Processing and mechanical properties of network ceramic/steel composites by pressureless infiltration

A new style Ni-containing alumina ceramic foam based continuous three-dimensional interconnected skeleton was prepared by impregnating a polymeric sponge with aqueous ceramic slurry.Subsequently,alumina ceramic foam/steel metal matrix composites(MMCs) were prepared successfully by sand mold casting technique.The microstructure and mechanical properties of MMCs were investigated by SEM,EDS and compressive test.The results show that the depth of infiltration is about 40 μm to the bonding interface of ceramic/steel and the fracture strength σmax and plastic strain limit εp of composite are 520 MPa and 11.2%,respectively.The fretting wear mechanism of MMCs is mainly performed at the oxidative wear mode with lower load/friction frequency and the predominant oxidation wear together with slight adhesive wear and abrasive wear multiple mode with higher load/ friction frequency.Moreover,the infiltration bonding and continuous three-dimensional interconnected ceramic skeleton play a vital role in the stability of the bonding interface and excellent mechanical properties.

Microstructure Characteristics and Possible Phase Evolution of the Coal Gangue-Steel Slag Ceramics Prepared by the Solid-State Reaction Methods

Industrial wastes such as steel slag and coal gangue etc.were chosen as raw materials for preparing ceramic via the conventional solid-state reaction method.With steel slag and coal gangue mixed in various mass ratios,from 100%steel slag to 100%coal gangue at 10%intervals,microstructure and possible phase evolution of the coal gangue-steel slag ceramics were investigated using X-ray powder diffraction,scanning electron microscopy,mercury intrusion porosimetry and Archimedes boiling method.The experimental results suggest that the phase compositions of the as-prepared ceramics could be altered with the increased amount of coal gangue in the ceramics.The anorthite-diopside eutectic can be formed in the ceramics with the mass ratios of steel slag to coal gangue arranged from 8:2 to 2:8,which was responsible for the melting of the steel slag-coal gangue ceramics at relatively high temperature.Further investigations on the microstructure suggested that the addition of the proper amount of steel slag in ceramic compositions was conducive to the pore formation and further contributed to an increment in porosity.

Thermodynamic analysis and formula optimization of steel slag-based ceramic materials by FACTsage software

Using steel slag as a main raw material of ceramics is considered as a high value-added way. However, the relationship among the initial composition, ceramic microstructure, and macroscopic properties requires further study. In this paper, a series of ceramics with different slag ratios （0-70wt%） were designed, and the software FACTsage was introduced to simulate the formation of crystalline phases. The simulation results indicate that mullite is generated but drastically reduced at the slag ratios of 0-25wt%, and anorthite is the dominant crystalline phase in the slag content of 25wt%-45wt%. When the slag ratio is above 45wt%, pyroxene is generated more than anorthite. This is because increasing magnesium can promote the formation of pyroxene. Then, the formula with a slag content of 40wt% was selected and optimized. X-ray diffraction results were good consistent with the simulation results. Finally, the water absorption and bending strength of optimized samples were measured.

Complementation in the composition of steel slag and red mud for preparation of novel ceramics

A method for preparing novel ceramics was developed in this study. Different ratios red muds were added to steel slags to optimize the preparation of novel ceramics by a traditional ceramic preparation process. The sintering mechanism, microstructure, and performance were studied by X-ray diffraction techniques, scanning electron microscopy, and combined experiments of linear shrinkage, water absorption, and flexural strength. The results confirmed that red mud can reduce the volumetric instabilities through the complementarity of red mud and ferroalloy slag. The crystal phases in the ceramics are all pyroxene group minerals, including diopside ferrian, augite, and diopside. The flexural strength of the ceramic that contains 40 wt% red mud and was prepared at the optimal sintering temperature(1140°C) is greater than 93 MPa; its corresponding water absorption is less than 0.05%.

