Kinetic study and model verification of reaction between alumina and charred layer

The abnormal ablation of insulation materials caused by slag deposition in solid rocket motors has gradually attracted considerable attention from researchers. First, an alumina-charred layer system was thermogravimetrically experimented with 1700–1850 °C using ultra-high-temperature thermogravimetric equipment based on the dominant equation of an Al₂O₃–C system obtained from previous studies. The kinetic parameters of the alumina-charred layer reaction system were then determined by the isothermal kinetic mathematical treatment method. Second, an ablation model was established to verify the accuracy of the kinetic parameters. The ablation thickness calculated by the model is nearly similar to that in the experimental results, with an error of 16.01%. Results show that the kinetic parameters of the alumina-charred layer's reaction system obtained in this study are credible and can be used for predicting the insulator's ablation under deposition conditions.     

Permalloy/alumina soft magnetic composite compacts obtained by reaction of Al-permalloy with Fe2O3 nanoparticles upon spark plasma sintering

Composite sintered soft magnetic materials of permalloy/alumina type have been obtained by reactive spark plasma sintering. The composite compacts have been obtained by sintering of Ni71.25Fe23.75Al5 alloy with 3 and 5% (wt.) Fe₂O₃ nanoparticles. The Ni based alloy with large particles (up to hundreds of μm) have been covered by a thin layer of iron ferric oxide nanoparticles (20–40 nm). The as obtained composite particles have been subjected to sintering process using a homemade installation at 900 °C for 10 min. Upon sintering process several reactions between Ni-based alloy and iron oxide are induced, the main phase resulting from reaction is alumina-Al₂O₃ as it results by X-ray diffraction investigations. According to the scanning electron microscopy and energy dispersive X-ray spectroscopy investigations, alumina forms a matrix embedding the Ni-based particles. The alumina matrix is continuous, but the layer has large variation in width, and offers a high electrical resistivity. A mechanism of formation is proposed for the alumina matrix composite compacts when using Al-permalloy powder and iron oxide. The compacts have been tested in DC and AC for magnetic characteristics.     

Study on mechanism of chip formation of grinding plasma-sprayed alumina ceramic coating

The mechanisms of ductile–brittle transition and surface/subsurface crack damage during the grinding of plasma–sprayed alumina ceramic coatings were investigated in an experiment and simulation on single diamond abrasive grain cutting. We observed that the brittle damage modes of alumina ceramic include boundary cracks, median cracks and lateral fractures. The normal force of the abrasive grain results in the initiation of median cracks, whereas the tangential force of the abrasive grain results in the propagation of median cracks in the direction of the abrasive grain cutting. Some cracks propagate downward to form machined surface cracks, whereas others propagate to the unmachined surface of the workpiece to produce brittle removal. Owing to the alternating tensile and compressive stresses, the material in contact with the top of the abrasive grain fractures continuously, forming the main morphology of the machined surface. The geometry and cutting depth of the abrasive grain have a significant influence on the ductile–brittle transition, whereas the cutting speed of the abrasive grain have no significant influence. On one hand, the stress concentration at the pore defects result in crack propagation to the deep layer; on the other hand, it reduces the local strength of the surface material, produces brittle fracturing, and interrupts crack propagation. The pores exposed on the machined surface and the broken morphology around them are important factors for reducing the surface roughness. Experimental observations show that the machined surface morphology of the alumina ceramic coating is composed of brittle fracturing, ductile cutting and plowing, cracks, original pores, and unmelted particles.     

Enhanced mechanical properties of 3D printed alumina ceramics by using sintering aids

