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Sample records for mullite

  1. Mullite and Mullite Ceramics

    DTIC Science & Technology

    1994-01-01

    highly reactive powder, which allowed us to obtain fully dense material at relatively low sintering temperatures . The mechanical properties (strength...constants a and b of mullites from two different syntheses are shown in the figure as a function of the calcination temperature . Both mullites show a...when they were formed at high temperature unless they were fired long duration. Mullite/zirconia composites prepared by reaction sintering of zircon

  2. Mullite Whiskers and Mullite-whisker Felt

    NASA Technical Reports Server (NTRS)

    Talmy, Inna G.; Haught, Deborah A.

    1993-01-01

    The Naval Surface Warfare Center has developed processes for the preparation of mullite (3(Al2O3)(dot)2(SiO2)) whiskers and mullite-whisker felt. Three patents on the technology were issued in 1990. The processes are based on chemical reactions between AlF3, Al2O3, and SiO2. The felt is formed in-situ during the processing of shaped powdered precursors. It consists of randomly oriented whiskers which are mutually intergrown forming a rigid structure. The microstructure and properties of the felt and size of the whiskers can be modified by varying the amount of Al2O3 in the starting mixture. Loose mullite whiskers can be used as a reinforcement for polymer-, metal-, and ceramic-matrix composites. The felt can be used as preforms for fabricating composite materials as well as for thermal insulation and high temperature, chemically stable filters for liquids (melts) and gases.

  3. Production of mullite fibers

    NASA Technical Reports Server (NTRS)

    Tucker, Dennis S. (Inventor); Sparks, J. Scott (Inventor)

    1991-01-01

    Disclosed here is a process for making mullite fibers wherein a hydrolizable silicon compound and an aluminum compound in the form of a difunctional aluminum chelate are hydrolized to form sols using water and an alcohol with a catalytic amount of hydrochloric acid. The sols are mixed in a molar ratio of aluminum to silicon of 3 to 1 and, under polycondensation conditions, a fibrous gel is formed. From this gel the mullite fibers can be produced.

  4. Making Mullite Fibers By Airgap Wet Spinning

    NASA Technical Reports Server (NTRS)

    Tucker, Dennis S.; Sparks, J. Scott

    1991-01-01

    Proposed process makes continuous mullite fibers retaining structural integrity at temperatures up to and somewhat beyond 1,300 degrees C. Process makes highly pure mullite fibers, without melting and without dangerous solvent.

  5. Synthesis of mullite powders by acrylamide polymerization.

    SciTech Connect

    Sin, A.; Picciolo, J. J.; Lee, R. H.; Gutierrez-Mora, F.; Goretta, K. C.; Energy Technology; INPG-CNRS

    2001-09-01

    Mullite (3Al{sub 2}O{sub 3} {center_dot} 2SiO{sub 2}) ceramics and composites are widely used. Synthesis of mullite powders, especially those that can be readily sintered, remains a focus of much current research. In support of recent efforts to fabricate mullite fibrous monoliths and to use superplastic flow to join ceramics, we have looked to synthesize reactive mullite powders. Recent advances in application of acrylamide polymers to ceramic synthesis offer promise of obtaining large quantities of high-quality powder at relatively low cost. We report here on synthesis from acrylamide monomers of mullite powders of two interesting particle sizes.

  6. Chemical vapor deposition of mullite coatings

    DOEpatents

    Sarin, Vinod; Mulpuri, Rao

    1998-01-01

    This invention is directed to the creation of crystalline mullite coatings having uniform microstructure by chemical vapor deposition (CVD). The process comprises the steps of establishing a flow of reactants which will yield mullite in a CVD reactor, and depositing a crystalline coating from the reactant flow. The process will yield crystalline coatings which are dense and of uniform thickness.

  7. Development program to produce mullite fiber insulation

    NASA Technical Reports Server (NTRS)

    Long, W. G.

    1975-01-01

    Processing methods were utilized to form a mullite fiber-Kaowool felt. The formation of a blended felt using the Rotoformer wet-laying method was successful. Felt products were evaluated for tensile strength, thermal stability, thermal conductivity and structural integrity at 1259 C and 1371 C. Textile processing methods failed in an attempt to form a yarn from staple and multifilament mullite fiber due to fiber damage through mechanical handling. The refractoriness of pure Kaowool ceramic fiber is improved with additions of 30% or greater mullite fiber.

  8. Development of Mullite Substrates and Containers

    NASA Technical Reports Server (NTRS)

    Sibold, J. D.

    1979-01-01

    The mullite-molten silicon interaction was evaluated through fabrication of a series of bodies made with variations in density, alumina-silica ratio, and glass-crystalline ratio. The materials were tested in a sessile drop technique. None of the variations stood up to extended exposure to molten silicon sufficiently to be recommended as a container material. However, directional solidification experiments suggest that, under proper conditions, contamination of the silicon by mullite containers can be minimized. To improve an already good thermal expansion match between mullite and silicon, compositional variations were studied. Altering of the alumina-silica ratio was determined to give a continuously varying thermal expansion. A standard mullite composition was selected and substrates 40 x 4 x .040 inches were fabricated. Slotted substrates of various configurations and various compositions were also fabricated.

  9. Plastic deformation of mullite/yttria composites.

    SciTech Connect

    Ramirez de Arellano Lopez, A.; Melendez-Martinez, J. J.; Routbort, J. L.; Cruse, T. A.; Koritala, R. E.; Goretta, K. C.; Energy Technology; Univ. de Sevilla

    2001-05-01

    Mullite (3Al{sub 2}O{sub 3.2}SiO{sub 2}) based composites have excellent mechanical and thermal properties. The same characteristics that give mullite good resistance to plastic deformation also make its sintering difficult. Yttria is one of the most commonly used additives to reduce sintering temperatures in mullite. Additionally vitreous silicates (Y{sub 2}Si{sub 2}O{sub 7}) could improve ductility. In this work we have used mullite samples with various amounts of Y{sub 2}O{sub 3} (0, 5 and 9 wt.%). Details of processing and characterization of these composites have been the subject of a previous publication. We have compared the ductility of these composites by means of compressive deformation tests at elevated temperatures. Creep tests were performed at temperatures between 1300 and 1400 C, in air, in a stress range of 0.69 to 34.5 MPa.

  10. Phase transformations in xerogels of mullite composition

    NASA Technical Reports Server (NTRS)

    Hyatt, Mark J.; Bansal, Narottam P.

    1988-01-01

    Monophasic and diphasic xerogels have been prepared as precursors for mullite (3Al2O3-2SiO2). Monophasic xerogel was synthesized from tetraethyl orthosilicate and aluminum nitrate nanohydrate and the diphasic xerogel from colloidal suspension of silica and boehmite. The chemical and structural evolutions, as a function of thermal treatment, in these two types of sol-gel derived mullite precursor powders have been characterized by DTA, TGA, X-ray diffraction, SEM and infrared spectroscopy. Monophasic xerogel transforms to an Al-Si spinel from an amorphous structure at approximately 980 C. The spinel then changes into mullite on further heating. Diphasic xerogel forms mullite at approximately 1360 C. The components of the diphasic powder react independently up to the point of mullite formation. The transformation in the monophasic powder occurs rapidly and yields strongly crystalline mullite with no other phases present. The diphasic powder, however, transforms rather slowly and contains remnants of the starting materials (alpha-Al2O3, cristobalite) even after heating at high temperatures for long times (1600 C, 6 hr). The diphasic powder could be sintered to high density but not the monophasic powder in spite of its molecular level homogeneity.

  11. Phase transformations in xerogels of mullite composition

    NASA Technical Reports Server (NTRS)

    Hyatt, Mark J.; Bansal, Narottam P.

    1990-01-01

    Monophasic and diphasic xerogels have been prepared as precursors for mullite (3Al203-2Si02). Monophasic xerogel was synthesized from tetraethyl orthosilicate and aluminum nitrate nanohydrate and the diphasic xerogel from colloidal suspension of silica and boehmite. The chemical and structural evolutions, as a function of thermal treatment, in these two types of sol-gel derived mullite precursor powders have been characterized by DTA, TGA, X-ray diffraction, SEM and infrared spectroscopy. Monophasic xerogel transforms to an Al-Si spinel from an amorphous structure at approximately 980 C. The spinel then changes into mullite on further heating. Diphasic xerogel forms mullite at approximately 1360 C. The components of the diphasic powder react independently up to the point of mullite formation. The transformation in the monophasic powder occurs rapidly and yields strongly crystalline mullite with no other phases present. The diphasic powder, however, transforms rather slowly and contains remnants of the starting materials (alpha-Al203, cristobalite) even after heating at high temperatures for long times (1600 C, 6 hr). The diphasic powder could be sintered to high density but not the monophasic powder in spite of its molecular level homogeneity.

  12. The modulated average structure of mullite.

    PubMed

    Birkenstock, Johannes; Petříček, Václav; Pedersen, Bjoern; Schneider, Hartmut; Fischer, Reinhard X

    2015-06-01

    Homogeneous and inclusion-free single crystals of 2:1 mullite (Al(4.8)Si(1.2)O(9.6)) grown by the Czochralski technique were examined by X-ray and neutron diffraction methods. The observed diffuse scattering together with the pattern of satellite reflections confirm previously published data and are thus inherent features of the mullite structure. The ideal composition was closely met as confirmed by microprobe analysis (Al(4.82 (3))Si(1.18 (1))O(9.59 (5))) and by average structure refinements. 8 (5) to 20 (13)% of the available Si was found in the T* position of the tetrahedra triclusters. The strong tendencey for disorder in mullite may be understood from considerations of hypothetical superstructures which would have to be n-fivefold with respect to the three-dimensional average unit cell of 2:1 mullite and n-fourfold in case of 3:2 mullite. In any of these the possible arrangements of the vacancies and of the tetrahedral units would inevitably be unfavorable. Three directions of incommensurate modulations were determined: q1 = [0.3137 (2) 0 ½], q2 = [0 0.4021 (5) 0.1834 (2)] and q3 = [0 0.4009 (5) -0.1834 (2)]. The one-dimensional incommensurately modulated crystal structure associated with q1 was refined for the first time using the superspace approach. The modulation is dominated by harmonic occupational modulations of the atoms in the di- and the triclusters of the tetrahedral units in mullite. The modulation amplitudes are small and the harmonic character implies that the modulated structure still represents an average structure in the overall disordered arrangement of the vacancies and of the tetrahedral structural units. In other words, when projecting the local assemblies at the scale of a few tens of average mullite cells into cells determined by either one of the modulation vectors q1, q2 or q3 a weak average modulation results with slightly varying average occupation factors for the tetrahedral units. As a result, the real

  13. Corrosion of Mullite by Molten Salts

    NASA Technical Reports Server (NTRS)

    Jacobson, Nathan S.; Lee, Kang N.; Yoshio, Tetsuo

    1996-01-01

    The interaction of molten salts of different Na2O activities and mullite is examined with furnace and burner tests. The more-acidic molten salts form small amounts of Al2O3; the more-basic molten salts form various Na2O-Al2O3-SiO2 compounds. The results are interpreted using the Na2O-Al203-SiO2 ternary phase diagram, and some possible diffusion paths are discussed. The generally higher melting points of Na2O-Al2O3-SiO2 compounds lead to better behavior of mullite in molten salts, as compared to SiO2-protected ceramics such as SiC. Mullite-coated SiC is discussed, and the corrosion behavior is evaluated.

  14. Functionally graded mullite coatings for gas turbines

    NASA Astrophysics Data System (ADS)

    Kulkarni, Tushar

    The next generation of heat exchangers and gas turbines require high performance materials as they need to operate at higher temperatures for higher efficiency. SiC and Si3N4 are promising candidates as they have excellent high temperature properties. However, when used in complex combustion environments found in gas-turbine applications, these materials have two major concerns; namely hot-corrosion and recession. It is well established that environmental barrier coatings (EBC) can be utilized to overcome these limitations. Although chemical vapor deposited (CVD) mullite (3Al2O 3.2SiO2) coatings developed before this study have shown promise in protecting Si-based substrates, there is concern that the silica content within the mullite coating itself might be susceptible to hot-corrosion and recession during long term exposure to corrosive atmospheres containing Na/V salts and water vapor. There is thus strong motivation to substantially reduce or even virtually eliminate the silica component from the surfaces of mullite coatings that are in direct contact with atmospheres containing corrosive oxides and steam. In this study, CVD has been used to deposit mullite coatings with potential promise to protect Si-based ceramics for high temperature applications. The composition of these functionally graded mullite coatings was varied from silica-rich close to the coating/substrate (SiC) interface for coefficient of thermal expansion match to alumina-rich towards the outer surface of the coating. In the process, the highest alumina-rich mullite ever reported has been deposited. The phase transformation and hot-corrosion behavior of the coatings was also investigated in this work. The coatings show immense potential to protect Si-based ceramics. It is expected that these coatings will have very broad impact by enabling gas turbines to operate at higher temperatures leading to improved fuel efficiency and reduced emissions.

  15. Microstructure and Mechanical Properties of Porous Mullite

    NASA Astrophysics Data System (ADS)

    Hsiung, Chwan-Hai Harold

    Mullite (3 Al2O3 : 2 SiO2) is a technologically important ceramic due to its thermal stability, corrosion resistance, and mechanical robustness. One variant, porous acicular mullite (ACM), has a unique needle-like microstructure and is the material platform for The Dow Chemical Company's diesel particulate filter AERIFY(TM). The investigation described herein focuses on the microstructure-mechanical property relationships in acicular mullites as well as those with traditional porous microstructures with the goal of illuminating the critical factors in determining their modulus, strength, and toughness. Mullites with traditional pore morphologies were made to serve as references via slipcasting of a kaolinite-alumina-starch slurry. The starch was burned out to leave behind a pore network, and the calcined body was then reaction-sintered at 1600C to form mullite. The samples had porosities of approximately 60%. Pore size and shape were altered by using different starch templates, and pore size was found to influence the stiffness and toughness. The ACM microstructure was varied along three parameters: total porosity, pore size, and needle size. Total porosity was found to dominate the mechanical behavior of ACM, while increases in needle and pore size increased the toughness at lower porosities. ACM was found to have much improved (˜130%) mechanical properties relative to its non-acicular counterpart at the same porosity. A second set of investigations studied the role of the intergranular glassy phase which wets the needle intersections of ACM. Removal of the glassy phase via an HF etch reduced the mechanical properties by ˜30%, highlighting the intergranular phase's importance to the enhanced mechanical properties of ACM. The composition of the glassy phase was altered by doping the ACM precursor with magnesium and neodymium. Magnesium doping resulted in ACM with greatly reduced fracture strength and toughness. Studies showed that the mechanical properties of the

  16. Spectroscopic characteristics of chromium doped mullite glass-ceramics

    SciTech Connect

    Wojtowicz, A.J.; Meng, W.; Lempicki, A.; Beall, G.H.; Hall, D.W.; Chin, T.C.

    1988-06-01

    Characteristics of chromium doped mullite ceramics are discussed with reference to possible laser applications. Dominant features are attributed to large and inherent spectroscopic inhomogeneity of mullite. The spectroscopic data are analyzed using a generalized McCumber theory. The peak stimulated emission cross section is 0.54 x 10/sup -20/ cm/sup 2/. This, together with preliminary single-pass measurements, indicate that gain for mullite is about 2.6 times smaller than gain for alexandrite.

  17. Development of fine diameter mullite fiber

    NASA Technical Reports Server (NTRS)

    Long, W. G.

    1974-01-01

    Results are presented of a program to develop and evaluate mullite fiber with a mean diameter under two microns. The two micron fiber is produced by a blowing process at room temperature from a low viscosity (10-25 poise) solution. The blown fiber was evaluated for dimensional stability in thermal cycling to 1371 C, and was equivalent to the 5 micron spun B and W mullite fiber. An additive study was conducted to evaluate substitutes for the boron. Three levels of chromium, lithium fluoride, and magnesium were added to the standard composition in place of boron and the fiber produced was evaluated for chemical and dimensional stability in thermal cycling to 1371 C. The magnesium was the most chemically stable, but the chrome additive imparted the best dimensional stability.

  18. Mullite-whisker reinforced molybdenum disilicide composites

    NASA Astrophysics Data System (ADS)

    McFayden, Andre Anthony

    Molybdenum disilicide (MoSisb2) is a potential high temperature structural material. The use of such materials may raise the operating temperatures of heat engines and therefore their efficiencies, leading to fuel savings. Molybdenum disilicide has good oxidation resistance to 1650sp°C and high temperature strength to about 1000sp°C. This work was an attempt to improve the poor room temperature toughness and high temperature creep resistance of this material. Mullite was used as a reinforcement in the form of whiskers. Whiskers may increase the toughness of a matrix by extrinsic mechanisms, while mullite has intrinsically high creep resistance. Mechanical property predictions were made for the proposed composite material. The toughening mechanisms examined were crack bridging, pullout, crack deflection and microcracking. For the bridging model alone, a doubling of the fracture toughness was expected for a 40 percent mullite whisker volume. The creep models examined were the isostress, isostrain, shear-lag and self-consistent scheme. The shear-lag model predicted a factor of five decrease in the creep rate compared to pure MoSisb2. Composites of MoSisb2 containing 0, 20 and 40 volume percent of mullite were fabricated by means of a powder processing route. This involved mixing powders of the component materials, followed by hot-pressing and hot isostatic pressing to form a composite body. Both equi-axed particles and elongated whiskers of mullite were used. The mullite whisker size, powder mixing time, and glass content of the initial MoSisb2 powder were also varied. The resulting materials were subjected to mechanical testing. At room temperature, indentation testing was used to determine the toughness and modulus of the composites. Indented beams were subjected to four-point bending until failure to determine the toughness. The maximum fracture toughness measured was 1.7 MPasurdm, compared to 1.6 MPasurdm for the matrix, with very little variation with

  19. Mullite/Mo interfaces formed by Intrusion bonding

    SciTech Connect

    Bartolome, Jose F.; Diaz, Marcos; Moya, Jose S.; Saiz, Eduardo; Tomsia, Antoni P.

    2003-04-30

    The microstructure and strength of Mo/mullite interfaces formed by diffusion bonding at 1650 C has been analyzed. Interfacial metal-ceramic interlocking contributes to flexural strength of approx. 140 MPa as measured by 3 point bending. Saturation of mullite with MoO2 does not affect the interfacial strength.

  20. Mechanical properties of a porous mullite material

    NASA Technical Reports Server (NTRS)

    Viens, Michael J.

    1991-01-01

    Modulus of rupture specimens were used to determine crack growth parameters of a porous mullite material. Strength testing was performed in ambient and moist environments. The power law crack growth rate parameters n and 1n B in 50 percent relative humidity were found to be 44.98 and 0.94, respectively. The inert strength, fracture toughness, and elastic modulus were also determined and found to be 19 MPa, 055 MPa(m) exp 1/2, and 11.6 GPa, respectively.

