Transient liquid phase sintering of high-purity mullite for high-temperature structural ceramics

High-purity mullite ceramics, promising engineering ceramics for high-temperature applications, were fabricated using transient liquid phase sintering to improve their high-temperature mechanical properties. Small amounts of ultrafine alumina or silica powders were uniformly mixed with the mullite precursor depending on the silica-alumina ratio of the resulting ceramics to allow for the formation of a transient liquid phase during sintering, thus, enhancing densification at the early stage of sintering and mullite formation by the reaction between additional alumina and the residual glassy phase (mullitization) at the final stage of sintering. The addition of alumina powder to the silica-rich mullite precursor resulted in a reaction between the glassy silica and alumina phases during sintering, thereby forming a mullite phase without inhibiting densification. The addition of fine silica powder to the mullite single-phase precursor led to densification with an abnormal grain growth of mullite, whereas some of the added silica remained as a glassy phase after sintering. The resulting mullite ceramics prepared using different powder compositions showed different sintering behaviors, depending on the amount of alumina added. Upon selecting an optimum process and the amount of alumina to be added, the pure mullite ceramics obtained via transient liquid phase sintering exhibited high density (approximately 99%) and excellent high-temperature flexural strength (approximately 320 MPa) at 1500 °C in air. These results clearly demonstrate that pure mullite ceramics fabricated via transient liquid phase sintering with compositions close to those of stoichiometric mullite could be a promising process for the fabrication of high-temperature structural ceramics used in an ambient atmosphere. The transient liquid phase sintering process proposed in this study could be a powerful processing tool that allows for the preparation of superior high-temperature structural ceramics used in the ambient processing atmosphere.     

Nanolayer CrAlN/TiSiN coating designed for tribological applications

With the goal to produce a hard and tough coating intended for tribological applications, CrAlN/TiSiN nanolayer coating was prepared by alternative deposition of CrAlN and TiSiN layers. In the first part of the article, a detailed study of phase composition, microstructure, and layer structure of CrAlN/TiSiN coating is presented. In the second part, its mechanical properties, fracture and tribological behavior are compared to the nanocomposite TiSiN coating. An industrial magnetron sputtering unit was used for coating deposition. X-ray photoelectron spectroscopy, energy dispersive X-ray spectroscopy, X-ray diffraction, scanning electron microscopy, and transmission electron microscopy were used for compositional and microstructural analysis. Mechanical properties and fracture behavior were studied by instrumented indentation and focused ion beam techniques. Tribological properties were evaluated by ball-on-disk test in a linear reciprocal mode. A complex layer structure was found in the nanolayer coating. The TiSiN layers were epitaxially stabilized inside the coating which led to formation of dislocations at interfaces, to introduction of disturbances in the coating growth, and as a result, to development of fine-grained columnar microstructure. Indentation load required for the onset of fracture was twice lower for the nanolayer CrAlN/TiSiN, compared to the nanocomposite TiSiN coating. This agrees very well with their mechanical properties, with H³/E² being twice higher for the TiSiN coating. However, the nanolayer coating experienced less severe damage, which had a strong impact on tribological behavior. A magnitude of order lower wear rate and four times lower steady state friction coefficient were found for the nanolayer coating.     

Enhanced electromagnetic microwave absorption of Fe/C/SiCN composite ceramics targeting in integrated structure and function

The Fe/C/SiCN composite ceramics were synthesized by polymer-derived method to obtain the integration of structure and functions. The electromagnetic waves (EMW) absorption properties at X and Ku bands were investigated. The addition of nano-sized Fe particles improved the magnetic loss and impedance matching, and the carbon nanotubes generated by the iron in-situ catalysis increased the internal relaxation polarization and interfacial polarization, which together improved the EMW absorption properties significantly. In particular, the Fe/C/SiCN-9 showed the optimum reflection loss (RL) of ?31.06 dB at 10.03 GHz with an effective absorption bandwidth (EAB, RL < ?10 dB) of 3.03 GHz at 2.51 mm, indicating the excellent EMW absorption properties of Fe/C/SiCN composite ceramics.     

