Research of Microstructure,Phase,and Mechanical Properties of Aluminum-Dross-Based Porous Ceramics

In this study,the effect of sintering temperature and the addition of kaolin,a sintering agent,on the microscopic,phase,and mechanical properties of ceramics were investigated using secondary aluminum dross(SAD)as the main component in the manufacturing of ceramics.The basic phases of the ceramics were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)without the addition of kaolin.The diffraction peaks of MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)kept decreasing while those of Al_(2)O_(3)kept increasing with an increase in temperature.In addition,the increase in temperature promoted the growth of the grains.The grains were uniform in size and regular in distribution,with a shrinkage of 2.2%,porosity of 72.5%,bulk density of 1.076 g/cm^(3),and compressive strength of 1.12 MPa.When the sintering temperature was 1450°C,the basic phases of the ceramic after the addition of kaolin were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2).With the increase of kaolin,the diffraction peaks of NaAl_(11)O_(17)and SiO_(2)decreased until they disappeared,while the diffraction peaks of Al_(2)O_(3)increased significantly.When kaolin was added at 30 wt.%,the ceramics obtained had shrinkage of 18%,a porosity of 47.26%,a bulk density of 1.965 g/cm^(3),and compressive strength of 31.9 MPa.Cracks existed inside the ceramics without the addition of kaolin,while the addition of kaolin significantly changed this defect.It is shown that SAD can obtain porous ceramics with good properties at a sintering temperature of 1450°C and a kaolin addition of 30 wt.%.

Progress in Preparation Technology of Porous Ceramics for High Temperature Dust Filtration

With the rapid industrialization and urbanization,the demand for air quality management is more and more urgent.High temperature dust filtration is one important environmental management technology.Porous ceramics are used as filter materials in the field of high-temperature dust filtration because of their unique advantages such as high filtration efficiency,as well as high temperature stability,particle loss resistance,corrosion resistance and durability.This paper mainly introduced several common preparation techniques of porous ceramics,including the traditional organic foam impregnation method,foaming method,in-situ combustion method,pore-forming method and other new methods such as the template method,gel injection molding method,freeze-drying method,multi-component co-precipitation method and hydrogel method.The principle,advantages and disadvantages of these preparation technologies and their research status were described.The application of these technologies in the field of high temperature dust filtration was briefly reviewed.Finally,the application prospect of the porous ceramics in the field of high temperature dust filtration was prospected.

Preparation of nano-TiO_2/diatomite-based porous ceramics and their photocatalytic kinetics for formaldehyde degradation

Diatomite-based porous ceramics were adopted as carriers to immobilize nano-TiO_2 via a hydrolysis-deposition technique. The thermal degradation of as-prepared composites was investigated using thermogravimetric–differential thermal analysis, and the phase and microstructure were characterized by X-ray diffraction, Fourier transform infrared spectroscopy, and transmission electron microscopy. The results indicated that the carriers were encapsulated by nano-TiO_2 with a thickness of 300–450 nm. The main crystalline phase of TiO_2 calcined at 650℃ was anatase, and the average grain size was 8.3 nm. The FT-IR absorption bands at 955.38 cm^(-1) suggested that new chemical bonds among Ti, O, and Si had formed in the composites. The photocatalytic(PC) activity of the composites was investigated under UV irradiation. Furthermore, the photodegradation kinetics of formaldehyde was investigated using the composites as the cores of an air cleaner. A kinetics study showed that the reaction rate constants of the gas-phase PC reaction of formaldehyde were κ = 0.576 mg·m^(–3)·min^(–1) and K = 0.048 m^3/mg.

Constructing Straight Pores and Improving Mechanical Properties of GangueBased Porous Ceramics

The large-scale accumulation and pollution of solid mining waste is an urgent issue.Coal gangue is a prominent type of solid waste,and shows promise for use in high value-added products due to its content of many important compounds,including SiO_(2) and Al2O3.This study proposed the preparation of highly porous ceramics from coal gangue,coal slime,and coconut palm fibers.The ceramics were produced at a sintering temperature of 950℃ with a fiber content of 6 wt%,which led to the formation of porous ceramics with a porosity of 66.93%,volume density of 1.0329 g/cm^(3),compressive strength of 1.1025 MPa,and thermal conductivity is 0.3919 K(W/mk).A finite element model of the porous ceramics was established using the Abaqus module in ANSYS software,where the stress distribution and compressive strength were simulated.Further,the relationship between porosity and compressive strength was analyzed.The thermal properties of the porous ceramics were analyzed using the Fluent module,where the simulated changes in porosity under various sintering temperatures were consistent with the experimental data.The preparation of this highly porous ceramic from solid waste coal gangue shows promise for the minimizing the impact of waste gas and wastewater pollution in the future.