  1. Cytotoxicity and genotoxicity property of hydroxyapatite-mullite eluates.

    PubMed

    Kalmodia, Sushma; Sharma, Vyom; Pandey, Alok K; Dhawan, Alok; Basu, Bikramjit

    2011-02-01

    Long-term biomedical applications of implant materials may cause osteolysis, aseptic losing and toxicity. Therefore, we investigated the cytotoxic and genotoxic potential of hydroxyapatite (HA) mullite eluates in L929 mouse fibroblast cells. The spark plasma sintered HA-20% mullite biocomposite (HA20M) were ground using mortar and pestle as well as ball milling. The cells were exposed for 6 h to varying concentrations (10, 25, 50, 75 and 100%) of the eluates of HA-20% mullite (87 nm), HA (171 nm) and mullite (154 nm). The scanning electron microscopy and MTT assay revealed the concentration dependent toxicity of H20M eluate at and above 50%. The analysis of the DNA damaging potential of HA, mullite and HA20M eluates using Comet assay demonstrated a significant DNA damage by HA20M which was largely related to the presence of mullite. The results collectively demonstrate the cytotoxic and genotoxic potential of HA20M eluate in L929 cells is dependent on particle size, concentration and composition.

  2. Growth of textured mullite fibers using polycrystalline precursors

    NASA Astrophysics Data System (ADS)

    Yoon, Wonki

    Fine ceramic oxide fibers are widely used as reinforcements in composites for high temperature applications. The primary goal of this research was to investigate the growth of textured or single crystal oxide fibers by heat treatment of polycrystalline or amorphous, extruded precursor fibers. Mullite was selected for this study due to its excellent chemical stability, creep resistance and strength at high temperatures. Micrographic analysis and in-situ synchrotron X-ray diffraction analysis have been performed on mullite systems in order to study the anisotropic grain growth and the effect of titania additions in mullite. The estimated activation energies from the SEM micrographic particle size analysis were 644.3 kJ/mol and 773.7 kJ/mol for the length and thickness, respectively. An in-situ synchrotron X-ray diffraction microstructure analysis was done with a Curved Image Plate (CIP) detector and the fiber was heat treated in a QLF. The apparent crystallite size showed anisotropy in crystallite growth. Furthermore, a higher growth rate along the [001] direction than the [110] direction was observed. Mullite whiskers were prepared by HF leaching and templated into polycrystalline mullite fibers by extrusion. Textured growth of mullite fibers with elongated grains, aligned along the long-axis of the fibers, was achieved by heat treatment. Repeated heat treatment cycles of a whisker-templated fiber showed a bamboo-like microstructure. It was confirmed by SEM, TEM and optical microscopy (OM) that the growth direction along the fiber length was the [001] direction of orthorhombic mullite.

  3. Development of CVD mullite coatings for Si-based ceramics

    NASA Astrophysics Data System (ADS)

    Auger, Michael Lawrence

    1999-09-01

    To raise fuel efficiencies, the next generation of engines and fuel systems must be lighter and operate at higher temperatures. Ceramic-based materials, which are considerably lighter than metals and can withstand working temperatures of up to 1400sp°C, have been targeted to replace traditional metal-based components. The materials used in combustion environments must also be capable of withstanding erosion and corrosion caused by combustion gases, particulates, and deposit-forming corrodants. With these demanding criteria, silicon-based ceramics are the leading candidate materials for high temperature engine and heat exchanger structural components. However, these materials are limited in gaseous environments and in the presence of molten salts since they form liquid silicates on exposed surfaces at temperatures as low as 800sp°C. Protective coatings that can withstand higher operating temperatures and corrosive atmospheres must be developed for silicon-based ceramics. Mullite (3Alsb2Osb3{*}2SiOsb2) was targeted as a potential coating material due to its unique ability to resist corrosion, retain its strength, resist creep, and avoid thermal shock failure at elevated temperatures. Several attempts to deposit mullite coatings by various processing methods have met with limited success and usually resulted in coatings that have had pores, cracks, poor adherence, and required thermal post-treatments. To overcome these deficiencies, the direct formation of chemically vapor deposited (CVD) mullite coatings has been developed. CVD is a high temperature atomistic deposition technique that results in dense, adherent crystalline coatings. The object of this dissertation was to further the understanding of the CVD mullite deposition process and resultant coating. The kinetics of CVD mullite deposition were investigated as a function of the following process parameters: temperature, pressure, and the deposition reactor system. An empirical kinetic model was developed

  4. Hot Hydrogen Exposure Degradation of the Strength of Mullite

    NASA Technical Reports Server (NTRS)

    Herbell, Thomas P.; Hull, David R.; Garg, Anita

    1996-01-01

    This study deals with the corrosion of near stoichiometric mullite (3Al2O3-2SiO2) by pure dry hydrogen gas. Exposure of the mullite samples was at temperatures of 1050 and 1250 C for times up to 500 hours. Preferential attack of the alumino-silicate glass present in the grain boundaries of the mullite occurred after 125 hours at 1250 C. Hydrogen scrubbing of the SiO2 from the glassy grain boundaries and the mullite grains yielded a porous alumina-rich surface. The room temperature strength increased after short exposure times at 1250 C (up to 125 hours), then decreased by 53 percent after exposure for 500 hours. At 1050 C, all exposure times (25 to 500 hours) decreased the strength. After 500 hours in hydrogen at 1050 C, the room temperature strength of mullite decreased 22 percent. We also observed a rapid 25 percent strength loss after short exposure times at 1050 C. This is attributed to the calcium/hydrogen assisted crystallization of the glassy, grain-boundary phase.

  5. Chromium crystal chemistry mullite-spinel refractory ceramics

    SciTech Connect

    Levy, D.; Gualtieri, A.; Quartieri, S.; Artioli, G.; Valle, M.

    1999-03-15

    A small amount of chromium oxide was added to a mullite-spinel refractory mixture to improve its thermal and mechanical properties. Two different compositions of mullite-spinel refractory were studied to define the crystal structures hosting the chromium cations, and the chromium solubility in spinel (MgAl{sub 2{minus}x}Cr{sub x}O{sub 4}) was determined. Powder X-ray diffraction (XRD), X-ray absorption near edge spectroscopy (XANES), and scanning electron microscopy (SEM) elemental distribution maps were used to determine the chromium crystal chemistry in the system. The observed maximum solubility of chromium in spinel was found at x = 1.2, but the presence of mullite in the mixture caused a strong decrease of this value. The chromium distribution among the crystal phases reflects the different reaction paths of the two samples: a stage involving spinel and melt drives all present chromium in the spinel, while a simultaneous crystallization of spinel-mullite distributes chromium cations between mullite, spinel, and secondary corundum.

  6. Mechanical behavior of mullite-zirconia composites

    NASA Astrophysics Data System (ADS)

    Sahnoune, F.; Saheb, N.

    2010-06-01

    In this work, mechanical properties of mullite-zirconia composites synthesised through reaction sintering of Algerian kaolin, α-Al2O3, and ZrO2 were characterized. Phases present and their transformations were characterized using x-ray diffraction. Hardness H and fracture toughness KIC were measured by Vickers indentation using a Zwick microhardness tester. The flexural strength was measured through three point bending test using an Instron Universal Testing Machine. It was found that the increase of ZrO2 content (from 0 to 32wt.%) decreased the microhardness of the composites from 14 to 10.8 GPa. However, the increase of ZrO2 content (from 0 to 24wt.%) increased the flexural strength of the composites from 142 to 390 MPa then decreased it with further increase of ZrO2 content. Also, the fracture toughness increased from 1.8 to 2.9 MPa.m1/2 with the increase of ZrO2 content from 0 to 32 wt.%; and the rate of the increase decreased at higher fractions of ZrO2 content. The average linear coefficient of thermal expansion (within the range 50 to 1450°C) for samples containing 0 and 16 wt.% ZrO2 sintered at 1600°C for 2 hours was 4.7 x10-6 K-1 and 5.2 x 10-6 K-1 respectively.

  7. Pressureless sintered high-strength mullite from commercial powder

    NASA Astrophysics Data System (ADS)

    Lehman, R. L.; Umezu, Y.

    1992-08-01

    High-strength monolithic mullite ceramics were prepared from commercial-grade power by carefully controlled processing of the powder followed by pressureless sintering at 1700 °C. Mullite powder was mechanically and chemically dispersed, ball milled, and screened prior to slip casting. Specimens were sintered to 97% of theoretical density under pressureless conditions. The furnace ramp and soak schedule was an important variable. Four-point flexural strengths of 250 MPa were achieved, exceeding literature values for pressureless sintering of Baikowski mullite powder.[a] Pore sizes were small and were not strength limiting. Griffith calculations suggest a critical flaw size of 20 μm, in good agreement with the maximum observed crystal size in the microstructure.

  8. Mullite coatings for corrosion protection of silicon carbide

    SciTech Connect

    Mulpuri, R.; Sarin, V.K.

    1995-08-01

    SiC based ceramics have been identified as the leading candidate materials for elevated temperature applications in harsh oxidation/corrosion environments. It has been established that a protective coating can be effectively used to avoid problems with excessive oxidation and hot corrosion. However, to date, no coating configuration has been developed that can satisfy the stringent requirements imposed by such applications. Chemical Vapor Deposited (CVD) mullite coatings due to their desirable properties of toughness, corrosion resistance, and a good coefficient of thermal expansion match with SiC are being investigated as a potential candidate. Since mullite has never been successfully grown via CVD, the thermodynamics and kinetics of its formation were initially established and used as a guideline in determining the initial process conditions. Process optimization was carried out using an iterative process of theoretical analysis and experimental work coupled with characterization and testing. The results of theoretical analysis and the CVD formation characteristics of mullite are presented.

  9. Synthesis of mullite coatings by chemical vapor deposition

    SciTech Connect

    Mulpuri, R.P.; Auger, M.; Sarin, V.K.

    1996-08-01

    Formation of mullite on ceramic substrates via chemical vapor deposition was investigated. Mullite is a solid solution of Al{sub 2}O{sub 3} and SiO{sub 2} with a composition of 3Al{sub 2}O{sub 3}{circ}2SiO{sub 2}. Thermodynamic calculations performed on the AlCl{sub 3}-SiCl{sub 4}-CO{sub 2}-H{sub 2} system were used to construct equilibrium CVD phase diagrams. With the aid of these diagrams and consideration of kinetic rate limiting factors, initial process parameters were determined. Through process optimization, crystalline CVD mullite coatings have been successfully grown on SiC and Si{sub 3}N{sub 4} substrates. Results from the thermodynamic analysis, process optimization, and effect of various process parameters on deposition rate and coating morphology are discussed.

  10. Spectroscopic characteristics of chromium-doped mullite glass-ceramics

    SciTech Connect

    Wojtowicz, A.J.; Meng, W.; Lempicki, A.; Beall, G.H.; Hall, D.W.

    1988-06-01

    The chromium (3+) ion has been widely used as an optical activator in solid-state, tunable laser materials. High octahedral field-stabilization energy and resistance against both oxidation and reduction minimize the dependence of chromium (3+) on the solid-state host matrix. However, the high sensitivity of electronic structure on crystal field strength makes the appropriate choice of host the condition for success. Characteristics of chromium-doped mullite ceramics are discussed with reference to possible laser applications. Dominant features are attributed to large and inherent spectroscopic inhomogeneity of mullite. The spectroscopic data are analyzed using a generalized McCumber theory. The peak-stimulated emission cross section is 0.54 x 10 to the -20 sq cm. This together with preliminary single-pass measurements, indicate that gain for mullite is about 2.6 times smaller than gain for alexandrite.

  11. Synthesis of mullite coatings by chemical vapor deposition

    SciTech Connect

    Mulpuri, R.P.; Sarin, V.K.

    1996-06-01

    Formation of mullite on ceramic substrates via chemical vapor deposition was investigated. Mullite is a solid solution of Al{sub 2}O{sub 3} and SiO{sub 2} with a composition of 3Al{sub 2}O{sub 3}{center_dot}2SiO{sub 2}. Thermodynamic calculations performed on the AlCl{sub 3}{endash}SiCl{sub 4}{endash}CO{sub 2}{endash}H{sub 2} system were used to construct equilibrium chemical vapor deposition (CVD) phase diagrams. With the aid of these diagrams and consideration of kinetic rate limiting factors, initial process parameters were determined. Through process optimization, crystalline CVD mullite coatings have been successfully grown on SiC and Si{sub 3}N{sub 4} substrates. Results from the thermodynamic analysis, process optimization, and effect of various process parameters on deposition rate and coating morphology are discussed. {copyright} {ital 1996 Materials Research Society.}

  12. An exploratory study of the microstructure of mullite fibers

    NASA Technical Reports Server (NTRS)

    Santoro, G. J.; Probst, H. B.; Buzek, B. C.

    1973-01-01

    Mullite fibers of three compositions, ranging from SiO2-rich to Al2O3-rich, were investigated by a number of transmission electron microscopy (TEM) techniques. The fibers were examined in the as-received condition and after subjecting them to thermal exposures as high as 142 C. The investigative techniques used included direct TEM of microtomed sections of mounted fibers and TEM of replicas of polished, chemically etched, and cathodically etched fibers. In addition, X-ray diffraction line broadening analyses was used for determining average crystallite size. A preliminary description of the microstructure of mullite fibers is given.

  13. Development of CVD Mullite Coatings for SiC Fibers

    SciTech Connect

    Sarin, V.K.; Varadarajan, S.

    2000-03-15

    A process for depositing CVD mullite coatings on SiC fibers for enhanced oxidation and corrosion, and/or act as an interfacial protective barrier has been developed. Process optimization via systematic investigation of system parameters yielded uniform crystalline mullite coatings on SiC fibers. Structural characterization has allowed for tailoring of coating structure and therefore properties. High temperature oxidation/corrosion testing of the optimized coatings has shown that the coatings remain adherent and protective for extended periods. However, preliminary tests of coated fibers showed considerable degradation in tensile strength.

  14. Study of the Crack Propagation in Alumina Mullite Zirconia and Mullite Zirconia Composites Obtained by Reaction Sintering

    NASA Astrophysics Data System (ADS)

    Gheldane, Farid; Souya, Lotfi Ain; Bouras, Seddik

    2011-12-01

    We studied resistance to the propagation of cracks on composites mullite zirconia and mullite alumina zirconia using the flexure tests SENB. The second nuance presents an R-curve effect interesting compared to mullite zirconia where the effect hardly appears. For understanding the mechanisms toughening, we used the SEM observations which showed that resistance to the propagation is mainly connected to the cracks bridging. The crack lengths are often calculated on the basis of compliance evolution during the R-curve tests. We show that the cracks lengths calculated starting from compliance underestimate in an important way the crack true values. The not fissured ligaments, responsible of the bridging mechanisms, are indeed also the cause of the error induced on compliance.

  15. Method for thermally spraying crack-free mullite coatings on ceramic-based substrates

    NASA Technical Reports Server (NTRS)

    Spitsberg, Irene T. (Inventor); Wang, Hongyu (Inventor); Heidorn, Raymond W. (Inventor)

    2000-01-01

    A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.

  16. Method for thermally spraying crack-free mullite coatings on ceramic-based substrates

    NASA Technical Reports Server (NTRS)

    Spitsberg, Irene T. (Inventor); Wang, Hongyu (Inventor); Heidorn, Raymond W. (Inventor)

    2001-01-01

    A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.

  17. The Final Proceedings for Mullite and Mullite Ceramics Held in Irsee, Germany on 7-9 September 1994

    DTIC Science & Technology

    1996-01-01

    rev min’ for 30 min and the the mullite phase. Thus, B20 3 significantly decreased particles in suspension were used for seeding. The the temperature...dimensions and geometry . For example, the diffu- system, aluminum borate (9A1203ŖB 20 3) forms sion distance from the mullite fibres of Richards et first in a...Preparation of crystallites was carried out by bottom, O k mt. conventional crushing with propanol in an agate mortar and transferring the suspension to carbon

  18. Thermal cycling characteristics of plasma synthesized mullite films

    SciTech Connect

    Monteiro, O.R.; Hou, P.Y.; Brown, I.G.

    1997-12-01

    The authors have developed a plasma-based technique for the synthesis of mullite and mullite-like films on silicon carbide substrate material. The method, which they refer to as MePIIID (for Metal Plasma Immersion Ion Implantation and Deposition), uses two vacuum arc plasma sources and simultaneous pulse biasing of the substrate in a low pressure oxygen atmosphere. The Al:Si ratio can be controlled via the separate plasma guns, and the film adhesion, structure and morphology can be controlled via the ion energy which in turn is controlled by the pulse bias voltage. The films are amorphous as-deposited, and crystalline mullite is formed by subsequent annealing at 1000 C for 2 hours in air. Adhesion between the aluminum-silicon oxide film and the substrate increases after this first annealing. They have tested the behavior of films when subjected to repetitive thermal cycling between room temperature and 1100 C, and found that the films retain their adhesion and quality. Here they review the plasma synthesis technique and the characteristics of the mullite films prepared in this way, and summarize the status of the thermal cycling experiments.

  19. New generation of plasma-sprayed mullite coatings on silicon carbide

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Miller, Robert A.; Jacobson, Nathan S.

    1995-01-01

    Mullite is promising as a protective coating for silicon-based ceramics in aggressive high-temperature environments. Conventionally plasma-sprayed mullite on SiC tends to crack and debond on thermal cycling. It is shown that this behavior is due to the presence of amorphous mullite in the conventionally sprayed mullite. Heating the SiC substrate during the plasma spraying eliminated the amorphous phase and produced coatings with dramatically improved properties. The new coating exhibits excellent adherence and crack resistance under thermal cycling between room temperature and 1000 to 1400 C. Preliminary tests showed good resistance to Na2CO3-induced hot corrosion.

  20. Sintered mullite from fly ash and alumina powder mixture

    SciTech Connect

    Sun Junmin; Li Yuqiong

    1997-12-31

    Fly ash generated in coal-fired power plants is produced mainly from the aluminosilicates in coal powder. To utilize fly ash in making refractory products, a study of the synthesis of mullite from fly ash and alumina powder mixture was initiated. A series of sintered products designated M70, M60, M50 was achieved with Al{sub 2}O{sub 3} contents in the mixtures being 70%, 60%, 50%, respectively. Properties of M70 and M60 are comparable to those of commercial mullite. Though the M50 cannot be used as superior refractory material, it has great potential in making ceramic kiln tools to replace the traditional clayey products.