Stereolithography based 3D printing provides an efficient pathway to fabricate alumina ceramics, and the exploration on the mechanical properties of 3D printed alumina ceramics is crucial to the development of 3D printing ceramic technology. However, alumina ceramics are difficult to sinter due to their high melting point. In this work, alumina ceramics were prepared via stereolithography based 3D printing technology, and the improvement in the mechanical properties was investigated based on the content, the type and the particle size of sintering aids (TiO₂, CaCO₃, and MgO). The flexural strength of the sintered ceramics increased greatly (from 139.2 MPa to 216.7 MPa) with the increase in TiO₂ content (from 0.5 wt% to 1.5 wt%), while significant anisotropy in mechanical properties (216.7 MPa in X-Z plane and 121.0 MPa in X–Y plane) was observed for the ceramics with the addition of 1.5 wt TiO₂. The shrinkage and flexural strength of the ceramics decreased with the increase in CaCO₃ content due to the formation of elongated grains, which led to the formation of large-sized residual pores in the ceramics. The addition of MgO help decrease the anisotropic differences in shrinkage and flexural strength of the sintered ceramics due to the formation of regularly shaped grains. This work provides guidance on the adjustment in flexural strength, shrinkage, and anisotropic behavior of 3D printed alumina ceramics, and provides new methods for the fabrication of 3D printed alumina ceramics with superior mechanical properties.     

Crack Appearance during Drying of an Alumina Gel: Thermo-Hydro-Mechanical Properties

Most heterogeneous catalyst supports used in refineries are composed of porous alumina ceramics. Drying has been identified as a critical process for final product mechanical strength. In the literature, numerous papers deal with drying-induced stresses, which can lead to crack initiation. However, there are few papers devoted to experimental study of drying conditions that promote cracking. The objective of this work is to enhance knowledge of cracking behavior, specifically by studying alumina gel drying. First, the relation between drying conditions and first crack initiation is studied experimentally. Then a complete thermo-hydro-mechanical characterization of the alumina gel is made, including moisture content as a parameter.     

An Unreacted Shrinking Core Model for Calcination and Similar Solid-to-Gas Reactions

A variation on the unreacted shrinking core model has been developed for calcination and similar non-catalytic solid-to-gas decomposition reactions in which no gaseous reactant is involved and the reaction rate decreases with increasing product gas concentration. The numerical solution of the model has been validated against an analytical solution for the isothermal case. The model parameters have been tuned using literature data for the thermal dehydration (calcination) of gibbsite to alumina over a wide range of temperatures, from 490 to 923 K. The model results for gibbsite conversion agreed well with the published experimental data. A reaction order with respect to water vapor concentration of n = ?1 was found to give a good fit to the data and yield activation energies consistent with literature values. Predictions of the non-isothermal unreacted shrinking core model compare well with a more complex distributed model developed previously by the authors.     

Characterization of thermochemical properties of Al nanoparticle and NiO nanowire composites

Thermochemical properties and microstructures of the composite of Al nanoparticles and NiO nanowires were characterized. The nanowires were synthesized using a hydrothermal method and were mixed with these nanoparticles by sonication. Electron microscopic images of these composites showed dispersed NiO nanowires decorated with Al nanoparticles. Thermal analysis suggests the influence of NiO mass ratio was insignificant with regard to the onset temperature of the observed thermite reaction, although energy release values changed dramatically with varying NiO ratios. Reaction products from the fuel-rich composites were found to include elemental Al and Ni, Al₂O₃, and AlNi. The production of the AlNi phase, confirmed by an ab initio molecular dynamics simulation, was associated with the formation of some metallic liquid spheres from the thermite reaction.     

Liquid phase formation in the system AlN–Al2O3–Y2O3. Part I: Experimental investigations

The liquid phase formation in the system AlN–Al₂O₃–Y₂O₃ was investigated via differential thermal analysis (DTA) combined with thermogravimetry (TG). For this purpose 17 samples covering a broad composition area of the quasi-ternary system were densified and heat-treated to achieve the equilibrium state. Melting temperatures were determined by DTA. SEM, EDX and XRD were used to study the phase assemblages and microstructures formed. The results were compared with thermodynamic calculations.     

Preparation and characterisation of self-flowing refractory material containing 971U type microsilica

Abstract

A newer composition of self-flowing low cement brown fused alumina castable containing 971U type microsilica was developed. Optimum flow characteristics were achieved using water addition of 4·6?wt-%. This batch was sintered at different firing temperatures up to 1500°C. To understand the effect of both firing temperatures and corresponding phases, the present castable was characterised in terms of X-ray diffraction, scanning electron microscopy, bulk density (BD), apparent porosity (AP), water absorption (WA), cold crushing strength (CCS) and self-leveling flowability. The results revealed that gradual increase in firing temperature from 1100 through 1500°C caused low AP and WA, and high CCS properties due to the densification of the castable.