Phase evolution and properties of glass ceramic foams prepared by bottom ash,fly ash and pickling sludge

Municipal solid waste incineration products of bottom ash(BA),fly ash(FA),and pickling sludge(PS),causing severe environ-mental pollution,were transformed into glass ceramic foams with the aid of CaCO3 as a pore-foaming agent during sintering.The effect of the BA/FA mass ratio on the phase composition,pore morphology,pore size distribution,physical properties,and glass structure was investigated,with results showing that with the increase in the BA/FA ratio,the content of the glass phase,Si-O-Si,and Q3Si units decrease gradually.The glass transmission temperature of the mixture was also reduced.When combined,the glass viscosity decreases,causing bubble coalescence and uneven pore distribution.Glass ceramic foams with uniform spherical pores are fabricated.When the content of BA,FA,and PS are 35wt%,45wt%,and 20wt%,respectively,contributing to high performance glass ceramic foams with a bulk density of 1.76 g/cm3,porosity of 56.01%,and compressive strength exceeding 16.23 MPa.This versatile and low-cost approach provides new insight into synergistically recycling solid wastes.

Preparation of Ceramic Foams Suitable for Aircraft Arresting by the Airport Runway Based on a Protein Foaming Agent

Crushable ceramic foams are more suitable to be used as an arrestor material applied in engineered materials arresting system （EMAS） for airport runway for their properties of widely controllable strength, negligible crushing-rebounding behavior, durability, and chemically-inert composition, comparing with traditional concrete foams. The synthesis of ceramic foams adopted direct-foaming method and used an animal protein as foaming agent. Kaolin, talc powder and alumina were the main raw materials. Effects of the ratios of raw materials, calcination temperatures, heating rates, holding time, viscosities of potyvinyl alcohol （PVA） solution as well as the amounts of protein foaming agent and water on microscopic structure, densities, compressive strength and open porosities of ceramic foams were investigated systematically. The results indicate that ceramic foams with typical pore sizes 100-300 μm, open porosities from 73.1% to 91.5%, densities from 0.25 to 0.62 g.cm-3, compressive strength from 0.19 to 4.89 MPa, are obtained by properly adjusting the parameters mentioned above. And the mechanical strength meets the requirement for the EMAS for airport runway. In addition, good correlations are observed among compressive strength, open porosity, microscopic structure, and crystal phase. Furthermore, the possibility of producing the general dimensions of such aircraft arresting components with the proposed method was also discussed.

Numerical simulation of excess-enthalpy combustion flame propagation of coal mine methane in ceramic foam

Based on the assumption of a local non-equilibrium of heat transfer between a solid matrix and gas,a mathematic model of coal mine methane combustion in a porous medium was established,as well the solid-gas boundary conditions.We simulated numerically the flame propagation characteristics.The results show that the flame velocity in ceramic foam is higher than that of free laminar flows;the maximum flame velocity depends on the combined effects of a radiation extinction coefficient and convection heat transfer in ceramic foam and rises with an increase in the chemical equivalent ratio.The radiation extinction coefficient cannot be used alone to determine the heat regeneration effects in the design of ceramic foam burners.

A novel technique for making open-cell Al_2O_3-ZrO_2 ceramic foam with plant seed template

The aim of the present research is to provide a technique for preparing open-cell Al2O3-ZrO2 ceramic foams with uniform cell size.This technique used plant seeds to array templates and centrifugal slip casting to obtain cell struts with high packing density.Aqueous Al2O3-ZrO2 slurries with up to 50 vol.% solid contents were prepared and the rheological characteristic of the slurries was investigated.Consolidation was performed at an acceleration of 2,860 g for 60 min.The effect of the characteristic of plant seeds on the drying behavior of Al2O3-ZrO2 green compact was analyzed.The effects of the solid contents of slurries on segregation phenomena of Al2O3 and ZrO2 particles and green compact uniformity were investigated.The compressive stress-strain curve and deformation behavior of Al2O3-ZrO2 ceramic foams prepared using plant seed template were analyzed.The results showed segregation phenomenon is negligible for highly stable slurry with 50 vol.% solid loading.The prepared cell struts of Al2O3-ZrO2 foams have high green density (61.9% TD), sintered density (99.1% TD) and homogeneous microstructure.When sintered at 1,550 ℃ for 2 h, the cell size of Al2O3-ZrO2 foam is approximately uniform and the diameter is about 1.1 mm.The porosity and compressive strength of sintered products is 66.2% and 5.86 MPa, respectively.