  1. Copper ions removal from water using functionalized carbon nanotubes–mullite composite as adsorbent

    SciTech Connect

    Tofighy, Maryam Ahmadzadeh; Mohammadi, Toraj

    2015-08-15

    Highlights: • CNTs–mullite composite was prepared via chemical vapor deposition (CVD) method. • The prepared composite was modified with concentrated nitric acid and chitosan. • The modified CNTs–mullite composites were used as novel adsorbents. • Copper ion removal from water by the prepared adsorbents was performed. • Langmuir and Freundlich isotherms and two kinetic models were applied to fit the experimental data. - Abstract: Carbon nanotubes–mullite composite was synthesized by direct growth of carbon nanotubes on mullite particles via chemical vapor deposition method using cyclohexanol and ferrocene as carbon precursor and catalyst, respectively. The carbon nanotubes–mullite composite was oxidized with concentrated nitric acid and functionalized with chitosan and then used as a novel adsorbent for copper ions removal from water. The results demonstrated that modification with concentrated nitric acid and chitosan improves copper ions adsorption capacity of the prepared composite, significantly. Langmuir and Freundlich isotherms and two kinetic models were applied to fit the experimental data. The carbon nanotubes growth on mullite particles to form the carbon nanotubes–mullite composite with further modification is an inherently safe approach for many promising environmental applications to avoid some concerns regarding environment, health and safety. It was found that the modified carbon nanotubes–mullite composite can be considered as an excellent adsorbent for copper ions removal from water.

  2. Development of fibrous monoliths from mullite, alumina, and zirconia powders

    SciTech Connect

    Polzin, B. J.; Cruse, T. A.; Singh, D.; Picciolo, J. J.; Tsaliagos, R. N.; Phelan, P. J.; Goretta, K. C.

    2000-06-29

    Fibrous monoliths (FMs) based on mullite combined with Al{sub 2}O{sub 3} and Y{sub 2}O{sub 3}-stabilized ZrO{sub 2} have been produced. These FMs incorporate duplex cells in which compressive residual stresses were engineered into the surfaces of the cells. The residual stresses should increase average cell strength, which may allow them to achieve mechanical properties comparable to those of Si{sub 3}N{sub 4}/BN FMs. The expected residual stresses have been calculated, and data on sintering and thermal expansion have been gathered. Prototype FMs were produced and their microstructure examined.

  3. Silicon carbide whisker-zirconia reinforced mullite and alumina ceramics

    DOEpatents

    Becher, Paul F.; Tiegs, Terry N.

    1987-01-01

    The flexural strength and/or fracture toughness of SiC whisker-reinforced composites utilizing mullite or alumina as the matrix material for the composite are increased by the addition of zirconia in a monoclinic or tetragonal phase to the matrix. The zirconia addition also provides for a lower hot-pressing temperature and increases the flexural strength and/or fracture toughness of the SiC whisker-reinforced composites over SiC whisker-reinforced composites of the similar matrix materials reinforced with similar concentrations of SiC whiskers.

  4. Development of low-thermal expansion mullite bodies

    NASA Technical Reports Server (NTRS)

    Leipold, M. H.; Sibold, J. D.

    1982-01-01

    A series of ceramic compositions based on variations in the crystal-glass ratio of a mullite body were developed. The thermal expansion of these compositions varies from 3.7 to 5.0 x 10 to the -6th/deg C to 800 C. The materials are particularly useful for applications involving silicon, in that an identical thermal expansion is available. The high-temperature creep data for the lower-expansion compositions are inferior as a result of their higher glass contents. Raw material sources and fabrication procedures for specific compositions are given.

  5. Mullite+CAS Bond Coat for Environmental Barrier Coatings for Si-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Opila, Elizabeth J.; Gray, Hugh R. (Technical Monitor)

    2002-01-01

    Current environmental barrier coatings (EBCs) for silicon-based ceramics consist of a bond coat and a top coat. Mullite bond coat modified by adding low CTE glass ceramics, such as BSAS (xBaO.1xSrO.Al2O3.2SiO2) or CAS (CaO.Al2O3.2SiO2), was developed in the NASA Enabling Propulsion Materials (EPM) Program. EBCs based on mullite+CAS bond coat were characterized using high steam thermal cycling test and high steam isothermal thermogravemitry (TGA) at 1225 C - 13,000 C. The Mullite+CAS bond coat showed far superior durability compared to mullite bond coat, due to enhanced crack resistance. A BSAS top coat provided further improved durability compared to EBCs with a yttria-stabilized zirconia (YSZ) top coat. Still further improvement in the durability was achieved by adding a silicon bond coat between the mullite and the substrate. However, the silicon/mullite+CAS/BSAS EBC showed inferior long-term durability compared to the current state-of-the art EBC (silicon/mullite+BSAS/BSAS EBC), presumably due to the higher CAS-silica chemical reactivity.

  6. Crystallization of mullite from kaolin according to optical spectroscopy of impurity ions

    NASA Astrophysics Data System (ADS)

    Igo, A. V.

    2017-06-01

    The luminescence spectra of Cr3+ and Eu3+ ions embedded in mullite ceramic samples are studied. The samples were annealed at temperatures from 600 to 1200°C. Beginning at a temperature of 890°C, the spectra demonstrated the presence of a newly formed crystal phase. At temperatures from 920 to 1200°C, the crystalline form manifested itself as a stable mullite phase. A temperature of 920°C corresponded to a sharp change in the symmetry of the crystal field around Eu3+ (phase transition). The parameters of the spectral lines of ions were used to estimate the mullite crystal-lattice disorder and the residual deformations in ceramic samples. The spread of the mullite crystal-lattice parameter is determined as |Δ a/a| ≈ 0.028 and is independent of the annealing temperature.

  7. Vitre-graf Coating on Mullite. Low Cost Silicon Array Project: Large Area Sillicon Sheet Task

    NASA Technical Reports Server (NTRS)

    Rossi, R. C.

    1979-01-01

    The processing parameters of the Vitre-Graf coating for optimal performance and economy when applied to mullite and graphite as substrates were presented. A minor effort was also performed on slip-cast fused silica substractes.

  8. Corrosion protection of SiC-based ceramics with CVD mullite coatings

    SciTech Connect

    Auger, M.L.; Sarin, V.K.

    1997-12-01

    For the first time, crystalline mullite coatings have been chemically vapor deposited on SiC substrates to enhance its corrosion and oxidation resistance. Thermodynamic and kinetic considerations have been utilized to produce mullite coatings with a variety of growth rates, compositions, and morphologies. The flexibility of processing can be exploited to produce coated ceramics with properties tailored to specific applications and varied corrosive environments.

  9. The development of chemically vapor deposited mullite coatings for the corrosion protection of SiC

    SciTech Connect

    Auger, M.; Hou, P.; Sengupta, A.; Basu, S.; Sarin, V.

    1998-05-01

    Crystalline mullite coatings have been chemically vapor deposited onto SiC substrates to enhance the corrosion and oxidation resistance of the substrate. Current research has been divided into three distinct areas: (1) Development of the deposition processing conditions for increased control over coating`s growth rate, microstructure, and morphology; (2) Analysis of the coating`s crystal structure and stability; (3) The corrosion resistance of the CVD mullite coating on SiC.

  10. Compressive Creep and Thermophysical Performance of Mullite Refractories

    SciTech Connect

    Hemrick, JG

    2002-04-01

    Compressive creep testing of ten commercially available mullite refractories was performed at 1300-1450 C and at static stresses between 0.2-0.6 MPa. These refractories were examined because they are used in borosilicate glass furnace crowns and superstructures along with in sidewall applications. Additionally, despite their high cost ({approx}$500/ft{sup 3}) they are cheaper than other refractories such as chrome alumina ({approx}$3000/ft{sup 3}) or fusion-cast alumina ({approx}900/ft{sup 3}) which are used as replacements for traditional silica refractories in harsh oxy-fuel environments. The corrosion resistances of these ten materials were also evaluated. In addition, measurements were made that tracked their dimensional stability, phase content, microstructure, and composition as a function of temperature and time. The techniques used for these characterizations and their respective analyses are described. An intent of this study was to provide objective and factual results whose interpretations were left to the reader.

  11. Sintering of Mullite-Containing Materials: I, Effect of Composition

    SciTech Connect

    Sacks, Michael D.; Pask, Joseph A.

    1982-02-01

    Sintering behavior of mullite-containing powders was studied over a range of chemical compositions (Al203/Si02 ratio). Densification measurements were made for both liquid phase-containing and solid state systems. Small amounts of liquid phase were observed to have a significant effect on densification rate. A linear relationship was obtained between the percent of theoretical density and the logarithm of time for compositions in the range 73-75 wt% Al2O3. Currently available models for intermediate stage sintering kinetics were considered to be inadequate for these systems. Lastly, grain boundary transport or diffusion appeared to be the primary mechanism of densification.

  12. Production of continuous mullite fiber via sol-gel processing

    NASA Technical Reports Server (NTRS)

    Tucker, Dennis S.; Sparks, J. Scott; Esker, David C.

    1990-01-01

    The development of a continuous ceramic fiber which could be used in rocket engine and rocket boosters applications was investigated at the Marshall Space Flight Center. Methods of ceramic fiber production such as melt spinning, chemical vapor deposition, and precursor polymeric fiber decomposition are discussed and compared with sol-gel processing. The production of ceramics via the sol-gel method consists of two steps, hydrolysis and polycondensation, to form the preceramic, followed by consolidation into the glass or ceramic structure. The advantages of the sol-gel method include better homogeneity and purity, lower preparation temperature, and the ability to form unique compositions. The disadvantages are the high cost of raw materials, large shrinkage during drying and firing which can lead to cracks, and long processing times. Preparation procedures for aluminosilicate sol-gel and for continuous mullite fibers are described.

  13. Processing of Rigidized Rei-mullite Insulative Composites

    NASA Technical Reports Server (NTRS)

    Gebhardt, J. J.; Gorsuch, P. D.; Braun, M. A.

    1973-01-01

    Systematic development and evaluation of ceramic fiber Mullite are summarized: (1) Major reductions in thermal protection system weight have been achieved by reducing the density and thermal conductivity of the insulation by 20 and 25 percent; (2) already adequate structural margins-of-safety have been greatly enhanced by increasing the tensile strength and strain-to-failure capabilities of the insulation by factors of 3 and 2; (3) cost effectiveness has been increased through the achievement of a high degree of uniformity and reproducibility of properties and through process simplification and binder modifications; and (4) maximization of multimission capability at surface temperatures of 1644 K has been achieved through firing cycle adjustments and the development of a material with high dimensional stability.

  14. Porous acicular mullite obtained by controlled oxidation of waste molybdenum disilicide

    SciTech Connect

    Bučevac, Dušan; Dapčević, Aleksandra; Maksimović, Vesna

    2014-02-01

    Highlights: • Waste MoSi{sub 2} heating elements were used as starting material for fabrication of porous acicular mullite. • Calcined MoSi{sub 2} powder was source of SiO{sub 2} and pore former at the same time. • Porous acicular mullite is promising material for filtration of diesel engine exhaust. • Samples with decent mechanical integrity and porosity of more than 60% were fabricated. - Abstract: Porous acicular mullite was fabricated by using waste MoSi{sub 2} heating element and Al{sub 2}O{sub 3}. Careful calcination of the pulverized heating element led to the formation of a mixture of MoO{sub 3} and amorphous SiO{sub 2}. This mixture was employed as both SiO{sub 2} precursor and pore former. The oxidation of MoSi{sub 2} and mullite formation were studied. The effect of fabrication temperature on phase composition, porosity, grain morphology, and compressive strength of sintered mullite was examined. Pure mullite with porosity of more than 60% and compressive strength of ∼20 MPa was obtained at temperature as low as 1300 °C. The microstructure consisted of elongated, rectangular, prism-like grains which are known to be effective in filtration of diesel engine exhaust. The increase in sintering temperature caused the change of grain morphology and reduction in compressive strength.

  15. Ion Insertion on the Crystal Structure, Photoluminescence, and Dielectric Properties of o-Mullite Nanoparticles

    NASA Astrophysics Data System (ADS)

    Sanad, M. M. S.; Rashad, M. M.; Abdel-Aal, E. A.; El-Shahat, M. F.; Powers, K.

    2014-09-01

    Nanocrystalline Gd3+-doped Gd x Al6- x Si2O13 mullite powders with x from 0.005 to 0.025 have been synthesized via a facile coprecipitation technique. X-ray diffraction results revealed that o-mullite was detected as the major phase for x = 0.0 to 0.01, whereas corundum α-Al2O3 was predominant for x = 0.025. It was found that the volume of the mullite unit cell increased with Gd3+ ion incorporation. Differential scanning calorimetry thermograms evinced that the exothermic peak temperature of mullite shifted to lower values with Gd3+ ion insertion. Transmission electron microscopy observations of pure mullite nanoparticles displayed orthorhombic-like shapes. Meanwhile, at 0.5% Gd3+ ion content, the mullite particles exhibited platelet-like shapes, which distorted into spheroidal-like crystals at high Gd3+ ion contents (1% and 2.5%). The photoluminescence spectra indicated that the intensity of the emission spectra improved considerably with Gd3+ ion doping. On the other hand, dielectric measurements of sintered samples showed that the maximum dielectric loss values were 1.7 and 1.4 at 1.5 MHz and 1.5 GHz, respectively, with 2.5% Gd3+ ion content.

  16. Ordered vacancy distribution in 2/1 mullite: a superspace model.

    PubMed

    Klar, Paul B; de la Pinta, Noelia; Lopez, Gabriel A; Etxebarria, Iñigo; Breczewski, Tomasz; Madariaga, Gotzon

    2017-06-01

    A mullite single crystal with composition Al4.84Si1.16O9.58 (2) exhibiting sharp satellite reflections was investigated by means of X-ray diffraction. For the refinement of a superspace model in the superspace group Pbam(α0½)0ss different scale factors for main and satellite reflections were used in order to describe an ordered mullite structure embedded in a disordered polymorph. The ordered fraction of the mullite sample exhibits a completely ordered vacancy distribution and can be described as a block structure of vacancy blocks (VBs) that alternate with vacancy-free blocks (VFBs) along a and c. The incommensurate nature of mullite originates from a modulation of the block size, which depends on the composition. The displacive modulation is analyzed with respect to the vacancy distribution and a possible Al/Si ordering scheme is derived, although the measurement itself is not sensitive to the Al/Si distribution. An idealized, commensurate approximation for 2/1 mullite is also presented. Comparison of the ordered superspace model with different preceding models reconciles many key investigations of the last decades with partly contradicting conclusions, where mullite was usually treated as either ordered or disordered instead of considering simultaneously different states of order.

  17. A study on the phytotoxicity of nano mullite and metal-amended nano mullite on mung bean plants.

    PubMed

    Dey, Anindita; Bagchi, Biswajoy; Das, Sukhen; Basu, Ruma; Nandy, Papiya

    2011-06-01

    The presence of engineered nanoparticles is continuously increasing in our environment and causing potential risks to the ecosystem. Researchers from various fields report many articles on the effects of different nanoparticles on plants, animals and microorganisms. Here we have studied for the first time the effect of nano mullite (NMu) and their metal- amended derivatives on the growth of mung bean plants. Results shows that the metal- amended NMu exerts adverse effects on the growth and biomass production of plants compared to NMu. For toxicity studies, we measured the germination index and relative root elongation, while leakage of electrolytes and root oxidizability were measured to study the effect of NMu on mung bean seeds and seedling tissues. Translocation and accumulation of NMu within different parts of the plant body were proved by elemental analysis of dried plant samples.

  18. Compressive creep of mullite containing Y{sub 2}O{sub 3}.

    SciTech Connect

    de Arellano-Lopez, A. R.; Melendez-Martinez, J. J.; Cruse, T. A.; Koritala, R. E.; Routbort, J. L.; Goretta, K. C.

    2002-10-09

    Compressive creep of mullite and mullite containing 5 and 9 wt% Y{sub 2}O{sub 3} has been investigated in the temperature range of 1300-1400 C over stresses between {approx}0.6 and 40 MPa in air. The nominally single-phase mullite deforms by diffusional flow with a stress exponent of 1 (for higher stresses) and an activation energy of 385{+-}20 kJ/mol. It is likely that the rate-controlling diffusing species is oxygen. Creep of the Y{sub 2}O{sub 3}-containing specimens was similar to that of the pure mullite at 1300 C. Near and above the temperature at which melting was observed in DTA, the Y{sub 2}O{sub 3}-containing specimens crept significantly faster than the pure mullite. Models of creep of materials that contain a glass phase can explain most, but not all, of the observed behavior. Creep rates were not significantly affected by partial crystallization of the glass to Y{sub 2}Si{sub 2}O{sub 7}, but the crystallized specimens exhibited cavitation at larger strains.

  19. Rheology Control of Highly Concentrated Mullite Suspensions with Polyelectrolyte for Robocasting

    SciTech Connect

    STUECKER,JOHN N.; CESARANO III,JOSEPH; HIRSCHFELD,DEIDRE A.

    2000-06-12

    Highly concentrated, aqueous mullite slurries were characterized and stabilized at solids concentrations as high as 60 vol% using less than 2 vol% of an organic polyelectrolyte dispersant. The maximum slurry concentration (60 vol%) is within 3 vol% of the maximum consolidated density of the slurry. The slurries were subsequently cast into parts by a solid freeform fabrication technique termed robocasting and characterized. Sedimentation analysis and viscometry provided the means of slurry characterization, while knowledge of polyelectrolyte and interparticle forces was used to interpret the sedimentation and viscometry data. Through proper control of slurry conditions, pseudoplastic mullite slurries were fabricated for use in the robocasting process. The slurries were robocast at 52 vol% solids and subsequently yielded a green density of 55 vol%. Fired densities of the robocasted slurries were high, with mullite >96% dense at 1,650 C.

  20. FUNCTIONALLY GRADED ALUMINA/MULLITE COATINGS FOR PROTECTION OF SILICON CARBIDE CERAMIC COMPONENTS FROM CORROSION

    SciTech Connect

    Prof. Stratis V. Sotirchos

    2001-02-01

    The main objective of this research project was the formulation of processes that can be used to prepare compositionally graded alumina/mullite coatings for protection from corrosion of silicon carbide components (monolithic or composite) used or proposed to be used in coal utilization systems (e.g., combustion chamber liners, heat exchanger tubes, particulate removal filters, and turbine components) and other energy-related applications. Since alumina has excellent resistance to corrosion but coefficient than silicon carbide, the key idea of this project has been to develop graded coatings with composition varying smoothly along their thickness between an inner (base) layer of mullite in contact with the silicon carbide component and an outer layer of pure alumina, which would function as the actual protective coating of the component. (Mullite presents very good adhesion towards silicon carbide and has thermal expansion coefficient very close to that of the latter.)

  1. Environmental testing of REI-Mullite thermal protection system for the space shuttle orbiter

    NASA Technical Reports Server (NTRS)

    Gluck, R.; Romano, R.; Thibault, H.