Grindability Evaluation of Ultrasonic Assisted Grinding of Silicon Nitride Ceramic Using Minimum Quantity Lubrication Based SiO_(2)Nanofluid

Minimum quantity Lubrication(MQL)is a sustainable lubrication system that is famous in many machining systems.It involve the spray of an infinitesimal amount of mist-like lubricants during machining processes.The MQL system is affirmed to exhibit an excellent machining performance,and it is highly economical.The nanofluids are understood to exhibit excellent lubricity and heat evacuation capability,compared to pure oil-based MQL system.Studies have shown that the surface quality and amount of energy expended in the grinding operations can be reduced considerably due to the positive effect of these nanofluids.This work presents an experimental study on the tribological performance of SiO_(2)nanofluid during grinding of Si_(3)N_(4)ceramic.The effect different grinding modes and lubrication systems during the grinding operation was also analyzed.Different concentrations of the SiO_(2)nanofluid was manufactured using canola,corn and sunflower oils.The quantitative evaluation of the grinding process was done based on the amount of grinding forces,specific grinding energy,frictional coefficient,and surface integrity.It was found that the canola oil exhibits optimal lubrication performance compared to corn oil,sunflower oil,and traditional lubrication systems.Additionally,the introduction of ultrasonic vibrations with the SiO_(2)nanofluid in MQL system was found to reduce the specific grinding energy,normal grinding forces,tangential grinding forces,and surface roughness by 65%,57%,65%,and 18%respectively.Finally,regression analysis was used to obtain an optimum parameter combinations.The observations from this work will aid the smooth transition towards ecofriendly and sustainable machining of engineering ceramics.

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Ceramic oxides,renowned for their exceptional combination of mechanical,thermal,and chemical properties,are indispensable in numerous crucial applications across diverse engineering fields.However,conventional manufacturing methods frequently grapple with limitations,such as challenges in shaping intricate geometries,extended processing durations,elevated porosity,and substantial shrinkage deformations.Direct additive manufacturing(dAM)technology stands out as a state-of-the-art solution for ceramic oxides production.It facilitates the one-step fabrication of high-performance,intricately designed components characterized by dense structures.Importantly,dAM eliminates the necessity for post-heat treatments,streamlining the manufacturing process and enhancing overall efficiency.This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides,with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques.A thorough investigation is conducted into the shaping quality,microstructure,and properties of diverse ceramic oxides produced through dAM.Critical examination is given to key aspects including feedstock preparation,laser-material coupling,formation and control of defects,in-situ monitoring and simulation.This paper concludes by outlining future trends and potential breakthrough directions,taking into account current gaps in this rapidly evolving field.

New Strategy for Boosting Cathodic Performance of Protonic Ceramic Fuel Cells Through Incorporating a Superior Hydronation Second Phase

For protonic ceramic fuel cells,it is key to develop material with high intrinsic activity for oxygen activation and bulk proton conductivity enabling water formation at entire electrode surface.However,a higher water content which benefitting for the increasing proton conductivity will not only dilute the oxygen in the gas,but also suppress the O_(2)adsorption on the electrode surface.Herein,a new electrode design concept is proposed,that may overcome this dilemma.By introducing a second phase with high-hydrating capability into a conventional cobalt-free perovskite to form a unique nanocomposite electrode,high proton conductivity/concentration can be reached at low water content in atmosphere.In addition,the hydronation creates additional fast proton transport channel along the two-phase interface.As a result,high protonic conductivity is reached,leading to a new breakthrough in performance for proton ceramic fuel cells and electrolysis cells devices among available air electrodes.