Molten Salts/Ceramic-Foam Matrix Composites by Melt Infiltration Method as Energy Storage Material

A new type of high temperature energy storage material was obtained through the melt infiltration method, using compounding SiC ceramic foam as matrix and Na2SO4 as phase change material. The resulting composite material was measured by XRD, SEM, TG-DSC methods. The experimental results indicate that the composite is composed of silicon carbide, sodium sulfate and square quartz, and no chemical reactions occurs between Na2SO4 and SiC matrix. Na2SO4 has a good bonding with the SiC ceramic foam matrix. As the composite material is characterized by high thermal energy storage density and high thermal conductivity, it is suit for energy storage under high temperature.

Influences of synthesis methods and modifier addition on the properties of Ni-based catalysts supported on reticulated ceramic foams

A method of synthesizing Ni-based catalysts supported on α-Al2O3-based foams was developed. The foams were impregnated with aqueous solutions of metal chlorides under an air atmosphere using an aerosol route. Separate procedures involved calcination to form oxides and drying to obtain chlorides on the foam surface. The synthesized samples were subsequently reduced with hydrogen. With respect to the Ni/Al2O3 catalysts, the chloride reduction route enabled the formation ofa Ni coating without agglomerates or cracks. Further research included catalyst modification by the addition of Pd, Cu, and Fe. The influences of the additives on the degree of reduction and on the low-temperature reduction effectiveness （533 and 633 K） were examined and compared for the catalysts obtained from oxides and chlorides. Greater degrees of reduction were achieved with chlorides, whereas Pd was the most effective modifier among those investigated. The reduction process was nearly complete at 533 K in the sample that contained 0.1wt% Pd. A lower reduction temperature was utilized, and the calcination step was avoided, which may enhance the economical and technological aspects of the developed catalyst production method.

Current Status and Application of Ceramic Foam Filter for Aluminum Melt

The importance of purification for aluminum and aluminum alloy casting was outlined. By comparing ceramic foam filters （CFF） in China and overseas, the existing problems and challenges of China＇ s CFF for aluminum were given. Measures to improve the performance of CFF were put forward based on material, preparation process, utility evaluation, etc.

Lightweight Si_(3)N_(4)@SiO_(2) ceramic foam for thermal insulation and electromagnetic wave transparency

Increasing porosity is one of the most direct ways to improve the thermal insulation and dielectric properties of materials.Until now,many wet methods for preparing Si_(3)N_(4) ceramic foams usually face the problems of complex rheology,long period,and expensive cost,and the reported pore sizes of Si_(3)N_(4) ceramic foams are typically micron-grade,resulting in a lack of competitiveness in thermal insulation and wave-transparent applications.In this paper,the Si_(3)N_(4)@SiO_(2) ceramic foams were prepared using an efficient dry-method,which combined three processes of low temperature chemical vapor deposition(LTCVD),template,and isostatic pressing.The method has the advantages of simple operation and short preparation period,and can realize near-net size molding and mass production.In addition,the evolution mechanisms of honeycomb microstructure and composition of Si_(3)N_(4)@SiO_(2) ceramic foam during sintering were studied by chemical reaction thermodynamics.The as-prepared Si_(3)N_(4)@SiO_(2) ceramic foam possesses low density(0.377 g·cm^(-3)),high compressive strength(7.5 MPa),low thermal conductivity(0.0808 W·m^(-1)·K^(-1)),and excellent dielectric properties(ε<1.32,tanδ<0.009)in the frequency range of 8-18 GHz,and its maximum working temperature in air can reach up to 1100℃.It will be recommended to be applied in the interlayer of Si_(3)N_(4) ceramic radome to improve its thermal insulation and electromagnetic wave transparency performances.

Tensile strength and damage of open-cell ceramic foams under cylindrical splitting test

To widen the understanding of tensile failure of reticulated ceramic foams and expand the available mechanical method,a cylindrical splitting test is developed in the present study based on alumina open-cell foams of three different pore densities.The biaxial method is validated by characterization of mechanical parameters,and the in-situ fracture process is validated by a digital image correlation,followed by a formula correction for effective tensile strength with consideration of discrete crack paths.For experimental setup curved loading platens,compliant pad and intermediate quasi-static loading rate are proposed for guaranteeing tensile failure under a radial compressive load.Tensile strength,fracture energy,and brittleness increase with the foam pore density,and the fracture behavior is a balanced result of materials and foam structural support strength.An analytical model of splitting tensile strength with structural parameters is derived,which implies its dependence on cell size and critical stress intensity factor of strut materials.