    1973-01-01

    Tests conducted to evaluate performances in the natural environments of salt spray, humidity, rain, vacuum, and cryogenic temperatures have shown the ceramic mullite fiber is completely compatible and that these environments have no adverse effects on subsequent mission performance. Rain erosion testing has indicated a damage threshold that must be accounted for in the final design. Tests conducted to evaluate the performance of ceramic mullite fiber to induced acoustic, re-entry, and structural load environments again have shown complete capability to fulfill mission environments. Although minor cracking of the sidewall coating was seen to occur throughout the induced environment test program, sidewall designs configured to provide increased flexibility have been successfully tested.

  2. Environment-oriented low-cost porous mullite ceramic membrane supports fabricated from coal gangue and bauxite.

    PubMed

    Lü, Qikai; Dong, Xinfa; Zhu, Zhiwen; Dong, Yingchao

    2014-05-30

    Porous mullite ceramic supports for filtration membrane were successfully fabricated via recycling of coal gangue and bauxite at sintering temperatures from 1100 to 1500°C with corn starch as pore-forming agent. The dynamic sintering behaviors, phase evolution, shrinkage, porosity and pore size, gas permeation flux, microstructure and mechanical property were systematically studied. A unique volume-expansion stage was observed at increased temperatures from 1276 to 1481°C caused by a mullitization-crystal-growth process. During this stage, open porosity increases and pore size distributions broaden, which result in a maximum of nitrogen gas flux at 1400°C. The X-ray diffraction results reveal that secondary mullitization took place from 1100°C and the major phase is mullite with a content of ∼84.7wt.% at 1400°C. SEM images show that the as-fabricated mullite supports have a porous microstructure composed of sintered glassy particles embedded with inter-locked mullite crystals, which grew gradually with increasing temperature from rod-like into blocky-like morphologies. To obtain mullite membrane supports with sufficient porosity and acceptable mechanical strength, the relationship between porosity and mechanical strength was investigated, which was fitted using a parabolic equation. Copyright © 2014 Elsevier B.V. All rights reserved.

  3. Recycling of Coal Fly Ash for the Fabrication of Porous Mullite/Alumina Composites

    PubMed Central

    Kim, Kyu H.; Yoon, Seog Y.; Park, Hong C.

    2014-01-01

    Coal fly ash with the addition of Al2O3 was recycled to produce mullite/alumina composites and the camphene-based freeze casting technique was processed to develop a controlled porous structure with improved mechanical strength. Many rod-shaped mullite crystals, formed by the mullitization of coal fly ash in the presence of enough silicate, melt. After sintering at 1300–1500 °C with the initial solid loadings of 30–50 wt.%, interconnected macro-sized pore channels with nearly circular-shaped cross-sections developed along the macroscopic solidification direction of camphene solvent used in freeze casting and a few micron-sized pores formed in the walls of the pore channels. The macro-pore size of the mullite/alumina composites was in the range 20–25 μm, 18–20 μm and 15–17 μm with reverse dependence on the sintering temperature at 30, 40 and 50 wt.% solid loading, respectively. By increasing initial solid loading and the sintering temperature, the sintered porosity was reduced from 79.8% to 31.2%, resulting in an increase in the compressive strength from 8.2 to 80.4 MPa. PMID:28788172

  4. Mullite-supported Rh catalyst: a promising catalyst for the decomposition of N2O propellant.

    PubMed

    Zhao, Xiangyun; Cong, Yu; Lv, Fei; Li, Lin; Wang, Xiaodong; Zhang, Tao

    2010-05-07

    A mullite-supported Rh catalyst with an unusual crystalline structure in favour of high-temperature reactions was applied for the first time to the catalytic decomposition of N(2)O propellants, and has shown a promising initial activity and thermal stability.

  5. Neutron-diffraction study up to 1600 °C of 3:2 mullite

    NASA Astrophysics Data System (ADS)

    Brunauer, G.; Frey, F.; Boysen, H.; Schneider, H.; Fischer, P.; Hansen, Th.; Többens, D.; Ehrenberg, H.

    Neutron-diffraction studies were carried out on pure and Cr-doped 3:2 (`sinter') mullite. To learn about structure-property relationships of this refractory material, thermal expansion coefficients and structural parameters were determined by in situ high-temperature investigations. Neutron experiments were performed at the powder diffractometers D2B/ILL, E9/HMI, and HRPT/PSI. All data gave a rather uniform picture of the thermal expansion coefficients: a linear behaviour below 1000 °C and significantly increased (mean) expansion between 1000 and 1600 °C. There is a marked anisotropy of the highest values along the b-axis of the orthorhombic mullite structure. Concerning the structural parameters and the derived bond lengths, there is an expansion of the Al1O6 octahedra, whereas the cross-linking Al2SiO4 tetrahedra stay more or less rigid, but may slightly rotate. Thus a major expansion along the b direction may be qualitatively understood. A structural discussion, however, is affected by the presence of disorder in mullite, in particular in Cr-doped mullite, as it is also reflected by the presence of a modulated diffuse background in the powder patterns.

  6. Toughness-curve behavior of some alumina-mullite composites

    NASA Astrophysics Data System (ADS)

    Khan, Ajmal

    Toughness-curve (T-curve) behavior of composites of polycrystalline, spherical, alumina agglomerates dispersed throughout fine-grained, constant toughness, 50/50 vol.% alumina-mullite matrices has been studied by the indentation-strength method. A coarse-grained version of a composite containing 30 vol.%, 55 mum diameter, agglomerates was shown to exhibit a pronounced T-curve. In comparison, the microstructural end-members of the composite, 100% AM50 matrix and 100% alumina, exhibited an invariant toughness and a moderate T-curve, respectively. Rule-of-mixtures calculations for the composite indicated that the most distinct T-curve mechanism observed, intra-agglomerate grain bridging, could only account for a fraction of the measured toughening. To unambiguously identify the predominant toughening mechanism, a fine-grained version of the composite in which the intra-agglomerate grain bridging mechanism was eliminated by reducing the grain size to a constant toughness level, was also studied. This composite exhibited a T-curve that rose over the same length scale as its coarse-grained counterpart, but to a somewhat lower saturation value. This T-curve is best explained as deriving predominantly from matrix frictional tractions, with possibly some additional contribution from matrix elastic bridging ligaments: both toughening mechanisms apparently being activated by the agglomerates. These mechanisms are proposed to account for the majority of the toughening exhibited by the coarse-grained composite, with the remaining toughening increment deriving from intra-agglomerate grain bridging. A systematic study of the effect of alumina agglomerate vol.% at a fixed diameter, and agglomerate diameter at a fixed vol.%, on indentation-strength response, was also conducted. Results for agglomerate content increasing from 15 to 45 vol.% were consistent with a concomitant T-curve shift towards longer crack lengths and greater long-crack toughness values. Results for agglomerate

  7. Reuse of spent FCC catalyst, waste serpentine and kiln rollers waste for synthesis of cordierite and cordierite-mullite ceramics.

    PubMed

    Ramezani, A; Emami, S M; Nemat, S

    2017-09-15

    Spent fluid catalytic cracking (FCC) was gathered from several petrochemical plants and calcined in a rotary furnace between 1000 and 1100°C in order to remove sulphur and hydrocarbon based impurities. Calcining process on FCC led to formation of AlVO4 ceramic phase, so converted the hazardous waste to non-hazardous applicable raw material. In this study, two ceramic bodies as cordierite and cordierite-mullite were synthesized with calcined spent FCC, waste serpentine, kiln rollers waste and high grade kaolin as raw materials. The XRD results showed that the cordierite and cordierite-mullite were synthesized successfully so that 96.4% of F1 (cordierite) sample fired at 1400°C was cordierite phase and F2 (cordierite-mullite) sample fired at 1450°C was completely cordierite and mullite phases. The synthesized cordierite and cordierite-mullite samples had lower porosity values and coefficient of thermal expansion (CTE) than similar industrial products. The negative CTE value that obtained from the cordierite sample up to 800°C is favorable for some applications. The considerable results of the synthesized cordierite and cordierite-mullite from this work present cost reduction of the two ceramic bodies production and may help to solve the environmental problems with the use of three waste sources in large scales. Copyright © 2017 Elsevier B.V. All rights reserved.

  8. Fabrication of Ordered Mullite Nanowhisker Array with Surface Enhanced Raman Scattering Effect

    PubMed Central

    Yang, Tao; Wang, Enhui; Wang, Fuqiang; Chou, Kuochih; Hou, Xinmei

    2015-01-01

    Mullite nanowhiskers are prepared by a facile technique at low temperature using mica and AlF3 as raw material. Mica acts as reactant as well as substrate. By controlling the reaction temperature and holding time, the mullite nanowhisker array with uniform morphology is obtained. The nanowhisker array possesses Al-rich single crystalline with an average of 80 nm in diameter and 20 μm in length. After decorated with Au nanoparticles, the array exhibits high surface enhanced Raman scattering (SERS) activity with an SERS enhancement factor (EF) of 1.35 × 109. It also remains good SERS signal detection with a relative standard deviation of 7.33% under corrosion condition. PMID:25867250

  9. Phase Composition and Microstructural Responses of Graded Mullite/YSZ Coatings Under Water Vapor Environments

    NASA Astrophysics Data System (ADS)

    Garcia, E.; Mesquita-Guimarães, J.; Miranzo, P.; Osendi, M. I.; Cojocaru, C. V.; Wang, Y.; Moreau, C.; Lima, R. S.

    2011-01-01

    Mullite-based systems have been considered as environmental barrier coatings (EBCs) for high temperature protection of Si-based ceramic (Si3N4, SiC) substrates against water vapor corrosion, for application in forthcoming turbine engines. Graded mullite/Y-ZrO2 composites plasma sprayed over Hexoloy SiC substrates were analyzed as EBCs. All feedstock materials were purposely prepared and singular spraying conditions were used to assure superior crystallization. The different coated specimens were subjected to temperatures of 1300 °C for 100-500 h under water vapor environment. The effect of water corrosion on the exposed coatings was investigated by focusing on their phase and microstructure changes.

  10. FUNCTIONALLY GRADED ALUMINA/MULLITE COATINGS FOR PROTECTION OF SILICON CARBIDE CERAMIC COMPONENTS FROM CORROSION

    SciTech Connect

    1997-10-01

    The main objective of this research project is the formulation of processes that can be used to prepare compositionally graded alumina/mullite coatings for protection from corrosion of silicon carbide components (monolithic or composite) used or proposed to be used in coal utilization systems (e.g., combustion chamber liners, heat exchanger tubes, particulate removal filters, and turbine components) and other energy-related applications. Mullite will be employed as the inner (base) layer and the composition of the film will be continuously changed to a layer of pure alumina, which will function as the actual protective coating of the component. Chemical vapor deposition reactions of silica, alumina, and aluminosilicates (mullite) through hydrolysis of aluminum and silicon chlorides in the presence of CO{sub 2} and H{sub 2} will be employed to deposit compositionally graded films of mullite and alumina. Our studies will include the kinetic investigation of the silica, alumina, and aluminosilicate deposition processes, characterization of the composition, microstructure, surface morphology, and mechanical behavior of the prepared films, and modeling of the various deposition processes. During this six-month reporting period, we continued the work on the development and construction of the thermogravimetric chemical vapor deposition system that we intend to employ for studying the deposition of alumina, silica, and aluminosilicates (such as mullite) from mixtures of metal chlorides in H{sub 2} and CO{sub 2}. Specifically, we worked on the development of the tubular flow reactor that will be used for producing aluminum chloride for delivery to the chemical vapor deposition system and of the vapor and gas supply system. Various problems arising from condensation of aluminum chlorides in some sections of the supply line were resolved, and we expect to perform experiments using mixtures containing AlCl{sub 3} in the next reporting period. Preliminary experiments on the

  11. Electrophoretic deposition of mullite in a continuous fashion utilizing non-aqueous polymeric sols

    SciTech Connect

    Brown, P.W.

    1995-12-31

    The feasibility of depositing mullite via electrophoretic deposition (EPD) onto a 2-d substrate, such as Nicalon{trademark} cloth, was determined in this preliminary study. Mullite coatings were deposited onto a C-coated Nicalon{trademark} cloth using a polymeric precursor. XRD data suggest that phase separation of the sol does not occur upon drying and subsequent thermal treatment of the sol. XRD also indicates an amorphous {r_arrow} crystalline transition between 800 and 900{degrees}C. The coatings appeared to be fairly uniform throughout the cloth cross-section, on the order of 250nm thick, and displayed a minimal amount of bridging. A large amount of 5 nanometer-sized porosity was uniformly distributed throughout the coating.

  12. An historical mullite fiber-reinforced ceramic composite: Characterization of the wootz' crucible refractory

    SciTech Connect

    Lowe, T.L. ); Merk, N.; Thomas, G. )

    1990-10-01

    Since at least the sixteenth century, the wootz'' ultra-high carbon white cast-iron ingot was produced in India by melting or carburising iron in a crucible. This ingot was forced into sword blades of so-called Damascus steel. The charged crucible was fired in a long (24-hour) single cycle at high temperature (1150-1250{degree}C) in a strongly reducing atmosphere. Raw materials for the refractory vessel are clay and coked'' rice husks. At high temperatures, two phases reinforce the glassy matrix: cristobalite relics of rice husks and a network of mullite crystals. This paper characterizes the microstructure and chemistry of the mullite network in the glassy matrix by means of a combination of techniques: optical microscopy, XRD, SEM, TEM and EDS, and HREM. 13 refs., 11 figs.

  13. Functionally Graded Alumina/Mullite Coatings for Protection of Silicon Carbide Ceramic Components from Corrosion

    SciTech Connect

    Sotirchos, S.V.

    1997-04-01

    During the six months of this reporting period, we accomplished the following: Preparatory work was done on the development of the feed supply system (for mixtures of AlCl{sub 3}, SiCl{sub 4}, H{sub 2} and CO{sub 2}) and effluent treatment section for the CVD system we plan to employ for coating preparation. A comprehensive literature survey of past work done on the chemical vapor deposition of silica, alumina and aluminosilicates (mullite) was carried out, and work was initiated on the study of thermochemical equilibrium in the Al/Si/Cl/C/O/H system so as to identify the boundaries of the region of the space of operating parameters and conditions where preparation of functionally graded mullite/ alumina coatings through CVD from metal chloride, CO{sub 2}, and H{sub 2} is feasible. Since the alumina/mullite films that are proposed to be developed can also be applied to carbon matrix composites provided that a layer that bridges the gap that exists between the thermal expansion coefficient of carbon and that of mullite is employed, experiments were conducted on the preparation of compositionally graded carbon/silicon carbide coatings. Deposition from mixtures of ethylene and methyltrichlorosilane or tetrachlorosilane (silicon tetrachloride) in hydrogen was used for the preparation of SiC/C coatings, and our experiments focused on the study of the occurrence of multiple steady states in the deposition process and the effects of the type of chlorosilane on the deposition rate and the deposit composition and their variation along the length of the reactor. The results showed that when operation is carried out outside the multiplicity region, codeposition of SiC and C from ethylene and chlorosilanes is a feasible route for preparation of SiC/C graded coatings.

  14. Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.

    2000-01-01

    Plasma-sprayed mullite (3Al2O3.2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon -based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface. Thus the modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while a weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause a premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

  15. Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.

    1999-01-01

    Plasma-sprayed mullite (3Al2O3 central dot 2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon-based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface, Thus modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

  16. Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.

    2000-01-01

    Plasma-sprayed mullite (3Al2O3.2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon -based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface. Thus the modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while a weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause a premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

  17. Mullite ceramic membranes for industrial oily wastewater treatment: experimental and neural network modeling.

    PubMed

    Shokrkar, H; Salahi, A; Kasiri, N; Mohammadi, T

    2011-01-01

    In this paper, results of an experimental and modeling of separation of oil from industrial oily wastewaters (desalter unit effluent of Seraje, Ghom gas wells, Iran) with mullite ceramic membranes are presented. Mullite microfiltration symmetric membranes were synthesized from kaolin clay and alpha-alumina powder. The results show that the mullite ceramic membrane has a high total organic carbon and chemical oxygen demand rejection (94 and 89%, respectively), a low fouling resistance (30%) and a high final permeation flux (75 L/m2 h). Also, an artificial neural network, a predictive tool for tracking the inputs and outputs of a non-linear problem, is used to model the permeation flux decline during microfiltration of oily wastewater. The aim was to predict the permeation flux as a function of feed temperature, trans-membrane pressure, cross-flow velocity, oil concentration and filtration time, using a feed-forward neural network. Finally the structure of hidden layers and nodes in each layer with minimum error were reported leading to a 4-15 structure which demonstrated good agreement with the experimental measurements with an average error of less than 2%.

  18. Corrosion protection of SiC-based ceramics with CVD mullite coatings

    SciTech Connect

    Sarin, V.; Mulpuri, R.; Auger, M.

    1996-04-20

    SiC based ceramics have been identified as the leading candidate materials for elevated temperature applications in harsh oxidation/corrosion environments. It has been established that a protective coating can be effectively used to avoid problems with excessive oxidation and hot corrosion. However, to date, no coating configuration has been developed that can withstand the rigorous requirements imposed by such applications. Chemical vapor deposited (CVD) mullite coatings due to their desirable properties of toughness, corrosion resistance, and good coefficient of thermal expansion match with SiC are being developed as a potential solution. Formation of mullite on ceramic substrates via chemical vapor deposition was investigated. Thermodynamic calculations performed on the AlCl{sub 3}- SiCl{sub 4}-CO{sub 2}-H{sub 2} system were used to construct equilibrium CVD phase diagrams. Through process optimization, crystalline CVD mullite coatings have been successfully grown on SiC and Si{sub 3}N{sub 4} substrates. Results from the thermodynamic analysis, process optimization, and effect of various process parameters on deposition rate and coating morphology are discussed.

  19. Mullite microsphere-filled lightweight calcium phosphate cement slurries for geothermal wells: Setting and properties

    SciTech Connect

    Sugama, T.; Carciello, N.R.; Nayberg, T.M.; Brothers, L.E.

    1995-08-01

    The chemical factors affecting the setting properties of microsphere-filled lightweight calcium phosphate cement (LCPC) slurries, ranging in density from 1.32 to 1.12 g/cc, at high hydrothermal temperature were investigated. The LCPC slurries consisted of calcium aluminate cement (CAC) as the base reactant, a {single_bond}({single_bond}NaPO{sub 3}{single_bond}){single_bond}{sub n} solution as the acid reactant, and mullite-shelled hollow microspheres as the lightweight additive. Two major aspects were studied; one was the importance of the chemical constituents of CAC, and the other was the rate of the hydrothermal reaction between the mullite shell and the Na ions dissociated from {single_bond}({single_bond}NaPO{sub 3}{single_bond}){single_bond}{sub n}. For the former, the use of CAC having C{sub 2}AS and CA phases as the major chemical components shortened the thickening time of LCPC slurries, whereas CACs with CA, CA{sub 2}, and {alpha}-Al{sub 2}O{sub 3} phase components extended the thickening time. For the hydrothermal reaction, an excess of zeolite X type formed by the uptake of Na by mullite microspheres reduced the thickening time.