Rational Design of Ruddlesden-Popper Perovskite Ferrites as Air Electrode for Highly Active and Durable Reversible Protonic Ceramic Cells

Reversible protonic ceramic cells(RePCCs)hold promise for efficient energy storage,but their practicality is hindered by a lack of high-performance air electrode materials.Ruddlesden-Popper perovskite Sr_(3)Fe_(2)O_(7−δ)(SF)exhibits superior proton uptake and rapid ionic conduction,boosting activity.However,excessive proton uptake during RePCC operation degrades SF’s crystal structure,impacting durability.This study introduces a novel A/B-sites co-substitution strategy for modifying air electrodes,incorporating Sr-deficiency and Nb-substitution to create Sr_(2.8)Fe_(1.8)Nb_(0.2)O_(7−δ)(D-SFN).Nb stabilizes SF’s crystal,curbing excessive phase formation,and Sr-deficiency boosts oxygen vacancy concentration,optimizing oxygen transport.The D-SFN electrode demonstrates outstanding activity and durability,achieving a peak power density of 596 mW cm^(−2)in fuel cell mode and a current density of−1.19 A cm^(−2)in electrolysis mode at 1.3 V,650℃,with excellent cycling durability.This approach holds the potential for advancing robust and efficient air electrodes in RePCCs for renewable energy storage.

Synthesis of steel slag ceramics: chemical composition and crystalline phases of raw materials

Two types of porcelain tiles with steel slag as the main raw material （steel slag ceramics） were synthesized based on the CaO-A1203-SiO2 and CaO--MgO-SiO2 systems, and their bending strengths up to 53.47 MPa and 99.84 MPa, respectively, were obtained. The presence of anorthite, a-quartz, magnetite, and pyroxene crystals （augite and diopside） in the steel slag ceramics were very different from the composition of traditional ceramics. X-ray diffraction （XRD） and electron probe X-ray microanalysis （EPMA） results illustrated that the addition of steel slag reduced the temperature of extensive liquid generation and further decreased the firing temperature. The considerable contents of glass-modifying oxide liquids with rather low viscosities at high temperature in the steel slag ceramic adobes promoted element diffusion and crystallization. The results of this study demonstrated a new approach for extensive and effective recycling of steel slag.

BEHAVIOUR OF BUFFER LAYER IN JOINING OF SIALON CERAMICS TO STEEL 40Cr

The buffer layer material itself may be influential to the bond strength between active brazing filler and ceramics.For Ag_(57)Cu_(38)Ti_5 filler metal,Cu or Ta is excellent buffer layer material, but Kovar or Ni-15Cr-15Co is worse.It was important to design a layer of soft buffer,such as Cu,to relax interfacial stress rather than hard buffer layer,such as Mo,to avoid stress. There is an optimum thickness range of soft buffer layer,saying h/L=0.02—0.1. It was a good solution to the interfacial stress problem to use soft/hard buffer layer to increase metal/ceramics joint strength.Finally,an idea of designing gradual materials as buffer layer between metal and ceramics was suggested.

Microstructure and properties of the joints of ZrO2 ceramic/ stainless steel brazed in vacuum with AgCuTi active filler metal

The ZrO2 ceranfic was successfully jointed to stainless steel by vacuum brazing with active filler metal. The AgCuTi active filler metal was used and the joining was performed at a temperature of 850 ℃ for 10 rain. The microstructures of the joints were characterized by metallographic microscopy, scanning electron microscopy （SEM）, and energy dispersive spectroscopy （EDS）. Metallographic microscopy analysis shows that the morphology of the cross section was a sandwich structure and the TiO is observed in the surface of ZrO2/ stainless steel. The diffusion and enrichment of the elements are the key roles in the brazing of ZrO2 ceramic and stainless steel. The formation of TiCu compounds inhibited the further diffusion of titanium into stainless steel or the ZrO2 ceramic to form TiO compound. In the experimental conditions, the average tensile strength is 80MPa for the joint of ZrO2 ceramic / AgCuTi/ stainless steel systems. A complete joint is formed between the ZrO2 ceramic and stainless steel with the leakage rate at the degree of 10 ^-12 Pa · m^3/s.