Effect of Starch Addition on Properties of Corundum-mullite Porous Ceramics

Corundum-mullite porous ceramics(CMPCs)were fabricated using fly ash and aluminum ash as the raw materials,adding different amounts of starch(0,10%,20%,and 30%,by mass)as the pore-forming agent,molding and firing at 1200℃ for 1 h.The apparent porosity,the bulk density,the cold compressive strength,the thermal shock resistance and the thermal conductivity of the CMPCs were tested.The phase composition and the microstructure of the CMPCs were characterized by XRD and SEM.The effect of the starch addition on the properties of the CMPCs was studied.The results show that:(1)the CMPCs with high porosity can be successfully prepared by adding starch as the pore-forming agent and firing at 1200℃ for 1 h;(2)with the starch addition increasing,the porosity increases;the cold compressive strength and the number of the quenching cycles of the CMPCs decrease,but they remain at high levels;meanwhile,the thermal conductivity decreases;(3)generally,when adding 20 mass%starch,the CMPC has the apparent porosity of 48.6%,the cold compressive strength of 52.1 MPa,the quenching cycles of 5 and the thermal conductivity of 1.63 W·m-1·K-1 and 1.52 W·m-1·K-1,respectively,at 25℃ and 500℃,showing good performance.

Effects of Pore-forming Agents on Properties of Silicon Carbide Porous Ceramics Prepared from Crystalline Silicon Cutting Waste

SiC powder was rapidly synthesized in an induction furnace with crystalline silicon cutting waste and active carbon as raw materials,and then SiC porous ceramics were prepared at 1600 t for 4 h with carbon embedded using the powder as raw material,the starch and the graphite as pore-forming agents.Effects of additions of different pore-forming agents on the phase composition,microstructures,physical properties,and cold crushing strength of the porous ceramics were investigated.The results show that the main crystalline phases of the synthetic powder areα-S iC(6H-SiC)andβ-SiC(3C-SiC).The phase composition of the porous ceramics includesα-S iC(6H-SiC),β-SiC(3C-SiC),FeSi,quartz and Si2N20.The apparent porosity and closed porosity of the porous ceramics prepared by adding starch are higher,and the cold compressive strength of the porous ceramics added with graphite is higher.As increasing the additions of the starch,the apparent porosity,closed porosity and linear shrinkage ratio of the porous ceramics increase,and the bulk density decreases correspondingly.When 20 mass%starch is added,the apparent porosity,closed porosity,linear shrinkage ratio and cold compressive strength are 57.05%,2.03%,5.10%and 10.20 MPa,respectively.

Preparation of Si3N4 Porous Ceramics via Combined Foam-gelcasting and Catalytic Nitridation with Fe Powder as Catalyst

Si3N4 porous ceramics were fabricated by a combined foam-gelcasting and catalytic nitridation method at 1473-1623 K using silicon powder as the starting material,hexadecyl trimethyl ammonium bromide(CTAB)as the foaming agent,and different amounts of micron Fe powder as the catalyst.The effects of the nitridation temperature and the Fe powder addition on the phase composition,the mechanical properties,and the microstructure of the samples were researched.The results show that when nitriding at 1573 K for 5 h and adding 1 mass%Fe powder(with respect to the Si powder),the sample has a high porosity and suitable mechanical properties:the porosity of 76.5%,the compressive strength of 16.2 MPa,and the specific strength of 22.7 MPa•cm3•g^-1.

Research Progress on Porous Ceramics Prepared from Industrial Solid Wastes

The situation of porous ceramics prepared from industrial waste slag(fly ash,red mud,metallurgical slag,tailings,etc.)was summarized.It was pointed out that the preparation of porous ceramics from industrial waste slag can bring long-term economic and social benefits.The development trend of secondary utilization of industrial waste slag was also prospected.