  20. Nucleation mechanisms in chemically vapor-deposited mullite coatings on SiC

    SciTech Connect

    Hou, P.; Basu, S.N.; Sarin, V.K.

    1999-07-01

    Dense, uniform, and adherent chemically vapor-deposited mullite coatings were deposited on SiC substrates using the AlCl{sub 3}{endash}SiCl{sub 4}{endash}H{sub 2}{endash}CO{sub 2} system. Typical coating morphology consisted of a thin interfacial layer of {gamma}{endash}Al{sub 2}O{sub 3} nanocrystallites embedded within a vitreous SiO{sub 2}-based matrix. When a critical Al/Si ratio of 3.2{plus_minus}0.29 was reached within this nanocrystalline layer, mullite crystals nucleated and grew as columnar grains. The thickness of the nanocrystalline layer decreased as the input AlCl{sub 3}/SiCl{sub 4} ratio was increased. In all cases, the Al/Si composition in the coating increased from the coating/substrate interface to the coating surface. Critical factors leading to the nucleation and growth of mullite crystals are discussed in this article. {copyright} {ital 1999 Materials Research Society.}

  1. Phase Transformation of Andalusite-Mullite and Its Roles in the Microstructure and Sinterability of Refractory Ceramic

    NASA Astrophysics Data System (ADS)

    Li, Bowen; He, Mengsheng; Wang, Huaguang

    2017-07-01

    Andalusite has been realized as a special mineral for the production of refractory ceramics due to its unique property to automatically decompose into mullite and silica during heating at high temperature. The phase transformation from andalusite to mullite plays a critical role for the effective applications of andalusite. This study investigated the microstructural characteristics and sinterability of andalusite powder during high-temperature decomposition. The andalusite powder was bonded with kaolin and prepared as a cylinder green body at 20 MPa; it was then fired at 1423 K to 1723 K (1150 °C to 1450 °C). The microstructures and mechanical strengths of the sintered ceramics were studied by the compressive test, X-ray diffraction, and scanning electron microscopy. The results showed that newly born mullite appeared as rodlike microcrystals and dispersed around the initial andalusite. At 1423 K (1150 °C), the mullitization of andalusite was started, but the complete mullitization was not found until firing at 1723 K (1450 °C). The compressive strength of the ceramics increased from 93.7 to 294.6 MPa while increasing the fire temperature from 1423 K to 1723 K (1150 °C to 1450 °C). Meanwhile, the bulk density of the ceramics was only slightly changed from 2.15 to 2.19 g/cm3.

  2. Fretting wear behavior of calcium phosphate-mullite composites in dry and albumin-containing simulated body fluid conditions.

    PubMed

    Nath, Shekhar; Ummethala, Raghunandan; Basu, Bikramjit

    2010-04-01

    In a recent work, it has been shown that it is possible to achieve a better combination of compressive strength, flexural strength and toughness properties in calcium phosphate (CaP) composites containing 20 and 30 wt% mullite (3Al(2)O(3).2SiO(2)). In view of their potential application as load bearing implants, the present work reports the friction and wear properties of the newly developed composites against zirconia under dry ambient as well as in simulated body fluid (SBF) containing bovine serum albumin (BSA) protein. For comparison, experiments were also conducted on monolithic hydroxyapatite (HAp, Ca(10)(PO(4))(6)(OH)(2)) and mullite under identical conditions. Under the investigated fretting conditions, the mullite-containing composites exhibited higher coefficient of friction (COF) of 0.4-0.6, compared to pure HAp (COF approximately 0.25-0.3). Although the wear resistance of the composites containing 20 or 30 wt% mullite was better in dry conditions, higher wear rate was measured in SBF conditions. The difference in tribological properties has been analyzed in reference to the difference in phase assemblage and mechanical properties. A comparison with some competing biomaterials reveals good potential of the investigated CaP-mullite composites for application as wear resistant implants.

  3. Comparative Study of Performance and Combustion Characteristics of Conventional and Low Heat Rejection (Mullite Coated) Diesel Engines

    NASA Astrophysics Data System (ADS)

    Patond, S. B.; Chaple, S. A.; Shrirao, P. N.; Shaikh, P. I.

    2013-06-01

    Tests were performed on a single cylinder, four stroke, direct injection, diesel engine whose piston crown, cylinder head and valves were coated with a 0.5 mm thickness of 3Al2O3·2SiO2 (mullite) (Al2O3 = 60%, SiO2 = 40%) over a 150 μm thickness of NiCrAlY bond coat. The working conditions for the conventional engine (without coating) and LHR (mullite coated) engine were kept exactly same to ensure a comparison between the two configurations of the engine. This paper is intended to emphasis on performance and combustion characteristics of conventional and LHR (Mullite coated) diesel engines under identical conditions. Tests were carried out at same operational constraints i.e. air-fuel ratio and engine speed conditions for both conventional engine (without coating) and LHR (mullite coated) engines. The results showed that, there was as much as 1.8 % increasing on brake power for LHR (mullite coated) engine compared to conventional engine (without coating) at full load The average decrease in brake specific fuel consumption in the LHR engine compared with the conventional engine was 1.76 % for full engine load. However, there was increasing on cylinder gas pressure and net heat release rate for LHR engine compared to conventional engine. Also the results revealed that, there was as much as 22% increasing on exhaust gas temperature for LHR engine compared to conventional engine at full engine load.

  4. Crystallisation in apatite-mullite glass-ceramics as a function of fluorine content

    NASA Astrophysics Data System (ADS)

    Stanton, Kenneth T.; Hill, Robert G.

    2005-02-01

    Apatite-mullite glass-ceramics are materials prepared by the controlled heat-induced devitrification of glasses of suitable composition and are under investigation for applications in dentistry and orthopaedics. The glasses used here are based on a system with the composition 1.5(5- x)SiO 2·(5- x)Al 2O 3·1.5P 2O 5·(5- x)CaO· xCaF 2. The amount of fluorine in the glasses was varied to investigate the crystallisation behaviour as a function of both fluorine content and temperature. The resultant crystalline phases are fluorapatite [Ca 10(PO 4) 6F 2], mullite [Al 6Si 2O 13] and in some cases, anorthite [CaAl 2Si 2O 8]. Crystal phases were identified using X-ray diffraction (XRD) from both the surface and the bulk of heat-treated monolithic samples and scanning electron microscopy (SEM) was used to image the crystal phase morphologies. Crystallisation characteristics varied widely in terms of apparent nucleation mechanism, crystal phases formed and microstructure. In general, glasses with higher fluorine content devitrified more readily to fluorapatite (FAp) with a higher nucleation density and for glasses with an intermediate to low fluorine content there tended to be an interdependence between FAp and mullite crystallisation. A greater tendency towards anorthite formation, especially at surfaces, was observed for glasses with lower fluorine contents. Furthermore, on decreasing the fluorine content, glasses tended to crystallise by formation of FAp spherulites with increasing diameter and with greater crystal aspect ratio.

  5. Kaolin processing waste applied in the manufacturing of ceramic tiles and mullite bodies.

    PubMed

    Menezes, Romualdo R; Farias, Felipe F; Oliveira, Maurício F; Santana, Lisiane N L; Neves, Gelmires A; Lira, Helio L; Ferreira, Heber C

    2009-02-01

    In the last few years, mineral extraction and processing industries have been identified as sources of environmental contamination and pollution. The kaolin processing industry around the world generates large amounts of waste materials. The present study evaluated the suitability of kaolin processing waste as an alternative source of ceramic raw material for the production of ceramic tiles and dense mullite bodies. Several formulations were prepared and sintered at different temperatures. The sintered samples were characterized to determine their porosity, water absorption, firing shrinkage and mechanical strength. The fired samples were microstructurally analysed by X-ray diffraction. The results indicated that ceramic tile formulations containing up to 60% of waste could be used for the production of tiles with low water absorption (approximately 0.5%) and low sintering temperature (1150 degrees C). Mullite formulations with more than 40% of kaolin waste could be used in the production of bodies with high strength, of about 75 MPa, which can be used as refractory materials.

  6. Upper Temperature Limit of Environmental Barrier Coatings Based on Mullite and BSAS

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Fox, Dennis S.; Eldridge, Jeffrey I.; Zhu, Dongming; Bansal, Narottam P.; Miller, Robert A.; Robinson, Raymond C.

    2002-01-01

    Current state-of-the-art environmental barrier coatings (EBCs) for Si-based ceramics consist of three layers: a silicon bond coat, an intermediate mullite (3Al2O3-2SiO2) or mullite + BSAS (1-xBaO-xSrO-Al2O3-2SiO2) layer, and a BSAS top coat. Areas of concern for long-term durability are environmental durability, chemical compatibility, silica volatility, phase stability, and thermal conductivity. Variants of this family of EBCs were applied to monolithic SiC and melt infiltrated SiC/SiC composites. Reaction between BSAS and silica results in low melting (approx. 1300 C) glasses at T > 1400 C, which can cause the spallation of the EBC. At temperatures greater than 1400 C, the BSAS top coat also degrades by formation of a porous structure, and it suffers significant recession via silica volatilization in water vapor-containing atmospheres. All of these degradation mechanisms can be EBC life-limiting factors. BSAS undergoes a very sluggish phase transformation (hexagonal celsian to monoclinic celsian), the implications of which are not fully understood at this point. There was evidence of rapid sintering at temperatures as low as 1300 C, as inferred from the sharp increase in thermal conductivity.

  7. FUNCTIONALLY GRADED ALUMINA/MULLITE COATINGS FOR PROTECTION OF SILICON CARBIDE CERAMIC COMPONENTS FROM CORROSION

    SciTech Connect

    1998-03-01

    The main objective of this research project is the formulation of processes that can be used to prepare compositionally graded alumina/mullite coatings for protection from corrosion of silicon carbide components (monolithic or composite) used or proposed to be used in coal utilization systems (e.g., combustion chamber liners, heat exchanger tubes, particulate removal filters, and turbine components) and other energy-related applications. Mullite will be employed as the inner (base) layer and the composition of the film will be continuously changed to a layer of pure alumina, which will function as the actual protective coating of the component. Chemical vapor deposition reactions of silica, alumina, and aluminosilicates (mullite) through hydrolysis of aluminum and silicon chlorides in the presence of CO{sub 2} and H{sub 2} will be employed to deposit compositionally graded films of mullite and alumina. Our studies will include the kinetic investigation of the silica, alumina, and aluminosilicate deposition processes, characterization of the composition, microstructure, surface morphology, and mechanical behavior of the prepared films, and modeling of the various deposition processes. During this reporting period, the construction and development of the chemical vapor deposition system was completed, and experiments were conducted on the deposition of alumina, silica, and aluminosilicates (such as mullite) from mixtures of AlCl{sub 3} and CH{sub 3}SiCl{sub 3} in CO{sub 2} and H{sub 2}. Work was mainly done on the investigation of the effects of the reaction temperature on the deposition kinetics. It was found that the temperature had a positive effect on the single oxides deposition rates and the codeposition rate. The apparent activation energy values extracted from the deposition rate vs. temperature curves in the high temperature region were similar for the three deposition processes, having a value around 20 kcal/mol. The codeposition rates were higher, by a

  8. Effects of synthesis conditions on structure and surface properties of SmMn2O5 mullite-type oxide

    NASA Astrophysics Data System (ADS)

    Thampy, Sampreetha; Ibarra, Venessa; Lee, Yun-Ju; McCool, Geoffrey; Cho, Kyeongjae; Hsu, Julia W. P.

    2016-11-01

    A mixed-phase compound that contains SmMn2O5 mullite-type oxides has been reported to display excellent catalytic activity for nitric oxide (NO) oxidation. Here we investigate the effects of calcination temperature and precipitation pH on structural, physical, chemical, and surface properties of SmMn2O5. As the calcination temperature increases from 750 °C to 1000 °C, mullite phase purity increases from 74% to 100%, while specific surface area (SSA) decreases from 23.6 m2/g to 5.1 m2/g with particle size increases correspondingly. Mullite phase purity (87%) is independent of pH between 8.5-10.4, whereas SSA monotonically increases from 12.5 m2/g at pH 8.1 to 27.4 m2/g at pH 13. X-ray photoelectron spectroscopy (XPS) studies reveal that the surface Mn/Sm ratio is similar to the bulk value and is unaffected by calcination temperature and pH values up to 10.4, whereas sample precipitated at pH 13 is surface-rich in Sm. NO chemisorption studies show that the SSA and surface Mn/Sm ratio determine NO uptake by SmMn2O5 mullite oxides.

  9. Transmission electron microscopy observations on phase transformations during aluminium/mullite composites formation by gas pressure infiltration

    SciTech Connect

    Pawlyta, M.; Tomiczek, B.; Dobrzański, L.A.; Kujawa, M.; Bierska-Piech, B.

    2016-04-15

    The porous ceramic preforms were manufactured using the powder metallurgy technique. First, the start-up material (halloysite with the addition of carbon fibres as the pore-forming agent) was slowly heated to 800 °C and then sintered at 1300 °C. Degradation of the carbon fibres enabled the open canals to form. At the end of the sintering process, the porous ceramic material consisting mainly of two phases (mullite and cristobalite) was formed, without any residual carbon content. During infiltration, the liquid metal filled the empty spaces (pores) effectively and formed the three-dimensional network of metal in the ceramic. The cristobalite was almost entirely decomposed. In the areas of its previous occurrence, there are new pores, only in the ceramic grains. The mullite, which was formed from halloysite during annealing, crystallized in the Pbam orthorhombic space group, with the (3Al{sub 2}O{sub 3}·2SiO{sub 2}) stoichiometric composition. The mullite structure does not change during the infiltration. The composite components are tightly connected. A transition zone between the ceramics and the metal, having the thickness of about 200 nm, was formed. The nanocrystalline zone, identified as γ-Al{sub 2}O{sub 3}, was formed by diffusing the product of the cristobalite decomposition into the aluminium alloy matrix. There is an additional, new phase, identified as (Mg,Si)Al{sub 2}O{sub 4} in the outer parts of the transition zone. - Highlights: • Phase changes after the infiltration of aluminium into porous mullite preforms were observed by TEM. • TEM observations confirm that during infiltration cristobalite was decomposed and the structure of mullite did not change. • Between the ceramic and the metal, a transition zone comprising a layer of γ-Al{sub 2}O{sub 3} and (Mg,Si)Al{sub 2}O{sub 4} was formed.

  10. FUNCTIONALY GRADED ALUMINA/MULLITE COATINGS FOR PROTECTION OF SILICON CARBIDE CERAMIC COMPONENTS FROM CORROSION

    SciTech Connect

    PROF. STRATIS V. SOTIRCHOS

    1998-10-01

    The main objective of this research project is the formulation of processes that can be used to prepare compositionally graded alumina/mullite coatings for protection from corrosion of silicon carbide components (monolithic or composite) used or proposed to be used in coal utilization systems (e.g., combustion chamber liners, heat exchanger tubes, particulate removal filters, and turbine components) and other energy-related applications. Mullite will be employed as the inner (base) layer and the composition of the film will be continuously changed to a layer of pure alumina, which will function as the actual protective coating of the component. Chemical vapor deposition reactions of silica, alumina, and aluminosilicates (mullite) through hydrolysis of aluminum and silicon chlorides in the presence of CO2 and H2 will be employed to deposit compositionally graded films of mullite and alumina. Our studies will include the kinetic investigation of the silica, alumina, and aluminosilicate deposition processes, characterization of the composition, microstructure, surface morphology, and mechanical behavior of the prepared films, and modeling of the various deposition processes. During this six-month reporting period, the experimental work on the investigation of the deposition of alumina, silica, and aluminosilicates from mixtures of methyltrichlorosilane (MTS), aluminum trichloride, carbon dioxide, and hydrogen was continued. Experiments were also conducted on the deposition processes of the simple oxides, alumina and silica, from mixtures containing only one chloride (AlCl3 and MTS, respectively). Deposition rate data were obtained in a relatively broad range of operating conditions: temperatures in the range 800-1000 o C, 100 Torr pressure, 0.006-0.015 AlCl3 feed mole fraction, 0.011- 0.027 CH3SiCl3 feed mole fraction, and 0.004-0.07 CO2 feed mole fraction, and various positions along the axis of the deposition reactor. Since the effect of temperature had been

  11. Mullite-corundum ceramic used as a catalyst carrier in the pyrolysis of hydrocarbon raw materials

    SciTech Connect

    Andrianov, N.T.; Adel'son, S.V.; Tarkhanova, O.B.; Zhagfarov, F.G.; Zhandarov, V.Y.

    1986-07-01

    The authors develop a carrier for catalysing the pyrolysis of petroleum products which possesses outstanding catalytic properties. Granular ceramic was the carrier material; the main components are alumina and silica. The starting materials for making the carrier consist of granular electrocorundum and Prosyanovsk kaolin. The highest yield of ethylene and the lowest yield of coke were obtained on carriers made from corundum and mullite. The catalyst was made by preparing the carrier with impregnation of the active body KVO/sub 3/ and with the promoter H/sub 3/BO/sub 3/, dried at 90/sup 0/ C, and then calcined. 3 Analysis shows that the best properties are possessed by specimens of catalysts prepared on carriers with 20% kaolin. Industrial use of catalytic pyrolysis will significantly improve savings of raw materials as a result of increasing the ethylene yield 1.3-1.4 times.

  12. Prediction of Service Life of Cordierite-Mullite Refractory Materials by Non-Destructive Methods

    SciTech Connect

    Boccaccini, D. N.; Kamseu, Elie; Cannio, M.; Romagnoli, M.; Veronesi, P.; Leonelli, C.; Volkov-Husoviae, T. D.; Dlouhy, I.; Boccaccini, A. R.

    2008-02-15

    Ultrasonic pulse velocity testing was used to perform non-destructive quality control of refractory plates used as substrates in fast firing of porcelain whitewares. The measurement of the ultrasonic velocity was used to asses the presence of internal voids or cracks originated from the manufacturing procedure. Image analysis was used to predict thermal stability of the refractory materials. Two cordierite-mullite compositions were investigated that are characterized by different microstructure morphologies and crack propagation behaviour. A brief discussion about the correlation between microstructure, crack propagation behaviour and thermal shock resistance is presented. Moreover, empirical models were developed to predict the service life of refractory plates from measured values of ultrasonic velocities in plates in the as-received state.

  13. Prediction of Service Life of Cordierite-Mullite Refractory Materials by Non-Destructive Methods

    NASA Astrophysics Data System (ADS)

    Boccaccini, D. N.; Kamseu, Elie; Volkov-Husoviæ, T. D.; Cannio, M.; Romagnoli, M.; Veronesi, P.; Dlouhy, I.; Boccaccini, A. R.; Leonelli, C.