Experimental study on the penetration effect of ceramics composite projectile on ceramic/A3 steel compound targets

In order to improve the penetration of projectiles into ceramic composite armors,the nose of 30 mm standard projectile was replaced by a toughened ceramic nose,and the performance of ceramic-nose projectiles penetrating into ceramic/A3 steel composite targets has been experimentally researched.According to impact dynamics theory,,the performances of 30 mm ceramic-nose projectile and 30 mm standard projectile penetrating into the ceramic/A3 steel composite targets were analyzed and compared using DOP method,especially focusing on the effects made by different nose structures and materials.The aperture and depth of perforation of projectile into the armor plates as well as the residual mass of bullet core under the same conditions were comparatively analyzed.A numerical simulation was built and computed by ANSYS/LS-DYNA.Based on the simulated results,the penetration performance was further analyzed in terms of the residual mass of bullet core.The results show that the ceramic nose has a great effect on the protection of bullet core.

Numerical Simulations of Tungsten Alloy Rods Penetration into Alumina Ceramic/Armor Steel Composite Target

The Johnson-Holmquist constitutive ceramic model is re-implemented into the LS_ DYNA3D program to simulate the penetration of long rod projectile into ceramic/armor steel composite targets. The damage evolution, fracture propagation, and spall damage in the ceramic/armor targets is represented during the simulation procedure and the accuracy of the penetration depth comparing between the simulating and experimental results is reliable with an error less than 8 %. The relationship between the mass efficiency factor, differential factor and ceramic tiles thickness is given out for the penetration results with/without a cover plate.

FEM simulation on residual stress distribution during diffusion bonding between Ti （ C, N） metallic ceramic/interlayer/40Cr steel

Based on ANSYS FEM software, the distribution of residual stress in the diffusion bonding joints between Ti（ C,N） metallic ceramic/interlayer/4OCr steel was calculated and experimentally ver^ed. The results showed that the trend on the distribution of residual stress field in the joints was not changed with the use of interlayer. The maximum residual stress was always located in metallic ceramic with area ranging from 1 mm to 4 mm to the interlayer. The maximum residual stress in the joints was also affected by diffusion temperature. The satellite pulse current during the initial stage on diffusion bonding can promote the formation of liquid film at the interface, by which diffusion temperature and loading pressure can be greatly decreased. The crack initiation was easily produced at the corner of Ti （ C, N） metallic ceramic close to the interlayer. If a higher residual stress produced in the joints, the crack was propagated into the whole ceramic.

Effects of Fe2O3 on the properties of ceramics from steel slag

Ferric oxide is one of the key factors affecting both the microstructure and the properties of CaO-MgO-SiO2-based ceramics. Research on this effect is significant in the utilization of iron-rich solid wastes in ceramics. Ceramic samples with various Fe2O3 contents（0 wt%, 5 wt%, and 10 wt%） were prepared and the corresponding physical properties and microstructure were studied. The results indicated that Fe2O3 not only played a fluxing role, but also promoted the formation of crystals. Ceramics with 5 wt% of Fe2O3 addition attained the best mechanical properties with a flexural strength of 132.9 MPa. Iron ions were dissolved into diopside, consequently causing phase transformation from diopside and protoenstatite to augite, thereby contributing to the enhancement of its properties. An excess amount of Fe2O3 addition（10 wt% or more） resulted in deteriorated properties due to the generation of an excess volume of liquid and the formation of high-porosity structures within ceramics.

Robust and Tunable Ferroelectricity in Ba/Co Codoped (K_(0.5)Na_(0.5))NbO_(3) Ceramics

The 0.98(K_(0.5)Na_(0.5))NbO_(3)-0.02Ba(Nb_(0.5)Co_(0.5))O_(3-δ) ceramics with doped Ba^(2+) and Co^(2+) ions are fabricated,and the impacts of the thermal process are studied.Compared with the rapidly cooled (RC) sample,the slowly cooled (SC) sample possesses superior dielectric and ferroelectric properties,and an 11 K higher ferroelectricparaelectric phase transition temperature,which can be attributed to the structural characteristics such as the grain size and the degree of anisotropy.Heat treatment can reversibly modulate the content of the oxygen vacancies,and in turn the ferroelectric hysteresis loops of the samples.Finally,robust and tunable ferroelectric property is achieved in SC samples with good structural integrity.