Fabrication and Properties of Aluminabased Reticulated Porous Ceramics

The primary impregnation slurry was prepared using active alumina(56.25 mass%),kaolin(15 mass%),zirconia(3.75 mass%),deionized water(25 mass%),and extra adding FS(0.2 mass%)and CMC(0.4 mass%).The effects of the active alumina particle size(d50=5.043,2.934,and 1.629μm)on the rheology and the thixotropy of the slurry were researched.It was found that the bimodal activeα-Al2O3(AMA-10)with d50=1.629μm was optimum.The secondary impregnation slurry was prepared using AMA-10,kaolin and zirconia as the main raw materials.Then the alumina-based reticulated porous ceramics were fabricated by the organic foam impregnation method combined with a secondary vacuum impregnation process.The influence of the AMA-10 content on the properties of the ceramics was studied.The residual stress of the specimens was analyzed by finite element analysis.The results show that the smaller alumina particle size and multimodal distribution are beneficial to the thixotropy of the primary impregnation slurry.The secondary vacuum impregnation technique can significantly improve the mechanical properties,the thermal shock resistance and the residual strength of the alumina-based reticulated porous ceramics.With the decrease of alumina content in the secondary impregnation slurry,the residual stress of the external layer of ceramic reinforcement gradually changes from tensile stress to compressive stress,which effectively inhibits the expansion of the surface crack,and remarkably improves the crushing strength retention ratio of alumina reticulated porous ceramics.

Research Progress on Thermal Shock Behavior of Porous Ceramics

Thermal-mechanical coupling effect causes a large stress within porous ceramics at high temperatures,resulting in strength attenuation and product reliability decline.Thermal shock resistance is one of the key factors to characterize the reliability of ceramic materials under thermal-mechanical coupling effect.It is important to study the thermal shock resistance of the porous ceramics to evaluate their service performance and improve their service life.To better evaluate the effect of the thermal shock resistance on properties of the porous ceramics,the evaluation theories,experimental characterization methods and influencing factors about the thermal shock performance of the porous ceramics were reviewed in this paper,and some future research directions were prospected.

High wave transmittance and low thermal conductivity Y-a-SiAlON porous ceramics for high-temperature radome applications

With the development of hypersonic vehicle technology,ceramic-based radome materials are highly demanded due to their high operating temperatures,good dielectric properties,and high mechanical properties.Althoughα-SiAlON is an ideal material for radome applications,its intrinsic low transmittance and high thermal conductivity limit its applications.Herein,we prepared Y-α-SiAlON porous ceramics through tert-butanol(TBA)gel-casting using the self-synthesizedα-SiAlON powder.The Y-α-SiAlON porous ceramics exhibited a uniform micron-level connected pore structure with the porosity(P)of 44.2%-58.6%.The real part of permittivity(s')was 3.13-4.18(8.2-12.4 GHz),which decreased significantly with the increasing porosity.The wave transmittance(|T|^(2))of the sample with porosity of 58.6%could exceed 80%in the thickness range of 6-10 mm.The thermal conductivity was maintained at a low level of 1.38-2.25 W·m^(-1)·K^(-1) owing to the introduction of the pore structure.The flexural strength was 44.73-88.33 MPa,which may be increased by rod-likeα-SiAlON grains.The results indicate that the prepared Y-α-SiAlON porous ceramics meet the requirements of high-temperature wave-transmitting materials for radome applications.

Lightweight quasi-layered elastic fibrous porous ceramics with high compressive stress and low thermal conductivity

Fibrous porous ceramics are attractive for use as thermal insulation materials.However,the intrinsic brit-tleness of rigid materials has remained challenging and severely restricts their applications.Here,we demonstrated a facile method for fabricating elastic fibrous porous ceramics(EFPCs)with high com-pressive strength and low thermal conductivity through ordinary press filtration and subsequent heat treatment.The quasi-layered structure and the well-bonded bridging fibers between layers are the key points for the elasticity of EFPCs.The advanced EFPCs exhibited low density(∼0.126 g cm^(−3)),high com-pressive stress(∼0.356 MPa),and low thermal conductivity(∼0.026 W m^(−1) K^(−1)).Compared with rigid porous fibrous materials,the EFPCs had deformability and excellent shape recovery.In contrast to flexible materials,the EFPCs possessed high compressive stress,thus endowing them with good resistance to de-formation.The emergence of this fascinating material may provide new insights for candidate materials in thermal insulation and other fields.