    2008-02-01

    Ultrasonic pulse velocity testing was used to perform non-destructive quality control of refractory plates used as substrates in fast firing of porcelain whitewares. The measurement of the ultrasonic velocity was used to asses the presence of internal voids or cracks originated from the manufacturing procedure. Image analysis was used to predict thermal stability of the refractory materials. Two cordierite-mullite compositions were investigated that are characterized by different microstructure morphologies and crack propagation behaviour. A brief discussion about the correlation between microstructure, crack propagation behaviour and thermal shock resistance is presented. Moreover, empirical models were developed to predict the service life of refractory plates from measured values of ultrasonic velocities in plates in the as-received state.

  14. Changes on electrical and structural properties of polyaniline and polypyrrol by mullite doping

    NASA Astrophysics Data System (ADS)

    González, C. P.; Montaño, A. M.; Estrada, S. E.; Ortiz, C. A.

    2016-02-01

    In this work, the effect of mullite dopant (mull) on the structural and electrical properties of two conductive polymers: polyaniline (PAni) and polypyrrole (PPy), which have great interest in science and materials engineering, has been evaluated. Doped polymers were synthesized with different contents of mineral and at two polymerization times (tP) by an in situ chemical synthesis in acidic aqueous solution and using Ammonium Persulfate (APS) as the reaction initiator. Structural characterization was performed by X-Ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR). The conductivity values (σac) were estimated from Electrochemical Impedance Spectroscopy (EIS). It was found that, at concentrations of work, were obtained higher values σac of conductivity at the highest concentration of the mineral, however, in some compounds the conductivity decreased. The variations in conductivity were attributed to PC-dopant interactions.

  15. Effects of in situ synthesized mullite whisker on mechanical properties of Al2O3-SiC composite by microwave sintering

    NASA Astrophysics Data System (ADS)

    Dang, Xudan; Wei, Meng; Fan, Bingbing; Guan, Keke; Zhang, Rui; Long, Weimin; Zhang, Hongsong

    2017-06-01

    In situ synthesis of mullite whisker was introduced to Al2O3-SiC composite by microwave sintering. The effects of sintering parameters (sintering temperature, holding time and SiC particle size) on thermal shock resistance of Al2O3-SiC composite were also studied in this paper. Original SiC particles coated with SiO2 by a sol-gel method were reacted with Al2O3 particles, resulting in the in situ growth of mullite. The phase composition was identified by x-ray diffraction (XRD). The bridging of mullite whisker between Al2O3 and SiC particles was observed by scanning electron microscopy (SEM) analysis. The thermal shock resistance of samples was investigated through the combination of water quenching and three-point bending methods. The results show that the thermal shock resistance of Al2O3-SiC composite with mullite whisker reinforced remarkably, indicating better mechanical properties than the Al2O3-SiC composite without mullite whisker. Finally, the optimum process parameters (the sintering temperature of 1500 °C, the holding time of 30 min, and the SiC particle size of 5 µm) for toughening Al2O3-SiC composite by in situ synthesized mullite whisker were obtained.

  16. Effect of V2O5 on the properties of mullite ceramics synthesized from high-aluminum fly ash and bauxite.

    PubMed

    Li, Jin-Hong; Ma, Hong-Wen; Huang, Wen-Hui

    2009-07-30

    In this communication, high-strength mullite ceramics was prepared from bauxite and high-aluminum fly ash that is a by-product of coal combustion in thermal power plants. The effects of the doping V(2)O(5) on the bulk density, apparent porosity, bending strength and microstructure of mullite ceramics were studied in detail. It was indicated that 5-10 mol% V(2)O(5) reduced the sintering temperature by 50 degrees C. The apparent porosity and water absorption of the mullite ceramics decreased with increasing V(2)O(5) content. Mullite ceramics with bending strength as high as 108 MPa were obtained at 1500 degrees C with the addition of 10 mol% V(2)O(5). X-ray diffraction analysis suggested that the prepared ceramics was mainly in phase of mullite, and scanning electron microscope images confirmed that it mostly existed in the shape of a long parallelepiped. This research may provide a new method in utilizing the vast resources of fly-ash waste from power plants in the production of low-cost mullite-based engineering materials.

  17. Two-layer anti-reflection coating with mullite and polyimide foam for large-diameter cryogenic infrared filters.

    PubMed

    Inoue, Yuki; Hamada, Takaho; Hasegawa, Masaya; Hazumi, Masashi; Hori, Yasuto; Suzuki, Aritoki; Tomaru, Takayuki; Matsumura, Tomotake; Sakata, Toshifumi; Minamoto, Tomoyuki; Hirai, Tohru

    2016-12-01

    We have developed a novel two-layer anti-reflection (AR) coating method for large-diameter infrared (IR) filters made of alumina, for use at cryogenic temperatures in millimeter wave measurements. Thermally sprayed mullite and polyimide foam (Skybond Foam) are used as the AR material. An advantage of the Skybond Foam is that the index of refraction is chosen between 1.1 and 1.7 by changing the filling factor. Combination with mullite is suitable for wide-band millimeter wave measurements with sufficient IR cutoff capability. We present the material properties, fabrication of a large-diameter IR filter made of alumina with this AR coating method, and characterizations at cryogenic temperatures. This technology can be applied to a low-temperature receiver system with a large-diameter focal plane for next-generation cosmic microwave background polarization measurements, such as POLARBEAR-2 (PB-2).

  18. Microstructure and properties of mullite-based porous ceramics produced from coal fly ash with added Al2O3

    NASA Astrophysics Data System (ADS)

    Zhu, Jian-bin; Yan, Hong

    2017-03-01

    Using coal fly ash slurry samples supplemented with different amounts of Al2O3, we fabricated mullite-based porous ceramics via a dipping-polymer-replica approach, which is a popular method suitable for industrial application. The microstructure, phase composition, and compressive strength of the sintered samples were investigated. Mullite was identified in all of the prepared materials by X-ray diffraction analysis. The microstructure and compressive strength were strongly influenced by the content of Al2O3. As the Al/Si mole ratio in the starting materials was increased from 0.84 to 2.40, the amount of amorphous phases in the sintered microstructure decreased and the compressive strength of the sintered samples increased. A further increase in the Al2O3 content resulted in a decrease in the compressive strength of the sintered samples. The mullite-based porous ceramic with an Al/Si molar ratio of 2.40 exhibited the highest compressive strength and the greatest shrinkage among the investigated samples prepared using coal fly ash as the main starting material.

  19. A facile preparation of mullite [Al2(Al(2.8)Si(1.2))O(9.6)] nanowires by B2O3-doped molten salts synthesis.

    PubMed

    Zhang, Pengyu; Liu, Jiachen; Du, Haiyan; Li, Sha; Xu, Rui

    2010-06-14

    Al-rich single-crystal mullite [Al(2)(Al(2.8)Si(1.2))O(9.6)] nanowires were prepared by B(2)O(3)-doped molten salts synthesis. The nanowires have diameters in the range 30-50 nm and typical lengths of 1 microm. The mullite nanowires were well dispersed and facile to obtain.

  20. Formation, stability and crystal structure of mullite-type Al6-xBxO9

    NASA Astrophysics Data System (ADS)

    Hoffmann, K.; Hooper, T. J. N.; Murshed, M. M.; Dolotko, O.; Révay, Z.; Senyshyn, A.; Schneider, H.; Hanna, J. V.; Gesing, Th. M.; Fischer, R. X.

    2016-11-01

    Mullite-type Al6-xBxO9 compounds were studied by means of powder diffraction and spectroscopic methods. The backbones of this structure are chains of edge-connected AlO6 octahedra crosslinked by AlO- and BO-polyhedra. Rietveld refinements show that the a and b lattice parameters can be well resolved, thus representing an orthorhombic metric. A continuous decrease of the lattice parameters most pronounced in c-direction indicates a solid solution for Al6-xBxO9 with 1.09≤x≤2. A preference of boron in 3-fold coordination is confirmed by 11B MAS NMR spectroscopy and Fourier calculations based on neutron diffraction data collected at 4 K. Distance Least Squares modeling was performed to simulate a local geometry avoiding long B-O distances linking two octahedral chains by planar BO3 groups yielding split positions for the oxygen atoms and a strong distortion in the octahedral chains. The lattice thermal expansion was calculated using the Grüneisen first-order equation of state Debye-Einstein-Anharmonicity model.

  1. Parametric Appraisal of Slurry-Sprayed Mullite Coatings for Coating Thickness

    NASA Astrophysics Data System (ADS)

    Verma, R.; Suri, N. M.; Kant, S.

    2016-10-01

    The slurry spray technique (SST) has been employed to deposit mullite-based coatings on ASTM 1018 low-carbon steel substrate for environmental barrier coating applications. A Taguchi L18 orthogonal array is adopted for optimization of the identified process variables and material parameters, namely stamping pressure, fly-ash content, and sintering additive, time, and temperature. The measured thickness of the produced coatings was chosen as the response characteristic for the present study. The optimum values of the process variables were predicted by employing analysis of variance based on raw data and the signal-to-noise (S/N) ratio. Based on analysis of the experimental results, the effect of each parameter level on the coating thickness is discussed. It is observed that the sintering temperature had a strong influence on the maximum coating thickness of the slurry-sprayed coating. The as-sprayed coatings fabricated using SST demonstrated splat morphology with continuous interface, suggesting good adherence to the substrate.

  2. Constraining 17O and 27Al NMR spectra of high-pressure crystals and glasses: New data for jadeite, pyrope, grossular, and mullite

    USGS Publications Warehouse

    Kelsey, K.E.; Stebbins, J.F.; Du, L.-S.; Hankins, B.

    2007-01-01

    The 17O NMR spectra of glasses quenched from melts at high pressure are often difficult to interpret due to overlapping peaks and lack of crystalline model compounds. High-pressure aluminosilicate glasses often contain significant amounts of [5]Al and [6]Al, thus these high-pressure glasses must contain oxygen bonded to high-coordinated aluminum. The 17O NMR parameters for the minerals jadeite, pyrope, grossular, and mullite are presented to assist interpretation of glass spectra and to help test quantum chemical calculations. The 17O NMR parameters for jadeite and grossular support previous peak assignments of oxygen bonded to Si and high-coordinated Al in high-pressure glasses as well as quantum chemical calculations. The oxygen tricluster in mullite is very similar to the previously observed tricluster in grossite (CaAl4 O7) and suspected triclusters in glasses. We also present 27Al NMR spectra for pyrope, grossular, and mullite.

  3. Effect of chemical composition on the sintering of mullite powders obtained by {gamma}-Al{sub 2}O{sub 3} and kaolin

    SciTech Connect

    Mariano, W.A.; Kiminami, R.H.G.A.

    1995-09-01

    The effects of different alumina content on sintering behaviour of mullite powder obtained by reaction sintering of a mixture of {gamma}-Al{sub 2}O{sub 3} and kaolin powders have been studied by using scanning electron microscopy, X-ray diffraction and apparent density measurements. Mullitization temperature was not changed with the composition of the samples. The XRD patterns of the powders with 68,0, 71,8 and 76wt% Al{sub 2}O{sub 3}, sintered above 1623K for 360s showed only the mullite phase. The sintered density of the powders increased with Al{sub 2}O{sub 3} content. The microstructural evolution and liquid phase appearance were studied and observed an exaggerated grain growth in the samples with 68,0 and 76MI/o of Al{sub 2}O{sub 3}.

  4. Development of a zirconia-mullite based ceramic for recuperator applications

    SciTech Connect

    Gonzalez, J.M. )

    1992-12-01

    GTE Products Corporation developed a compact ceramic high temperature recuperator for recovering heat from relatively clean exhaust gases at temperatures up to 2500F. The DOE program allowed GTE to improve the technical and economic characteristics of the recuperator and stimulate industrial acceptance of the recuperator as an energy-saving technology. From January 1981 to December 1984, 561 recuperators were installed by GTE on new or retrofitted furnaces. With over 1200 units sold commercially between 1981 and 1990, GTE has documented the effect (long and short term) of corrosive attack from alkalies and lead. One objective of this contract was to develop Z-1000 a zirconia-mullite mixed oxide ceramic for use in ceramic recuperator applications susceptible to corrosion. To first and second pass of the ceramic recuperator would utilize the current cordierite-mixed-oxide ceramic. A Z-1000 matrix element would be used in the preheated air side's third pass (exhaust inlet). Thermal stresses on Z-1000 cross flow module could be minimized by selecting appropriate heat transfer surface areas for each pass. A large surface area for first and second pass (cordierite section) could provide for sufficient heat transfer for 50% effectiveness. A surface area that generates minimal heat transfer in the third pass (Z-1000) section is envisioned. Heat transferred in this section reduces the differential temperature across the matrix and the thermal stresses. Hence, thermal shock resistance of the material in the third pass becomes less critical; however, its corrosion resistance must be sufficient to withstand corrosive attack. This modular design could utilize a field repairable, disposable matrix. This report is concerned with process technology development for fabricating such a matrix, and a series of corrosion tests that established the potential corrosion resistance of the Z-1000 ceramic.

  5. Indirect selective laser sintering of an apatite-mullite glass-ceramic for potential use in bone replacement applications.

    PubMed

    Goodridge, R D; Dalgarno, K W; Wood, D J

    2006-01-01

    The feasibility of using indirect selective laser sintering (SLS) to produce parts from glass-ceramic materials for bone replacement applications has been investigated. A castable glass based on the system SiO2 x Al2O3 x P2O5 x CaO x CaF2 that crystallizes to a glass-ceramic with apatite and mullite phases was produced, blended with an acrylic binder, and processed by SLS. Green parts with good structural integrity were produced using a wide range of processing conditions, allowing both monolayer and multilayer components to be constructed. Following SLS the parts were post-processed to remove the binder and to crystallize fully the material, evolving the apatite and mullite phases. The parts were heated to 1200 degrees C using a number of different time-temperature profiles, following which the processed material was analysed by differential thermal analysis, X-ray diffraction, and scanning electron microscopy, and tested for flexural strength. An increase in strength was achieved by infiltrating the brown parts with a resorbable phosphate glass, although this altered the crystal phases present in the material.

  6. Effects of soda-lime-silica waste glass on mullite formation kinetics and micro-structures development in vitreous ceramics.

    PubMed

    Marinoni, Nicoletta; D'Alessio, Daniela; Diella, Valeria; Pavese, Alessandro; Francescon, Ferdinando

    2013-07-30

    The effects of soda-lime waste glass, from the recovery of bottle glass cullet, in partial replacement of Na-feldspar for sanitary-ware ceramic production are discussed. Attention is paid to the mullite growth kinetics and to the macroscopic properties of the final output, the latter ones depending on the developed micro-structures and vitrification grade. Measurements have been performed by in situ high temperature X-ray powder diffraction, scanning electron microscopy, thermal dilatometry, water absorption and mechanical testing. Glass substituting feldspar from 30 to 50 wt% allows one (i) to accelerate the mullite growth reaction kinetics, and (ii) to achieve macroscopic features of the ceramic output that comply with the latest technical requirements. The introduction of waste glass leads to (i) a general saving of fuel and reduction of the CO2-emissions during the firing stage, (ii) a preservation of mineral resources in terms of feldspars, and (iii) an efficient management of the bottle glass refuse by readdressing a part of it in the sanitary-ware manufacturing.

  7. Temperature-dependent structural studies of mullite-type Bi2Fe4O9

    NASA Astrophysics Data System (ADS)

    Murshed, M. Mangir; Nénert, Gwilherm; Burianek, Manfred; Robben, Lars; Mühlberg, Manfred; Schneider, Hartmut; Fischer, Reinhard X.; Gesing, Thorsten M.

    2013-01-01

    We report on the temperature-dependent structural studies on the mullite-type Bi2Fe4O9 compound. The crystal structures were determined using both powder X-ray diffraction and single crystal neutron diffraction. The thermal expansion of the cell parameters from smallest to largest occurred in the order a

  8. Ab initio calculations of mechanical, thermodynamic and electronic structure properties of mullite, iota-alumina and boron carbide

    NASA Astrophysics Data System (ADS)

    Aryal, Sita Ram

    The alumino-silicate solid solution series (Al 4+2xSi2-2 xO10-x) is an important class of ceramics. Except for the end member (x=0), Al2 SiO5 the crystal structures of the other phases, called mullite, have partially occupied sites. Stoichiometric supercell models for the four mullite phases 3Al2O 3 · 2SiO2 · 2Al 2O3 · SiO2, 4 Al2O3· SiO 2, 9Al2O3 · SiO2, and iota-Al2 O3 (iota-alumina) are constructed starting from experimentally reported crystal structures. A large number of models were built for each phase and relaxed using the Vienna ab initio simulation package (VASP) program. The model with the lowest total energy for a given x was chosen as the representative structure for that phase. Electronic structure and mechanical properties of mullite phases were studied via first-principles calculations. Of the various phases of transition alumina, iota-Al 2O3 is the least well known. In addition structural details have not, until now, been available. It is the end member of the aluminosilicate solid solution series with x=1. Based on a high alumina content mullite phase, a structural model for iota- Al2O3 is constructed. The simulated x-ray diffraction (XRD) pattern of this model agrees well with a measured XRD pattern. The iota-Al2 O3 is a highly disordered ultra-low-density phase of alumina with a theoretical density of 2854kg/m3. Using this theoretically constructed model, elastic, thermodynamic, electronic, and spectroscopic properties of iota-Al2 O3 have been calculated and compared it with those of alpha- Al2O3 and gamma- Al2O3. Boron carbide (B4C) undergoes an amorphization under high velocity impacts. The mechanism of amorphization is not clear. Ab initio methods are used to carry out large-scale uniaxial compression simulations on two polytypes of stoichiometric boron carbide (B4C), B 11C-CBC, and B12- CCC where B11C or B12 is the 12-atom icosahedron and CBC or CCC is the three-atom chain. The simulations were performed on large supercells of 180 atoms

  9. High Temperature Elastic Properties of Single Crystal Mullite (Approximately 2.5Al2O3.SiO2) by Brillouin Spectroscopy

    NASA Technical Reports Server (NTRS)

    Palko, James W.; Sayir, Ali; Sinogeikin, Stanislav V.; Kriven, Waltraud M.; Bass, Jay D.; Farmer, Serene C. (Technical Monitor)

    2001-01-01

    The complete elastic tensor of mullite has been determined by brillouin spectroscopy at room temperature and elevated temperatures up to 1200C. Equivalent, isotropic moduli (bulk, shear, and Young's) have been calculated. The room temperature values obtained using Voigt-Reuss-Hill averaging are: K(sub VRH) = 173.5 + 6.9 GPa, G(sub VRH) = 88.0 + 3.5 GPa, E(sub VRH) = 225.9 + 9.0 GPa. All moduli show relatively gradual decreases with temperature. The temperature derivatives obtained for the equivalent, isotropic moduli are: dK(sub VRH)/dT = - 17.5 + 2.5 MPa/deg. C, dG(sub VRH)/dT = -8.8 + 1.4 MPa/deg. C, dE(sub VRH)/dT = -22.6 + 2.8 MPa/deg C. Substantial differences between bulk properties calculated from the single crystal measurements in this study and the properties reported in the literature for polycrystalline sintered mullite are identified, indicating the importance of factors such as microstructure, intergranular phases, and composition to the elasticity of mullite ceramics.

