Ceramics composites from iron ore tailings and blast furnace slag

The search for materials and methods capable of reducing human impacts on the environment is of utmost importance nowadays. This study's primary purpose was to analyze the technical feasibility of ceramic composites production utilizing Fundão Dam's Iron Ore Tailings (IOT), Blast Furnace Slag (BFS) from charcoal, and Foundry Sand (FS) as partial substitutes for the traditional raw materials – sand and clay – for application in building industry materials. The composites were molded in rectangular specimens and fired at temperatures of 900, 950, 1000, 1050, and 1200 °C. The developed materials were analyzed and characterized by X-Ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), Thermogravimetry (TGA), and Differential Thermal Analysis (DTA). The obtained materials had flexural strength modulus of up to 12.19 MPa, water absorption ranging from 2 to 22%, linear shrinkage ranging from 0.02 to 6.50%, and apparent density ranging from 2.03 to 1.63 g/cm³. The study of the internal structure formation process revealed the formation of amorphous structures in the composites. The results demonstrated that these waste materials may be jointly used in construction materials, contributing to the reduction of natural resource extraction, besides enabling their correct disposal, minimizing environmental impacts, and improving the life quality of the surrounding communities.     

Two-step method to deposit ZrO2 coating on carbon fiber: Preparation,characterization, and performance in SiC composites

Recently, ceramic matrix composites reinforced by short carbon fibers (CFs) attracted increasing attentions. To further improve mechanical properties and oxidation resistances, CFs were subjected to oxidation and acidification followed by sol-gel dip-coating to deposit ZrO₂ on their surfaces. ZrO₂-C_f/SiC composites were fabricated by joint hot compression molding and sintering, compared to C_f/SiC and SiC prepared by the same method. Microstructural analyses indicated that ZrO₂ coatings were successfully deposited on CF surfaces, formed strong bonding and interfaces between CF and the matrix. Meanwhile, CFs were found uniformly distributed in SiC matrix with random orientations. Flexural curves of ZrO₂-C_f/SiC and C_f/SiC revealed the presence of “false plasticity” regions after sharp drops, which were quite different from brittle flexural behavior of SiC ceramic. Compression strength of the three samples showed step-up growth. ZrO₂-C_f/SiC exhibited the highest value, indicating the introduction of CFs and ZrO₂ coatings do have great influence on mechanical performances. After heat treatment, ZrO₂-C_f/SiC exhibited better oxidation resistance than C_f/SiC, with weight loss ratios estimated to ??3.76% and ??6.43%, respectively. These improved properties indicated that ZrO₂-C_f/SiC would be excellent alternatives to other existence materials under ultra-high temperature environments.     

Tough salami-inspired Cf/ZrB2 UHTCMCs produced by electrophoretic deposition

One of the biggest challenges of the materials science is the mutual exclusion of strength and toughness. This issue was minimized by mimicking the natural structural materials. To date, few efforts were done regarding materials that should be used in harsh environments. In this work we present novel continuous carbon fiber reinforced ultra-high-temperature ceramic matrix composites (UHTCMCs) for aerospace featuring optimized fiber/matrix interfaces and fibers distribution. The microstructures – produced by electrophoretic deposition of ZrB₂ on unidirectional carbon fibers followed by ZrB₂ infiltration and hot pressing – show a maximum flexural strength and fracture toughness of 330 MPa and 14 MPa m^1/2, respectively. Fracture surfaces are investigated to understand the mechanisms that affect strength and toughness. The EPD technique allows the achievement of a peculiar salami-inspired architecture alternating strong and weak interfaces.     

New anti-ablation candidate for carbon/carbon composites: Preparation,composition and ablation behavior of Y2Hf2O7 coating under an oxyacetylene torch

Y₂Hf₂O₇ possesses low thermal conductivity and high melting point, which make it promising for a new anti-ablation material. For evaluating the thermal stability and the potential applications of Y₂Hf₂O₇ on anti-ablation protection of C/C composites, Y₂Hf₂O₇ ceramic powder was synthesized by solution combustion method and Y₂Hf₂O₇ coating was prepared on the surface of SiC coated C/C composites using SAPS. Results shown that the coating exhibits good ablation resistance under the heat flux of 2.4?MW/m² with the linear and mass ablation rates are 0.16?μm?s^?1 and ?0.028?mg?s^?1, respectively, after ablation for 40?s. With the prolonging of the ablation time, the increasing thermal stress causes the increase of cracks. Moreover, the chemical erosion from SiO₂ and the physical volatilization of low temperature molten products aggravate failure of the Y₂Hf₂O₇ coating.     

Optimized dual-function varistor-capacitor ceramics of core-shell structured xBi2/3Cu3Ti4O12/(1-x)CaCu3Ti4O12 composites

xBi_2/3Cu₃Ti₄O₁₂/(1-x)CaCu₃Ti₄O₁₂ composites were prepared by traditional solid-state reaction method. Extremely high nonlinear coefficient of 25 and breakdown field of 18.92 kV·cm⁻¹ were obtained in small current range of 0.1−1 mA·cm^-2. In addition, reduced dielectric loss of 0.055 was achieved with high dielectric constant of 1369. Optimized nonlinear and dielectric properties were integrated to make the composites a promising dual-function varistor-capacitor candidate. Microstructure analysis discovered two areas with various Bi/Ca ratio, designated as Bi-H and Bi-L respectively. It was found that the maximum ratio of Bi-H/Bi-L heterogeneous interface corresponded to optimized nonlinear and dielectric performance, which was associated with elevated potential barrier height and huge grain boundary resistance. Combined with relaxation analysis, a core-shell structure was proposed to elaborate microstructure evolution in xBi_2/3Cu₃Ti₄O₁₂/(1-x)CaCu₃Ti₄O₁₂ composite. According to the core-shell model, variation of heterogeneous interface was illustrated on how to influence nonlinear properties, which was well fitted to experimental results.     