Porous Ultra-high Temperature Ceramics for Ultra-high Temperature Thermal Protection System

Ultra-high temperature ceramics(UHTCs)are a family of borides,carbides and nitrides of transition elements such as hafnium,zirconium,tantalum and niobium.They exhibit the highest known melting points,good mechanical strength,good chemical and thermal stability under certain conditions.In last decade,researchers dedicated to characterize porous UHTCs aiming to develop novel thermal insulating materials that could withstand temperatures over 2000℃.In this article,the preparation and characteristics of porous UHTCs were reviewed.Dry processing,colloidal processing and solution processing routes have been used to prepare porous UHTCs with porosities ranging from 5%to 97%and pore sizes ranging from hundreds of nanometers to hundreds of micrometers.The obtained porous UHTCs are chemically and dimensionally stable at temperatures up to 2000℃ during static state high-temperature thermal aging.

Preparation of Thermal Insulation Ceramics Using Felsic Tailings as Main Raw Material and Soda-ash Dregs as Flux

Low-cost thermal insulation porous ceramics with uniform pore diameter and low bulk density were prepared with soda-ash dregs and felsic tailings.We investigated the effect of temperature,foaming agent,fluxing agent,Al_(2)O_(3)and CaO content on the pore structure and crystal phase of porous ceramics.The effect of Ca^(2+)in soda-ash dregs on the preparation of quartz-feldspar based porous ceramics was studied.The results showed that the contribution of Ca^(2+)to the preparation of porous ceramics in this system was mainly to accelerate the Si-O bond fracture and reduce the sintering temperature at the initial stage of sintering,which destroyed the needle-like feldspar in the high temperature melt and reduced the melt viscosity,thus reduced the foaming resistance and promoted the porous products with uniform pore size distribution.The Ca^(2+)content on the high side can participate in the formation of crystals in sintering.The generated needle-like diopside and augite,which have small length-diameter ratio,will negligibly change in the viscosity of melt at high temperatures,and their inhibition effect on pores is not as good as that of feldspar with large length-diameter ratio,resulting in the merger and collapse of pores.But the increase of diopside and augite can improve the compressive strength of porous products to some extent.Porous ceramic products containing needle-like feldspar phase can be prepared by using two kinds of solid waste,which can improve the compressive strength of the products and reduce the raw material cost and energy consumption while comprehensively utilizing the double solid waste.The optimal product has a bulk density of 0.45 g/cm^(3),a compressive strength of 3.17 MPa,and a thermal conductivity of 0.11 W/(m·K).

Facile fabrication of cordierite-based porous ceramics with magnetic properties

In this paper,cordierite-based porous ceramics with magnetic properties have been firstly in-situ synthesized by using MgO,Al_(2)O_(3),and SiO_(2) powders as raw materials and Fe_(3)O_(4) as a functional additive.Combining with the foam freeze casting method,near net size fabrication(total linear shrinkage<2.86%)of the magnetic porous materials was realized by adjusting the amount of Fe_(3)O_(4).The porosity,compressive strength,and saturation magnetization of the prepared materials were 83.9%-87.8%,1.51-2.65 MPa,and 1.2-5.8 emu/g,respectively.The phase composition and microstructure evolutions during sintering were investigated briefly.The results showed that the synthesis temperature of cordierite was lowered about 100℃ due to the addition of Fe_(3)O_(4).Except for the main phase-cordierite,Mg-Al-Fe spinel and α-Fe_(2)O_(3) also existed in the final materials.The lattice parameters of the Mg-Al-Fe spinel and the amount of α-Fe_(2)O_(3) changed obviously with the change in the sintering temperature and Fe_(3)O_(4) amount,which mainly influenced the magnetic properties of the prepared materials.Thus,a facile fabrication method of the cordierite-based porous ceramics with the magnetic properties has been put forward in this paper.