Food Study of Ceramic Objects from Artisanal Pottery in the City of Katiola in Côte d’Ivoire

In Côte d’Ivoire, there is no regulation regarding the use of traditional ceramics in food. However, their possible impact on human health is not known. Two types of tests must be carried out to study container/content interactions in order to ensure a possible migration of ceramic constituents towards food. The aptitude test of food contact with traditional ceramics intended to come into contact with foodstuffs which determines lead, cadmium, cobalt, arsenic and aluminum release. The migration tests with traditional ceramic food simulants under contact time and temperature conditions are as close as possible to reality. In the aptitude tests of food contact, the utensils comply with French and European regulations concerning the migration of aluminum, cadmium and lead, except that of cobalt. In migration tests with food simulants, the ceramics presented different results. All utensils can be used without danger, except the plates.

A novel process of preparing glass-ceramics directly from molten steel slag

A novel process technology to prepare glass-ceramics directly from molten steel slag （MSS） is proposed in the study. The liquid-solid mixing method was used to adjust the components of the MSS and glass-ceramics was obtained. The effects of heat-treatment conditions on the microstructure ,physical and mechanical properties of samples were studied. Economical benefits of the novel process were analyzed. The results show that heat-treatment is a very effective approach to achieving crystallization. The dominant crystal phase in products is diopside [ （ Mg6Al2Fe2 ） Ca （ Si1.5 Al5 ） O2 ]. The shape of the crystallization is like a granule. The glass-ceramic samples exhibited good mechanical properties and presented chemical stability. The economic benefits of the process are remarkable due to less energy consumption compared with conventional glass-ceramics production methods.

Energy ceramic design for robust battery cathodes and solid electrolytes

Microstructural design and processing science of ceramics from materials to devices are critical to the present and future applications in various fields.They have profound effects on the mechanical and functional properties,as well as the reliability and lifetime of ceramics.The stability issue has been attracting more and more attentions,as many devices are pushed towards extreme service conditions to gain additional benefits such as energy density and efficiency.In this pespective article,we shall discuss on four selected topics of energy ceramic design,including the oxygen evolution issue of oxide battery cathodes under extreme charge voltages,the synthesis conundrum of single-crystalline battery cathodes,the metal/ceramic interface contact problem in all-solid-state lithium-metal batteries,and the nature of hole polarons in oxygen ion and protonic ceramic electrolytes.Our understanding and solutions to these challenging problems shall be discussed.The new fundamental insights and rationally optimized processing practices presented here could help to develop advanced interdisciplinary ceramics further,enabling exciting applications in the coming decades.

Structural and Luminescent Properties of Mg_(0.25-x)Al_(2.57)O_(3.79)N_(0.21):xMn^(2+)Green-Emitting Transparent Ceramic Phosphor

A series of spinel-type Mg_(0.25-x)Al_(2.57)O_(3.79)N_(0.21):xMn^(2+)(MgAlON:xMn^(2+))phosphors were synthesized by the solid-state reaction route.The transparent ceramic phosphors were fabricated by pressureless sintering followed by hot-isostatic pressing(HIP).The crystal structure,luminescence and mechanical properties of the samples were systematically investigated.The transparent ceramic phosphors with tetrahedrally coordinated Mn^(2+)show strong green emission centered around 515 nm under blue light excitation.As the Mn^(2+)concentration increases,the crystal lattice expands slightly,resulting in a variation of crystal field and a slight red-shift of green emission peak.Six weak absorption peaks in the transmittance spectra originate from the spin-forbidden ^(4)T_(1)(^(4)G)→^(6)A_(1) transition of Mn^(2+).The decay time was found to decrease from 5.66 to 5.16 ms with the Mn^(2+)concentration.The present study contributes to the systematic understanding of crystal structure and properties of MgAlON:xMn^(2+)green-emitting transparent ceramic phosphor which has a potential application in high-power light-emitting diodes.