₂SO₄ at 25 °C up to 168 h of immersion time) by means of direct current method (Tafel curves) and electrochemical impedance spectroscopy (EIS). The Rutherford backscattering spectroscopy (RBS) indicated that the films are very pure with the correct Al₂O₃ stoichiometry, while the IR absorption spectra showed that the films did not contain any OH groups. The surface film morphology was investigated by atomic force microscopy (AFM) and displayed a globular texture. The films were very smooth, with a maximum root mean square roughness, for example, of 14 nm for a 0.96 μm thick coating. The EIS data confirmed, as expected, that a 2.40 μm Al₂O₃ layer ensures the best corrosion protection after 168 h of immersion in the very acidic environment used.     

The catalytic performance in oxidative coupling of methane and the surface basicity of La2O3, Nd2O3, ZrO2 and Nb2O5

The catalytic performance in oxidative coupling of methane (OCM) of unmodified pure La₂O₃, Nd₂O₃, ZrO₂ and Nb₂O₅ has been investigated under various conditions. The results confirmed that the activity of La₂O₃ and Nd₂O₃ was always much higher than that of the remaining two. The surface basicity/base strength distribution of pure La₂O₃, Nd₂O₃, ZrO₂ and Nb₂O₅ was measured using a test reaction of transformation of 2-butanol and a temperature-programmed desorption of CO₂. Both methods showed that La₂O₃ and Nd₂O₃ had high basicity and contained medium and strong basic sites (lanthanum oxide more and neodymium oxide somewhat less). ZrO₂ had only negligible amount of weak basic sites and Nb₂O₅ was rather acidic. The confrontation of the basicity and catalytic performance indicated that in the case of investigated oxides, the basicity (especially strong basic sites) could be a decisive factor in determination of the catalytic activity in OCM. Only in the case of ZrO₂ it was observed a moderate catalytic performance in spite of negligible basicity. The influence of a gas atmosphere used in the calcination of oxides (flowing oxygen, helium and nitrogen) on their basicity and catalytic activity in OCM had been also investigated. Contrary to earlier observations with MgO, no effect of calcination atmosphere on the catalytic performance of investigated oxides in OCM and on their basicity was observed.     

Effect of Y2O3 and Er2O3 co-dopants on phase stabilization of bismuth oxide

Bi₂O₃ compositions were prepared to investigate the effect of rare earth metal oxides as co-dopants on phase stability of bismuth oxide. Compositions containing 9-14 mol% of Y₂O₃ and Er₂O₃ were synthesized by solid state reaction. The structural characterization was carried out using X-ray powder diffraction. The XRD results show that the samples containing 12 and 14 mol% total dopants had cubic structure, whereas the samples with lower dopant concentrations were tetragonal. Comparing the lattice parameters of the cubic phases of (Bi₂O₃)_0.88(Y₂O₃)_0.06(Er₂O₃)_0.06 and (Bi₂O₃)_0.86(Y₂O₃)_0.07(Er₂O₃)_0.07 revealed that lattice parameter decreases by increasing the dopant concentration. The XRD pattern and the powder density results indicated the formation of solid solution in the studied systems. After annealing samples with cubic phase at 600 °C for various periods of time, phase transformation to tetragonal and rhombohedral occurs.     

UV laser microprocessing and post chemical etching on ultrathin Al2O3 ceramic substrate

In this study, an Nd:YVO₄ UV laser was used for microprocessing ultrathin (125 μm) ceramic plates for use as a multi-layer microchip substrate. The effects of the UV laser microprocessing parameters, including laser power density, frequency, laser scanning speed, and pass delay on microprocessing accuracy and quality (kerf width and arithmetic average roughness R_a on the kerf sidewall) were investigated by means of a 4 × 4 orthogonal design. The key processing parameters were determined and optimized for small kerf width and minimal R_a of the kerf sidewall while retaining high production efficiency. Subsequent chemical etching of the laser processed areas was performed to reduce the kerf surface and kerf sidewall roughness by removing debris and the thin recast layer for the required size precision and post gilding treatment. The results showed that a clean surface and crack-free kerf sidewall with roughness R_a of 0.16 μm could be achieved by laser microprocessing and chemical etching.     

Tribological properties of Al2O3 nanoparticles as lubricating oil additives

Nano-scale Al₂O₃ spherical particles, prepared via a hydrothermal method and modified by silane coupling agent, can be well-dispersed in lubricating oil. The tribology properties of Al₂O₃ nanoparticles as lubricating oil additives have been studied by four-ball and thrust-ring friction test, which illustrate that the modified Al₂O₃ nanoparticles can effectively improve the lubricating behaviors compared to the base oil. When the added concentration is 0.1 wt%, the friction coefficient and the wear scar diameter are both smallest. The lubrication mechanism is that a self-laminating protective film is formed on the friction surface and the wear behavior changes from sliding friction to rolling friction.     

Steady State Isotopic Transient Kinetic Analysis of Flameless Methane Combustion over Pd/Al2O3 and Pt/Al2O3 Catalysts

The SSITKA measurements were performed in the steady state of complete methane oxidation on the Pd/Al₂O₃ and Pt/Al₂O₃ catalysts. It was found that the number of intermediates and their average life-time on the catalyst surface changes with the increase of reaction temperature. On the Pd/Al₂O₃ catalyst there is larger number of active centres than on Pt/Al₂O₃ catalyst which permits the course of methane oxidation at lower temperatures.     

Mechanical properties of Al2O3-Cr2O3/Cr3C2 nanocomposite fabricated by spark plasma sintering

The fine grains of Al₂O₃-Cr₂O₃/Cr-carbide nanocomposites were prepared by employing recently developed spark plasma sintering (SPS) technique. The initial materials were fabricated by a metal organic chemical vapor deposition (MOCVD) process, in which Cr(CO)₆ was used as a precursor and Al₂O₃ powders as matrix in a spouted chamber. The basic mechanical properties like hardness, fracture strength and toughness, and the nanoindentation characterization of nanocomposites such as Elastics modulus (E), elastic work (W_e) and plastic work (W_p) were analyzed. The microstructure of dislocation, transgranular and step-wise fracture surface were observed in the nanocomposites. The nanocomposites show fracture toughness of (4.8 MPa m^1/2) and facture strength (780 MPa), which is higher than monolithic alumina. The strengthening mechanism from the secondary phase and solid solution are also discussed in the present work. Nanoindentation characterization further illustrates the strengthening of nanocomposites.