Carbon Capture from Flue Gas Based on the Combination of Non-Contact Hydrophobic Porous Ceramic Membrane and Bubbling Absorption

A hybrid system combined with a non-contact membrane and bubbling absorption is proposed to capture CO_(2) from flue gas.The non-contact way of membrane and liquid absorbent effectively avoids the reduction of gas diffusion flux through the membrane.High-porosity ceramic membranes in hybrid systems are used for gas-solid separation in fuel gas treatment.Due to the high content of H_(2)O and cement dust in the flue gas of the cement plant,the membrane is hydrophobically modified by polytetrafluoroethylene(PTFE)to improve its anti-water,anti-fouling,and self-cleaning performances.The results show that the diffusion flux of CO_(2) through the membrane is still higher than 7.0×10^(−3) mol/m^(2)s(20%CO_(2) concentration)even under the influence of water and cement dust.In addition,slaked lime selected as the absorbent is cheap and the product after bubbling absorption is nano-scale light calcium carbonate.To sum up,the hybrid system combining non-contact membrane and bubbling absorption is expected to be used to capture carbon dioxide from the flue gas of the cement plant.

Preparation and Application Progress of Porous Alumina

Porous alumina ceramics are widely used in various fields because of their unique characteristics in structure and properties.This article mainly provided an overview of preparation techniques of porous alumina ceramics;besides,the principles and the characteristics of pore-forming agents processes,gel-casting processes,freeze-casting processes,anodizing processes and other common processes in obtaining the required properties of porous alumina ceramics were introduced.Meanwhile,the relevant applications and the performance of porous alumina ceramics were described.The research prospects of porous alumina ceramics were put forward based on the research status at the end of this paper.

Preparation and Properties of Si2N2O Ceramics for Microwave Sintering Furnaces

Si2N2O ceramics were prepared using amorphous Si3N4 as the raw material and Li2CO3 as the sintering additive through vacuum multi-stage sintering.The influence of the Li2CO3 addition(0%,1%,2%,3%,and 5%,by mass)on the phase composition,the microstructure,the porosity,the mechanical properties,the dielectric constant and the tangent of the dielectric loss angle of the porous Si2N2O ceramics was investigated.The results reveal that a suitable addition of Li2CO3 can promote the generation of Si2N2O but excessive or inadequate Li2CO3 causes decomposition of Si2N2O ceramics.The prepared porous Si2N2O ceramics have good mechanical properties,good thermal shock resistance,and low dielectric properties,which have excellent potential for application in microwave sintering furnaces.

Effect of Y_(2)O_(3 )Addition on Preparation and Properties of β-SiAlON Reticular Porous Ceramic Filters

β-Si Al ON reticular porous ceramics(Si_(6-Z)Al_(Z)O_(Z)N_(8-Z),Z=2)were prepared withα-Al_(2)O_(3),AlN and Si as raw materials and Y_(2)O_(3)as the sintering aid by the foam impregnation method.The influence of the Y_(2)O_(3)addition(0,3%,6%and 9%,by mass)on the microstructure and the properties of the samples was studied.The results show that the Y_(2)O_(3)addition is conductive to the sintering of samples and the growth of grains.The sample added with 6%Y_(2)O_(3)has the optimal properties:the apparent porosity of 82.9%,the bulk density of 0.53 g·cm^(-3),the cold compressive strength of 1.97 MPa,and the residual cold compressive strength of 1.68 MPa after oxidation,which can be used as porous ceramic filters.

Preparation and properties of a low-cost porous ceramic support from low-grade palygorskite clay and silicon-carbide with vanadium pentoxide additives

Alow-cost porous ceramic support was prepared from low-grade palygorskite clay(LPGS) and silicon carbide(SiC)with vanadium pentoxide(V_(2) O_(5)) additives by a dry-press forming method and sintering.The effects of SiC-LPGS ratio,pressing pressure,carbon powder pore-forming agent and V_(2) O_(5) sintering additives on the microstructure and performance of the supports were investigated.The addition of an appropriate amount of SiC to the LPGS can prevent excessive shrinkage of the support during sintering,and increase the mechanical strength and open porosity of the supports.The presence of SiC(34.4%) led to increases in the open porosity and mechanical strength of 40.43% ± 0.21% and(17.76 ± 0.51) MPa,respectively,after sintering at 700℃ for 3 h.Because of its low melting point,V_(2) O_(5) can melt to liquid during sintering,which increases the mechanical strength of the supports and retains the porosity.Certainly,this can also encourage efficient use of the LPGS and avoid wasting resources.