Photocatalytic Activities of TiO_2 Coated on Different Semiconductive SiC Foam Supports

Different semiconductive SiC foam supports were prepared by varying the sintering temperature and atmosphere, and with or without alkaline solution treatment and high temperature oxidation following a macromolecule pyrogenation combined with reaction bonding method. Nano-TiO2 particles were immobilized onto these SiC foam supports by a composite sol-gel method. The phase, surface morphology, the type of conduction and the photocatalytic activity of the TiO2-SiC composite photocatalysts were studied. The TiO2 coated on p-type Si-free SiC support showed the highest photocatalytic efficiency in degradation of 4- aminobenzenesulfonic acid （4-ABS） in aqueous solution as compared to that coated on n-type SiC support and p-type SiC supports with residual Si or Si02 on the surface. The result showed that the TiO2 coatings immobilized on p-type semiconductive SiC foam supports exhibited obviously higher photocatalytic activity in comparison to that coated on n-type SiC foam support. The p-n heterojunctions formed between the p-type SiC supports and n-type TiO2 coatings might be able to account for the better charge separation and transfer as well as the photocatalytic activity of the TiO2-SiC composite photocatalyst.

Unique microstructure and thermal insulation property of a novel waste-utilized foam ceramic

A characteristic CaO-Al2O3-SiO2 based foam ceramic was prepared by melt-foaming with solid wastes as main raw materials.The similarity to sandwich hole wall microstructure of this novel thermal insulating material was presented and the relationships between this unique microstructure and porosity,density,thermal conductivity and strength were discussed.Comparing the measured and theoretical values with that of the traditional foam ceramic,it can be found that,for the matching of fine skeleton with hole wall,this original sandwich structure can reduce thermal conductivity and increase flexural strength effectively.

Rare-earth-niobate high-entropy ceramic foams with enhanced thermal insulation performance

The introduction of porous structures into high-entropy ceramics is expected to further improve its thermal insulation performance.In this work,a series of novel rare-earth-niobate high-entropy ceramic foams((Dy_(0.2)Ho_(0.2)Y_(0.2)Er_(0.2)Yb_(0.2))_(3)NbO_(7))with hierarchical pore structures were prepared by a particle-stabilized foaming method.Atomic-scale analysis reveals that high entropy causes atom displacement and lattice distortion.The high-entropy ceramic foams exhibit high porosity(90.13%-96.13%)and ultralow thermal conductivity(0.0343-0.0592 W/(m·K))at room temperature.High-entropy ceramic foam prepared by a 20 wt%slurry sintered at 1500℃has the porosity of 96.12%and extremely low thermal conductivity of 0.0343 W/(m·K).The existence of walls and secondary pores contributes to reduced thermal conductivity.There is a temperature difference of over 800℃between frontside and backside of the sample under fire resistance test.The research indicates that these as-prepared high-entropy ceramic foams are expected to be promising thermal insulation materials.

Effect of Al powder and silica sol on the structure and mechanical properties of Al_2O_3-ZrO_2 foams

Polymeric sponge replication method is one of the common ways for ceramic foam production. The existence of central triangular voids in the struts results in a decrease of mechanical properties limiting their applications. To remove this defect, some additives consisting of Al powder particles and silica sol are added to ceramic slurries consisting of Al2O3 and ZrO2 （partially stabilized zirconia）. With increasing temperature for pyrolyzing and sintering of raw materials, first the Al powder and then the glass phase which consisted of melted Al2O3, ZrO2 and SiO2 was soaked into hollow struts. SEM investigations showed that the center of foam struts were free of hollows. XRD considerations depicted that a ZrO2 phase with tetragonal crystallographic structure is present in the produced foam which could be the reason of improved toughness and mechanical properties. Compressive strength of foams increased significantly due to the decrease of closed porosity. The Weibull statistical study showed remarkable increasing of the Weibull module and its value for foams with 10, 20 and 30 ppi was 5.91, 6.06 and 6.53 respectively.

Electromagnetically Modified Filtration of Liquid Aluminium With a Ceramic Foam Filter

Conventional Ceramic Foam Filter(CFF)technology has some difficulties in removing fine particulates(e.g.<20 μm)from liquid aluminium.In the present work the filtration behaviour of 30,50 and 80 ppi CFF filters have been studied in the presence of magnetic fields in the range of 0.06-0.2T,produced by induction coils operated at 50 Hz. A feed recipe containing 90 wt.%of the aluminium alloy A356 doped with 10 wt.%A356 composite,containing 15 wt% SiC particles with a particle size ranging from 13 to 23 μm,was used.When the results obtained for the experiments conducted under the influence of a magnetic field where compared with similar reference gravity filtration experiments profound changes were observed in the distribution of particulates within,over and below the filter.Significant improvements in the wetting behaviour of the liquid metal to the CFF surface were also observed.It is believed that a successful change in filtration mechanisms is obtained as a result of the presence of the Lorentz forces and the metal recirculation produced by the magnetic field.The magnitude of the Lorentz forces,i.e.the magnetic pressure,are in the present work discussed in relation to the filtration results,and quantified based on experimental data and validated 2D axial symmetric Finite Element Modelling(FEM).