NNI-1型C_5/C_6烷烃异构化催化剂长周期运行分析及建议

中国石化海南炼油化工有限公司0.2 Mt/a C5/C6烷烃异构化装置以连续重整装置的拔头油为原料,使用NNI-1催化剂,采用一次通过流程,不设脱异戊烷塔和稳定塔,经设在连续重整装置内的脱丁烷塔稳定处理后作为汽油调合组分。该装置于2006年9月开工投产,截至2015年3月已连续运行3个周期。长周期运行分析结果表明:前两个周期中NNI-1催化剂具有较高的异构化活性及选择性,C5异构化率为60%左右,C6异构化率为80%左右,C6选择性为15%左右,产品辛烷值基本达到技术指标要求(RON≥78);而在第三周期运行中,催化剂积炭增加等原因导致其异构化活性及选择性降低,异构化产品辛烷值提升能力呈现逐步衰减的趋势,提高反应苛刻度已不能弥补催化剂活性下降造成的产品辛烷值降低。为保证装置长周期运行,建议择机停工对催化剂进行再生,或是直接换用与装置原料性质匹配的异构化催化剂。     

Longitudinal permeability determination of dual-scale fibrous materials

In this work, the longitudinal permeability of squarely packed dual-scale fiber preforms is studied theoretically. These fiber preforms are composed of aligned porous tows and the tows are tightly packed. The effective permeability is calculated as a parallel-like network of intra-tow permeability and inter-tow permeability, which are quantified by Darcy’s law and the inscribed radius between tows, respectively. The jump velocity at the interface between inter-tow fluids and porous tows is considered, as derived by substituting Beavers and Joseph’s correlation into Brinkman’s equation. We further examine the effects of intra-tow permeability on the effective permeability of the fibrous system with three interface conditions: (1) interface velocity = 0, (2) interface velocity = mean intra-tow velocity, and (3) interface velocity = jump velocity. The jump-velocity-based model is found to be closest to numerical data. The influence of the fiber volume fraction of tows on the effective permeability is also analyzed.     

Analysis of adhesively bonded CFRE composite scarf joints modified with MWCNTs

The main objective of the present work is to improve the performance of bonded joints in carbon fiber composite structures through introducing Multi-Walled Carbon Nanotubes (MWCNTs) into Epocast 50-A1/946 epoxy, which was primarily developed for joining and repairing of composite aircraft structures. Results from tension characterizations of structural adhesive joints (SAJs) with different scarf angles (5–45°) showed improvement up to 40% compared to neat epoxy (NE)–SAJs. Special attention was considered to investigate the performance of SAJs with 5° scarf angle under different environments. The tensile strength and stiffness of both NE-SAJs and MWCNT/E-SAJs were dramatically decreased at elevated temperature. Water absorption showed a marginal drop of about 2.0% in the tensile strength of the moist SAJs compared to the dry one. Cracks initiation and propagation were detected effectively using instrumented-SAJs with eight strain gauges. The experimental results agree well with the predicted using three-dimensional finite element analysis model.     

Stochastic free vibration analyses of composite shallow doubly curved shells – A Kriging model approach

This paper presents the Kriging model approach for stochastic free vibration analysis of composite shallow doubly curved shells. The finite element formulation is carried out considering rotary inertia and transverse shear deformation based on Mindlin’s theory. The stochastic natural frequencies are expressed in terms of Kriging surrogate models. The influence of random variation of different input parameters on the output natural frequencies is addressed. The sampling size and computational cost is reduced by employing the present method compared to direct Monte Carlo simulation. The convergence studies and error analysis are carried out to ensure the accuracy of present approach. The stochastic mode shapes and frequency response function are also depicted for a typical laminate configuration. Statistical analysis is presented to illustrate the results using Kriging model and its performance.