  10. A low-cost mullite-titania composite ceramic hollow fiber microfiltration membrane for highly efficient separation of oil-in-water emulsion.

    PubMed

    Zhu, Li; Chen, Mingliang; Dong, Yingchao; Tang, Chuyang Y; Huang, Aisheng; Li, Lingling

    2016-03-01

    Oil-in-water (O/W) emulsion is considered to be difficult to treat. In this work, a low-cost multi-layer-structured mullite-titania composite ceramic hollow fiber microfiltration membrane was fabricated and utilized to efficiently remove fine oil droplets from (O/W) emulsion. In order to reduce membrane cost, coal fly ash was effectively recycled for the first time to fabricate mullite hollow fiber with finger-like and sponge-like structures, on which a much more hydrophilic TiO2 layer was further deposited. The morphology, crystalline phase, mechanical and surface properties were characterized in details. The filtration capability of the final composite membrane was assessed by the separation of a 200 mg·L(-1) synthetic (O/W) emulsion. Even with this microfiltration membrane, a TOC removal efficiency of 97% was achieved. Dilute NaOH solution backwashing was used to effectively accomplish membrane regeneration (∼96% flux recovery efficiency). This study is expected to guide an effective way to recycle waste coal fly ash not only to solve its environmental problems but also to produce a high-valued mullite hollow fiber membrane for highly efficient separation application of O/W emulsion with potential simultaneous functions of pure water production and oil resource recovery. Copyright © 2015 Elsevier Ltd. All rights reserved.

  11. The effect of TiO2 concentration on properties of apatite-mullite glass-ceramics for dental use.

    PubMed

    Fathi, Hawa M; Johnson, Anthony

    2016-02-01

    The aim of this study was to evaluate the effect of TiO2 concentration on the properties of apatite-mullite glass-ceramics namely strength and the chemical solubility to comply with the ISO standard recommendations for dental ceramics (BS EN ISO 6872-2008). Ten novel glass-ceramic materials were produced based on the general formula (4.5SiO2-3Al2O3-1.5P2O5-3CaO-CaF2-xTiO2) where x varied from 0.5 to 5 wt%. Glass with no TiO2 added (HG1T0.0) was used as a reference. Discs of 12 mm diameter and 1.6 mm (±0.2 mm) thickness were prepared for both biaxial flexural strength (BFS) and chemical solubility testing, in accordance with the BS EN ISO 6872-2008 for dental ceramics. All produced materials were investigated using differential thermal analysis (DTA), X-ray diffraction (XRD), and scanning electron microscopy (SEM). Energy dispersive X-ray analysis (EDS) was also carried out on some samples to identify the element composition of samples. Increasing the concentration of TiO2 from 0.5 wt% to 2 wt% significantly (P<0.05) increased the chemical solubility of the material. With the material containing 2.5 wt% of TiO2, the solubility significantly reduced (P<0.05) and resulted in a solubility value of 228.3 μm/cm(2) and BFS value of 197.9 MPa. Increasing the TiO2 concentration more than 2.5 wt%, led to a significant (P<0.05) increase in solubility and a reduction in BFS. TiO2 is an effective agent for improving the durability and the mechanical properties of an apatite-mullite glass-ceramic only up to 2.5 wt% concentration. Copyright © 2015 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  12. Optimisation of the enamelling of an apatite-mullite glass-ceramic coating on Ti6Al4V.

    PubMed

    O'Flynn, Kevin P; Stanton, Kenneth T

    2011-09-01

    Apatite-mullite glass-ceramics (AMGCs) are under investigation as a potential alternative to hydroxyapatite (HA) as a coating for cementless fixation of orthopaedic implants. These materials have tailorable mechanical and chemical properties that make them attractive for use as bioactive coatings. Here, AMGC coatings on Ti(6)Al(4)V were investigated to determine an improved heat treatment regime using a systematic examination of the different inputs: composition of glass, nucleation hold and crystallisation hold. An upper limit to the heat treatment temperature was determined by the α + β --> β of Ti(6)Al(4)V at 970°C. The glass composition was modified to produce different crystallisation temperatures and sintering characteristics. A glass was found that is fully crystalline below 970°C and has good sinterability. The effects of different heat treatment time and temperature combinations on the coating and substrate morphologies were examined and the most suitable combination determined. This sample was further investigated and was found to have qualitatively good adhesion and evidence of an interfacial reaction region between the coating and substrate indicating that a chemical reaction had occurred. Oxygen infiltration into the substrate was quantified and the new route was shown to result in a 63% reduction in penetration depth.

  13. Development of a zirconia-mullite based ceramic for recuperator applications. DOE/ORNL Ceramic Technology Project

    SciTech Connect

    Gonzalez, J.M.

    1992-12-01

    GTE Products Corporation developed a compact ceramic high temperature recuperator for recovering heat from relatively clean exhaust gases at temperatures up to 2500F. The DOE program allowed GTE to improve the technical and economic characteristics of the recuperator and stimulate industrial acceptance of the recuperator as an energy-saving technology. From January 1981 to December 1984, 561 recuperators were installed by GTE on new or retrofitted furnaces. With over 1200 units sold commercially between 1981 and 1990, GTE has documented the effect (long and short term) of corrosive attack from alkalies and lead. One objective of this contract was to develop Z-1000 a zirconia-mullite mixed oxide ceramic for use in ceramic recuperator applications susceptible to corrosion. To first and second pass of the ceramic recuperator would utilize the current cordierite-mixed-oxide ceramic. A Z-1000 matrix element would be used in the preheated air side`s third pass (exhaust inlet). Thermal stresses on Z-1000 cross flow module could be minimized by selecting appropriate heat transfer surface areas for each pass. A large surface area for first and second pass (cordierite section) could provide for sufficient heat transfer for 50% effectiveness. A surface area that generates minimal heat transfer in the third pass (Z-1000) section is envisioned. Heat transferred in this section reduces the differential temperature across the matrix and the thermal stresses. Hence, thermal shock resistance of the material in the third pass becomes less critical; however, its corrosion resistance must be sufficient to withstand corrosive attack. This modular design could utilize a field repairable, disposable matrix. This report is concerned with process technology development for fabricating such a matrix, and a series of corrosion tests that established the potential corrosion resistance of the Z-1000 ceramic.

  14. Fabrication of mullite-bonded porous SiC ceramics from multilayer-coated SiC particles through sol-gel and in-situ polymerization techniques

    NASA Astrophysics Data System (ADS)

    Ebrahimpour, Omid

    In this work, mullite-bonded porous silicon carbide (SiC) ceramics were prepared via a reaction bonding technique with the assistance of a sol-gel technique or in-situ polymerization as well as a combination of these techniques. In a typical procedure, SiC particles were first coated by alumina using calcined powder and alumina sol via a sol-gel technique followed by drying and passing through a screen. Subsequently, they were coated with the desired amount of polyethylene via an in-situ polymerization technique in a slurry phase reactor using a Ziegler-Natta catalyst. Afterward, the coated powders were dried again and passed through a screen before being pressed into a rectangular mold to make a green body. During the heating process, the polyethylene was burnt out to form pores at a temperature of about 500°C. Increasing the temperature above 800°C led to the partial oxidation of SiC particles to silica. At higher temperatures (above 1400°C) derived silica reacted with alumina to form mullite, which bonds SiC particles together. The porous SiC specimens were characterized with various techniques. The first part of the project was devoted to investigating the oxidation of SiC particles using a Thermogravimetric analysis (TGA) apparatus. The effects of particle size (micro and nano) and oxidation temperature (910°C--1010°C) as well as the initial mass of SiC particles in TGA on the oxidation behaviour of SiC powders were evaluated. To illustrate the oxidation rate of SiC in the packed bed state, a new kinetic model, which takes into account all of the diffusion steps (bulk, inter and intra particle diffusion) and surface oxidation rate, was proposed. Furthermore, the oxidation of SiC particles was analyzed by the X-ray Diffraction (XRD) technique. The effect of different alumina sources (calcined Al2O 3, alumina sol or a combination of the two) on the mechanical, physical, and crystalline structure of mullite-bonded porous SiC ceramics was studied in the

  15. Role of Y{sub 2}O{sub 3}, CaO, MgO additives on structural and microstructural behavior of zirconia/mullite aggregates

    SciTech Connect

    Mishra, D. K.; Prusty, Sasmita; Mohapatra, B. K.; Singh, S. K.; Behera, S. N.

    2012-07-23

    Zirconia mullite (MUZ), Y{sub 2}O{sub 3}-MUZ, CaO-MUZ and MgO-MUZ composites, synthesized through plasma fusion technique, are becoming important due to their commercial scale of production within five minutes of plasma treatment from sillimanite, zircon and alumina mixture. The X-ray diffraction studies reveal the monoclinic zirconia phase in MUZ composite whereas mixed monoclinic, tetragonal and cubic phases of zirconia have been observed in Y{sub 2}O{sub 3}, CaO, MgO added MUZ composites. The Y{sub 2}O{sub 3}, CaO and MgO additives act as sintering aids to favour the transformation and stabilisation of tetragonal and cubic zirconia phases at room temperature. These additives also play a key role in the development of various forms of microstructure to achieve dense MUZ composites.

  16. Study of the interfacial reactions between a bioactive apatite-mullite glass-ceramic coating and titanium substrates using high angle annular dark field transmission electron microscopy.

    PubMed

    Stanton, Kenneth T; O'Flynn, Kevin P; Nakahara, Shohei; Vanhumbeeck, Jean-François; Delucca, John M; Hooghan, Bobby

    2009-04-01

    Glass of generic composition SiO(2) . Al(2)O(3) . P(2)O(5) . CaO . CaF(2) will crystallise predominantly to apatite and mullite upon heat-treatment. Such ceramics are bioactive, osseoconductive, and have a high resistance to fracture. As a result, they are under investigation for use as biomedical device coatings, and in particular for orthopaedic implants. Previous work has shown that the material can be successfully enamelled to titanium with an interfacial reaction zone produced during heat treatment. The present study uses high angle annular dark field transmission electron microscopy (HAADF-TEM) to conduct a detailed examination of this region. Results show evidence of complex interfacial reactions following the diffusion of titanium into an intermediate layer and the production of titanium silicides and titanium phosphides. These results confirm previously hypothesised mechanisms for the bonding of silicate bioceramics with titanium alloys.

  17. The effect of ZrO2 and TiO 2 on solubility and strength of apatite-mullite glass-ceramics for dental applications.

    PubMed

    Fathi, Hawa M; Miller, Cheryl; Stokes, Christopher; Johnson, Anthony

    2014-03-01

    The effect of ZrO2 and TiO2 on the chemical and mechanical properties of apatite-mullite glass-ceramics was investigated after sample preparation according to the ISO (2768:2008) recommendations for dental ceramics. All materials were characterized using differential thermal analysis, X-ray diffraction, scanning electron microscopy and energy dispersive spectroscopy. X-ray fluorescence spectroscopy was used to determine the concentrations of elements present in all materials produced. The chemical solubility test and the biaxial flexural strength (BFS) test were then carried out on all the samples. The best solubility value of 242 ± 61 μg/cm(2) was obtained when HG1T was heat-treated for 1 h at the glass transition temperature plus 20 °C (Tg + 20 °C) followed by 5 h at 1200 °C. The highest BFS value of 174 ± 38 MPa was achieved when HG1Z and HG1Z+T were heat-treated for 1 h at the Tg + 20 °C followed by 7 h at 1200 °C. The present study has demonstrated that the addition of TiO2 to the reference composition showed promise in both the glass and heat-treated samples. However, ZrO2 is an effective agent for developing the solubility or the mechanical properties of an apatite-mullite glass-ceramic separately but does not improve the solubility and the BFS simultaneously.

  18. EFFECT OF QUARTZ/MULLITE BLEND CERAMIC ADDITIVE ON IMPROVING RESISTANCE TO ACID OF SODIUM SILICATE-ACTIVATED SLAG CEMENT. CELCIUS BRINE.

    SciTech Connect

    SUGAMA, T.; BROTHERS, L.E.; VAN DE PUTTE, T.R.

    2006-06-01

    We evaluated the usefulness of manufactured quartz/mullite blend (MQMB) ceramic powder in increasing the resistance to acid of sodium silicate-activated slag (SSAS) cementitious material for geothermal wells. A 15-day exposure to 90{sup o} CO{sub 2}-laden H{sub 2}SO{sub 4} revealed that the MQMB had high potential as an acid-resistant additive for SSAS cement. Two factors, the appropriate ratio of slag/MQMB and the autoclave temperature, contributed to better performance of MQMB-modified SSAS cement in abating its acid erosion. The most effective slag/MQMB ratio in minimizing the loss in weight by acid erosion was 70/30 by weight. For autoclave temperature, the loss in weight of 100 C autoclaved cement was a less than 2%, but at 300 C it was even lower. Before exposure to acid, the cement autoclaved at 100 C was essentially amorphous; increasing the temperature to 200 C led to the formation of crystalline analcime in the zeolitic mineral family during reactions between the mullite in MQMB and the Na from sodium silicate. In addition, at 300 C, crystal of calcium silicate hydrate (1) (CSH) was generated in reactions between the quartz in MQMB and the activated slag. These two crystalline phases (CSH and analcime) were responsible for densifying the autoclaved cement, conveying improved compressive strength and minimizing water permeability. The CSH was susceptible to reactions with H{sub 2}SO{sub 4}, forming two corrosion products, bassanite and ionized monosilicic acid. However, the uptake of ionized monosilicic acid by Mg dissociated from the activated slag resulted in the formation of lizardite as magnesium silicate hydrate. On the other hand, the analcime was barely susceptible to acid if at all. Thus, the excellent acid resistance of MQMB-modified SSAS cement was due to the combined phases of lizardite and analcime.

  19. Low cost, YAG and mullite fibers by continuous extrusion and pyrolysis of metal carboxylate precursors. Final report, 1 March 1997--31 August 1998

    SciTech Connect

    Svedberg, R.; Vitale, M.; Laine, R.M.; Chew, K.W.; Weinmann, M.

    1998-08-31

    Optimal ceramic reinforced CMS`s and MMC`s are the key to the success of many Air Force programs because of the significant promise these lightweight, high strength materials offer for meeting projected performance and protection requirements for a wide variety of aerospace applications. This Phase 1 program has explored methods of producing continuous yttrium aluminum garnet (Y{sub 3}Al{sup 5}O{sub 12}) and mullite (3Al{sub 2}O{sub 3}SiO{sub 2}) fibers. In Task 1, synthesis reactors have been constructed with 12:1 and 50:1 capacities that will enable the authors to produce up to 2 kg of precursor compounds in a single reactor directly from Al(OH){sub 3} and/or SiO{sub 2}. In Task 2, fiber processing properties were optimized. They can produce 3 m/min of 30 micrometer ave. dia. Fiber and spool it. This translates to 180 m/h. They have initiated efforts to optimize the spinning process to meet the expectations of Phase 2 work to produce 10s m/h of multi-fiber tows suitable for manufacture of ceramic/ceramic composites. In Task 3, Fiber properties for hand drawn fibers produced in earlier studies showed bend strengths as 1.9 Gpa (assuming e = 280 Gpa), but tensile tests on continuously processed fibers have yet to be done. Phase 1 goals will be to refine the processing steps necessary to produce larger quantities of fibers, with better control of fiber diameters, pyrolysis treatments and finally mechanical properties. The authors also expect to extend their efforts to improve the mullite fiber system. They must learn to cure these fibers as they are being spun and then conduct pyrolysis studies.

  20. Elastic Modulus Evolution and Behavior of Si/Mullite/BSAS-Based Environmental Barrier Coatings Exposed to High Temperature in Water Vapor Environment

    NASA Astrophysics Data System (ADS)

    Cojocaru, C. V.; Kruger, S. E.; Moreau, C.; Lima, R. S.

    2011-01-01

    Si-based ceramics (e.g., SiC and Si3N4) are known as promising high-temperature structural materials in various components where metals/alloys reached their ultimate performances (e.g., advanced gas turbine engines and structural components of future hypersonic vehicles). To alleviate the surface recession that Si-based ceramics undergo in a high-temperature environmental attack (e.g., H2O vapor), appropriate refractory oxides are engineered to serve as environmental barrier coatings (EBCs). The current state-of-the-art EBCs multilayer system comprises a silicon (Si) bond coat, mullite (3Al2O3·2SiO2) interlayer and (1 - x)BaO· xSrO·Al2O3·2SiO2, 0 ≤ x ≤ 1 (BSAS) top coat. In this article, the role of high-temperature exposure (1300 °C) performed in H2O vapor environment (for time intervals up to 500 h) on the elastic moduli of air plasma sprayed Si/mullite/BSAS layers deposited on SiC substrates was investigated via depth-sensing indentation. Laser-ultrasonics was employed to evaluate the E values of as-sprayed BSAS coatings as an attempt to validate the indentation results. Fully crystalline, crack-free, and near-crack-free as-sprayed EBCs were engineered under controlled deposition conditions. The absence of phase transformation and stability of the low elastic modulus values (e.g., ~60-70 GPa) retained by the BSAS top layers after harsh environmental exposure provides a plausible explanation for the almost crack-free coatings observed. The relationships between the measured elastic moduli of the EBCs and their microstructural behavior during the high-temperature exposure are discussed.

  1. Coatings for mullite insulation

    NASA Technical Reports Server (NTRS)

    Bolinger, P. N.; Rauch, H. W., Sr.

    1976-01-01

    Series of coatings provides hard, impermeable, waterproof layer. Inclusion of color oxides imparts high emittance to surface. Refractory fillers investigated include TiO2, BaO.ZrO2, SrO.TiO2 ziron, spodumene, petalite, and kryptonite. Colorants include Cr2O3, NiO, and CoO.

  2. An X-ray micro-fluorescence study to investigate the distribution of Al, Si, P and Ca ions in the surrounding soft tissue after implantation of a calcium phosphate-mullite ceramic composite in a rabbit animal model.