Flexural behaviour of RC slabs strengthened with prestressed CFRP strips using different anchorage systems

The Externally Bonded Reinforcement (EBR) technique using Carbon Fiber-Reinforced Polymers (CFRP) has been commonly used to strengthen concrete structures in flexure. The use of prestressed CFRP material offers several advantages well-reported in the literature. Regardless of such as benefits, several studies on different topics are missing. The present work intends to contribute to the knowledge of two commercially available systems that differ on the type of anchorage: (i) the Mechanical Anchorage (MA), and (ii) the Gradient Anchorage (GA). For that purpose, an experimental program was carried out with twelve slabs monotonically tested under displacement control up to failure by using a four-point bending test configuration. The effect of type of anchorage system (MA and GA), prestrain level (0 and 0.4%), width (50 mm and 80 mm) and thickness (1.2 mm and 1.4 mm) of the CFRP laminate, and the surface preparation (grinded and sandblasted) on the flexural response were the main studied parameters. Better performance was observed for the slabs: (i) with prestressed laminates, (ii) for the MA system, and (iii) with sandblasted surface preparation.     

Preparation,characterization and properties of polycaprolactone diol-functionalized multi-walled carbon nanotube/thermoplastic polyurethane composite

Multi-walled carbon nanotubes (MWCNTs) were chemically functionalized to prepare thermoplastic polyurethane (PU) composites with enhanced properties. In order to achieve a high compatibility of functionalized MWCNTs with the PU matrix, polycaprolactone diol (PCL), as one of PU’s monomers, was selectively grafted on the surface of MWCNTs (MWCNT–PCL), while carboxylic acid groups functionalized MWCNTs (MWCNT–COOH) and raw MWCNTs served as control. Both MWCNT–COOH and MWCNT–PCL improved the dispersion of MWCNTs in the PU matrix and interfacial bonding between them at 1 wt% loading fraction. The MWCNT–PCL/PU composite showed the greatest extent of improvement, where the tensile strength and modulus were 51.2% and 33.5% higher than those of pure PU respectively, without sacrificing the elongation at break. The considerable improvement in both mechanical properties and thermal stability of MWCNT–PCL/PU composite should result from the homogeneous dispersion of MWCNT–PCL in the PU matrix and strong interfacial bonding between them.     

Homogenization with uncertainty in Poisson ratio for polymers with rubber particles

The main aim of this work is dual computer analysis of probabilistic coefficients for the homogenized tensor of the polymer filled with the rubber particles having randomized Poisson ratios of both constituents. The major issue is to verify an influence of a randomness in rubber Poisson ratio close to the compressibility limit on the uncertainty of the effective tensor probabilistic characteristics. Probabilistic analysis presented here is carried out using mainly the stochastic perturbation technique provided by the common application of the traditional FEM commercial code ABAQUS and the symbolic computations package MAPLE. This FEM-based technique employs polynomial response function of the optimum order recovered from the weighted least squares method and following a set of deterministic solutions obtained for various values of the randomized input parameter. Optimization procedure is released entirely into a symbolic environment, where maximization of the correlation factor together with minimization of the fitting variance and approximation error are applied. Homogenization technique consists in equating of deformation energies for the real composite and the artificial one characterized by the effective elasticity tensor with uncertainty.     

Influence of SiC content on the oxidation of carbon fibre reinforced ZrB2/SiC composites at 1500 and 1650 °C in air

The microstructure and the oxidation resistance in air of continuous carbon fibre reinforced ZrB₂–SiC ceramic composites were investigated. SiC content was varied between 5–20?vol.%, while maintaining fibre content at ～40?vol.%. Short term oxidation tests in air were carried out at 1500 and 1650?°C in a bottom-up loading furnace. The thickness, composition and microstructure of the resulting oxide scale were analysed by SEM-EDS and X-Ray diffraction. The results show that contents above 15?vol.% SiC ensure the formation of a homogeneous protective borosilicate glass that covers the entire sample and minimizes fibre burnout. The scale thickness is ～90?μm for the sample containing 5?vol.% SiC and decreases with increasing SiC content.     

Covariance matrix adaptation evolution strategy based design of fixed structure robust H∞ loop shaping controller

This paper proposes the application of Covariance Matrix Adaptation Evolution Strategy (CMA-ES) in fixed structure H_∞ loop shaping controller design. Integral Time Absolute Error (ITAE) performance requirement is incorporated as a constraint with an objective of maximization of stability margin in the fixed structure H_∞ loop shaping controller design problem. Pneumatic servo system, separating tower process and F18 fighter aircraft system are considered as test systems. The CMA-ES designed fixed structure H_∞ loop-shaping controller is compared with the traditional H_∞ loop shaping controller, non-smooth optimization and Heuristic Kalman Algorithm (HKA) based fixed structure H_∞ loop shaping controllers in terms of stability margin. 20% perturbation in the nominal plant is used to validate the robustness of the CMA-ES designed H_∞ loop shaping controller. The effect of Finite Word Length (FWL) is considered to show the implementation difficulties of controller in digital processors. Simulation results demonstrated that CMA-ES based fixed structure H_∞ loop shaping controller is suitable for real time implementation with good robust stability and performance.