    PubMed

    Martin, Richard A; Jaffer, Zahira; Tripathi, Garima; Nath, Shekhar; Mohanty, Mira; Fitzgerald, Victoria; Lagarde, Pierre; Flank, Anne-Marie; Stamboulis, Artemis; Basu, Bikramjit

    2011-11-01

    Synthetic calcium phosphates, despite their bioactivity, are brittle. Calcium phosphate- mullite composites have been suggested as potential dental and bone replacement materials which exhibit increased toughness. Aluminium, present in mullite, has however been linked to bone demineralisation and neurotoxicity: it is therefore important to characterise the materials fully in order to understand their in vivo behaviour. The present work reports the compositional mapping of the interfacial region of a calcium phosphate--20 wt% mullite biocomposite/soft tissue interface, obtained from the samples implanted into the long bones of healthy rabbits according to standard protocols (ISO-10993) for up to 12 weeks. X-ray micro-fluorescence was used to map simultaneously the distribution of Al, P, Si and Ca across the ceramic-soft tissue interface. A well defined and sharp interface region was present between the ceramic and the surrounding soft tissue for each time period examined. The concentration of Al in the surrounding tissue was found to fall by two orders of magnitude, to the background level, within ~35 μm of the implanted ceramic.

  3. Elucidating structural order and disorder phenomena in mullite-type Al4B2O9 by automated electron diffraction tomography

    NASA Astrophysics Data System (ADS)

    Zhao, Haishuang; Krysiak, Yaşar; Hoffmann, Kristin; Barton, Bastian; Molina-Luna, Leopoldo; Neder, Reinhard B.; Kleebe, Hans-Joachim; Gesing, Thorsten M.; Schneider, Hartmut; Fischer, Reinhard X.; Kolb, Ute

    2017-05-01

    The crystal structure and disorder phenomena of Al4B2O9, an aluminum borate from the mullite-type family, were studied using automated diffraction tomography (ADT), a recently established method for collection and analysis of electron diffraction data. Al4B2O9, prepared by sol-gel approach, crystallizes in the monoclinic space group C2/m. The ab initio structure determination based on three-dimensional electron diffraction data from single ordered crystals reveals that edge-connected AlO6 octahedra expanding along the b axis constitute the backbone. The ordered structure (A) was confirmed by TEM and HAADF-STEM images. Furthermore, disordered crystals with diffuse scattering along the b axis are observed. Analysis of the modulation pattern implies a mean superstructure (AAB) with a threefold b axis, where B corresponds to an A layer shifted by ½a and ½c. Diffraction patterns simulated for the AAB sequence including additional stacking disorder are in good agreement with experimental electron diffraction patterns.

  4. Thermal stability of mullite RMn₂O₅ (R  =  Bi, Y, Pr, Sm or Gd): combined density functional theory and experimental study.

    PubMed

    Li, Chenzhe; Thampy, Sampreetha; Zheng, Yongping; Kweun, Joshua M; Ren, Yixin; Chan, Julia Y; Kim, Hanchul; Cho, Maenghyo; Kim, Yoon Young; Hsu, Julia W P; Cho, Kyeongjae

    2016-03-31

    Understanding and effectively predicting the thermal stability of ternary transition metal oxides with heavy elements using first principle simulations are vital for understanding performance of advanced materials. In this work, we have investigated the thermal stability of mullite RMn2O5 (R  =  Bi, Pr, Sm, or Gd) structures by constructing temperature phase diagrams using an efficient mixed generalized gradient approximation (GGA) and the GGA  +  U method. Simulation predicted stability regions without corrections on heavy elements show a 4-200 K underestimation compared to our experimental results. We have found the number of d/f electrons in the heavy elements shows a linear relationship with the prediction deviation. Further correction on the strongly correlated electrons in heavy elements could significantly reduce the prediction deviations. Our corrected simulation results demonstrate that further correction of R-site elements in RMn2O5 could effectively reduce the underestimation of the density functional theory-predicted decomposition temperature to within 30 K. Therefore, it could produce an accurate thermal stability prediction for complex ternary transition metal oxide compounds with heavy elements.

  5. Anisotropic thermal expansion and anharmonic phonon behavior of mullite-type Bi{sub 2}Ga{sub 4}O{sub 9}

    SciTech Connect

    Murshed, M. Mangir Gesing, Thorsten M.

    2013-09-01

    Graphical abstract: - Highlights: • Anisotropic lattice thermal expansion of Bi{sub 2}Ga{sub 4}O{sub 9} was modeled using extended Grüneisen first-order approximation. • The model includes harmonic, quasi-harmonic and intrinsic anharmonic contributions to the internal energy. • Temperature dependent Raman frequency shift and line-width was analyzed using symmetric phonon decay channel. - Abstract: We report the lattice thermal expansion and the temperature-dependent phonon behavior of the mullite-type Bi{sub 2}Ga{sub 4}O{sub 9} complex oxide. The thermal expansion was studied using composite data collected from powder and single crystal X-ray diffraction between 100 K and 1273 K. The lattice expansion occurred in the order of a < c < b. The anisotropic expansion behavior was monitored with respect to thermal expansion coefficients and the anisotropy factor. The volume thermal expansion was expressed using an extended Grüneisen first-order approximation to the zero-pressure equation of state; the model includes harmonic, quasi-harmonic and intrinsic anharmonic contributions to the internal energy as a function of temperature. The temperature dependent Raman spectra were collected from a single crystal between 78 K and 1273 K. The shift of the frequencies and the broadening of the line-widths with increasing temperature helped to analyze the anharmonicity and the thermal behavior of some phonons.

  6. Thermal stability of mullite RMn2O5 (R  =  Bi, Y, Pr, Sm or Gd): combined density functional theory and experimental study

    NASA Astrophysics Data System (ADS)

    Li, Chenzhe; Thampy, Sampreetha; Zheng, Yongping; Kweun, Joshua M.; Ren, Yixin; Chan, Julia Y.; Kim, Hanchul; Cho, Maenghyo; Kim, Yoon Young; Hsu, Julia W. P.; Cho, Kyeongjae

    2016-03-01

    Understanding and effectively predicting the thermal stability of ternary transition metal oxides with heavy elements using first principle simulations are vital for understanding performance of advanced materials. In this work, we have investigated the thermal stability of mullite RMn2O5 (R  =  Bi, Pr, Sm, or Gd) structures by constructing temperature phase diagrams using an efficient mixed generalized gradient approximation (GGA) and the GGA  +  U method. Simulation predicted stability regions without corrections on heavy elements show a 4-200 K underestimation compared to our experimental results. We have found the number of d/f electrons in the heavy elements shows a linear relationship with the prediction deviation. Further correction on the strongly correlated electrons in heavy elements could significantly reduce the prediction deviations. Our corrected simulation results demonstrate that further correction of R-site elements in RMn2O5 could effectively reduce the underestimation of the density functional theory-predicted decomposition temperature to within 30 K. Therefore, it could produce an accurate thermal stability prediction for complex ternary transition metal oxide compounds with heavy elements.

  7. Structural, electrical and multiferroic properties of La-doped mullite Bi{sub 2}Fe{sub 4}O{sub 9} thin films

    SciTech Connect

    Raghavan, C.M.; Kim, J.W.; Kim, J.-W.; Kim, S.S.

    2015-10-15

    Highlights: • Chemical solution deposited La-doped Bi{sub 2}Fe{sub 4}O{sub 9} thin film. • Structural, electrical and multiferroic properties were investigated. • La-doped Bi{sub 2}Fe{sub 4}O{sub 9} exhibited enhanced electrical and multiferroic properties. - Abstract: Thin films of (Bi{sub 2−x}La{sub x})Fe{sub 4}O{sub 9} (x = 0 and x = 0.05) were prepared on Pt(1 1 1)/Ti/SiO{sub 2}/Si(1 0 0) substrates by using a chemical solution deposition method to investigate structural, microstructural, electrical and multiferroic properties. Both the thin films were crystallized in mullite type phases with orthorhombic structures containing no secondary and impurity phases, which was confirmed by X-ray diffraction and Raman spectroscopy studies. The (Bi{sub 1.95}La{sub 0.05})Fe{sub 4}O{sub 9} thin film exhibited improved electrical and multiferroic properties at room-temperature. The leakage current density of the (Bi{sub 1.95}La{sub 0.05})Fe{sub 4}O{sub 9} thin film was one order of magnitude lower than that of the Bi{sub 2}Fe{sub 4}O{sub 9} thin film. Furthermore, in the thin film form, (Bi{sub 2−x}La{sub x})Fe{sub 4}O{sub 9} exhibited better stability against electrical breakdowns and enhanced multiferroic properties.

  8. Thermal expansion of mullite-type Bi{sub 2}Al{sub 4}O{sub 9}: A study by X-ray diffraction, vibrational spectroscopy and density functional theory

    SciTech Connect

    Mangir Murshed, M.; Mendive, Cecilia B.; Curti, Mariano; Šehović, Malik; Friedrich, Alexandra; Fischer, Michael; Gesing, Thorsten M.

    2015-09-15

    Polycrystalline Bi{sub 2}Al{sub 4}O{sub 9} powder samples were synthesized using the glycerine method. Single crystals were produced from the powder product in a Bi{sub 2}O{sub 3} melt. The lattice thermal expansion of the mullite-type compound was studied using X-ray diffraction, Raman spectroscopy and density functional theory (DFT). The metric parameters were modeled using Grüneisen approximation for the zero pressure equation of state, where the temperature-dependent vibrational internal energy was calculated from the Debye characteristic frequency. Both the first-order and second-order Grüneisen approximations were applied for modeling the volumetric expansion, and the second-order approach provided physically meaningful axial parameters. The phonon density of states as well as phonon dispersion guided to set the characteristic frequency for simulation. The experimental infrared and Raman phonon bands were compared with those calculate from the DFT calculations. Selective Raman modes were analyzed for the thermal anharmonic behaviors using simplified Klemens model. The respective mode Grüneisen parameters were calculated from the pressure-dependent Raman spectra. - Graphical abstract: Crystal structure of mullite-type Bi{sub 2}Al{sub 4}O{sub 9} showing the edge-sharing AlO{sub 6} octahedra running parallel to the c-axis. - Highlights: • Thermal expansion of Bi{sub 2}Al{sub 4}O{sub 9} was studied using XRD, FTIR, Raman and DFT. • Metric parameters were modeled using Grüneisen approximation. • Phonon DOS and phonon dispersion helped to set the Debye frequency. • Mode Grüneisen parameters were calculated from the pressure-dependent Raman spectra. • Anharmonicity was analyzed for some selective Raman modes.

  9. Temperature-dependent structural studies of mullite-type Bi{sub 2}Fe{sub 4}O{sub 9}

    SciTech Connect

    Murshed, M. Mangir; Nenert, Gwilherm; Burianek, Manfred; Robben, Lars; Muehlberg, Manfred; Schneider, Hartmut; Fischer, Reinhard X.; Gesing, Thorsten M.

    2013-01-15

    We report on the temperature-dependent structural studies on the mullite-type Bi{sub 2}Fe{sub 4}O{sub 9} compound. The crystal structures were determined using both powder X-ray diffraction and single crystal neutron diffraction. The thermal expansion of the cell parameters from smallest to largest occurred in the order a

  10. Chromium substitution in mullite type bismuth aluminate: Bi{sub 2}Cr{sub x}Al{sub 4−x}O{sub 9} with 0≤x≤2.0

    SciTech Connect

    Debnath, Tapas; Ullah, Ahamed; Rüscher, Claus H.; Hussain, Altaf

    2014-12-15

    Nominal compositions Bi{sub 2}Cr{sub x}Al{sub 4−x}O{sub 9} with 0.0≤x≤2.0 (Δx=0.2) were prepared using appropriate amounts of nitrates dissolved in glycerine and heated at 800 °C for 24 h as we previously used for the preparation of solid solution series Bi{sub 2}M{sub x}/M′{sub 4−x}O{sub 9} (M/M′=Fe/Al, Ga/Al and Fe/Ga). The samples were characterized using XRD, FTIR and optical microscopic techniques. Analyses of XRD data show mullite type single phase can be prepared up to x=1.2. The lattice parameters (a, b and c) increases with increasing Cr content. Further increase in x (i.e., x≥1.4) show the presence of some additional phases indicating a limiting value for Cr doping is in the range of 1.2≤x<1.4. The effect of Cr incorporation could also be observed in the infrared absorption spectra via systematic hard mode shifts of certain lattice modes, e.g. the Bi–O related vibration changes from 96 cm{sup −1} to 93 cm{sup −1} with increasing x up to 1.2 and certain intensity changes together with shift in peak positions. Interestingly, the absence of any splitting and shift of the high energy IR absorption peak at 821 cm{sup −1} as assigned to the characteristic tetrahedral type dimer, Al{sub 2}O{sub 7}, indicate that the Cr thus partially substitutes only the octahedrally coordinated Al. This is confirmed by Rietveld structure refinements, too. - Graphical abstract: Structural model of Cr doped bismuth aluminate, Bi{sub 2}Cr{sub x}Al{sub 4−x}O{sub 9}. - Highlights: • Chromium doped bismuth aluminate, Bi{sub 2}Cr{sub x}Al{sub 4−x}O{sub 9} with mullite type structure are synthesized. • The samples are characterized by XRD and FTIR techniques. • Cr can replace only certain amount of octahedrally coordinated Al in Bi{sub 2}Al{sub 4}O{sub 9} under present experimental conditions.

  11. New pressure induced phase transitions in mullite-type Bi2(Fe4-xMnx)O10-δ complex oxides

    SciTech Connect

    Kalita, Patricia E; Cornelius, Andrew L; Lipinska, Kristina E; Lufaso, Michael W; Kann, Zachary R; Sinogeikin, Stanislav; Hemmers, Oliver A; Schneider, Hartmut

    2016-07-29

    Single phased mullite-type Bi2Fe4-xMnxO10-δ mixed crystals (0.25 ± x ± 3.125) and the end-member Bi2Fe4O9, synthesized from the oxides by reaction sintering up to 825°C, were studied at high-pressures in order to probe their high-pressure behavior and any possible structural phase transitions. In-situ synchrotron radiation-based powder X-ray diffraction was carried out in a diamond anvil cell, under quasi-hydrostatic conditions, up to a pressure of about 20 GPa at room temperature for each sample. A pressure-induced phase transition was found in all samples. The transition appeared spread over a pressure range and was not completed at the top investigated pressure. This is the first report of a pressure-induced phase transition in Bi2Fe4-xMnxO10-δ mixed crystals.

  12. Mechanochemical-thermal preparation and structural studies of mullite-type Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} solid solutions

    SciTech Connect

    Da Silva, K.L.; Sepelak, V.; Duevel, A.; Paesano, A.; Hahn, H.; Litterst, F.J.; Heitjans, P.; Becker, K.D.

    2011-05-15

    A series of Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} solid solutions (0{<=}x{<=}1), prepared by mechanochemical processing of Bi{sub 2}O{sub 3}/Ga{sub 2}O{sub 3}/Al{sub 2}O{sub 3} mixtures and subsequent annealing, was investigated by XRD, EDX, and {sup 27}Al MAS NMR. The structure of the Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} solid solutions is found to be orthorhombic, space group Pbam (No. 55). The lattice parameters of the Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} series increase linearly with increasing gallium content. Rietveld refinement of the XRD data as well as the analysis of the {sup 27}Al MAS NMR spectra show a preference of gallium cations for the tetrahedral sites in Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9}. As a consequence, this leads to a far from random distribution of Al and Ga cations across the whole series of solid solutions. -- Graphical Abstract: Mullite-type Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} mixed crystals (0{<=}x{<=}1) prepared by a combined mechanochemical-thermal route possess a non-random distribution of Ga{sup 3+} and Al{sup 3+} cations over the sites of tetrahedral (T) and octahedral [O] coordination, characterized by the preference of Ga{sup 3+} (Al{sup 3+}) for tetrahedral (octahedral) sites. Display Omitted Highlights: {yields} Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} (0{<=}x{<=}1) were synthesized via mechanochemical-thermal route. {yields} The lattice parameters of Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} increase linearly with gallium content. {yields} Quantitative information on the cation distribution in Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} is derived. {yields} Ga{sup 3+} and Al{sup 3+} show the preference for tetrahedral and octahedral sites, respectively.

  13. Crystal-chemistry of mullite-type aluminoborates Al{sub 18}B{sub 4}O{sub 33} and Al{sub 5}BO{sub 9}: A stoichiometry puzzle

    SciTech Connect

    Fisch, Martin; Armbruster, Thomas; Rentsch, Daniel; Libowitzky, Eugen; Pettke, Thomas

    2011-01-15

    Orthorhombic Al{sub 2}O{sub 3}-rich aluminoborate is an important ceramic material for which two slightly different compositions have been assumed: Al{sub 5}BO{sub 9} (5Al{sub 2}O{sub 3}:B{sub 2}O{sub 3}) and Al{sub 18}B{sub 4}O{sub 33} (9Al{sub 2}O{sub 3}:2B{sub 2}O{sub 3}). The formula Al{sub 18}B{sub 4}O{sub 33} (=Al{sub 4.91}B{sub 1.09}O{sub 9}) was derived from results of chemical analyses when crystal structure data were not yet available. Subsequent structural investigations indicated Al{sub 5}BO{sub 9} composition. Nevertheless, Al{sub 18}B{sub 4}O{sub 33} was still accepted as the correct stoichiometry assuming that additional B replaces 9% Al. Powder samples of both compositions and ones with excess boron were prepared by solid state reactions between {alpha}-Al{sub 2}O{sub 3} and B{sub 2}O{sub 3}/H{sub 3}BO{sub 3} at temperatures above 1100 {sup o}C and single-crystals were grown from flux at 1100 and 1550 {sup o}C. Products were investigated by single-crystal and powder XRD, {sup 11}B and {sup 27}Al solid-state MAS-NMR, Raman and FTIR spectroscopy as well as Laser-ablation ICP-MS. No indication of the predicted 9% B{yields}Al substitution was found. LA ICP-MS indicated 12.36(27) wt% B{sub 2}O{sub 3} corresponding to Al{sub 4.97}B{sub 1.03}O{sub 9}. Hence, the suggested Al{sub 18}B{sub 4}O{sub 33} stoichiometry can be excluded for all synthesized samples. A very low amount of Al vacancies at a five-fold coordinated site are likely, charge balanced by an additional nearby three-fold coordinated B site. All evidences indicate that the title compound should be reported as Al{sub 5-x}B{sub 1+x}O{sub 9} with x<0.038(6), which is close to Al{sub 5}BO{sub 9}. -- Graphical abstract: A chemical composition of Al{sub 18}B{sub 4}O{sub 33}=Al{sub 4.91}B{sub 1.09}O{sub 9}=9Al{sub 2}O{sub 3}:2B{sub 2}O{sub 3} has been assumed for mullite-type aluminoborate with Al{sub 5}BO{sub 9} structure. However, samples prepared by different routes showed compositions close to 5Al

  14. 3-D woven, mullite matrix, composite filter

    SciTech Connect

    Lane, J.E.; Painter, C.J.; Radford, K.C. LeCostaouec, J.F.

    1995-12-01

    Westinghouse, with Techniweave as a major subcontractor, is conducting a three-phase program aimed at providing advanced candle filters for a 1996 pilot scale demonstration in one of the two hot gas filter systems at Southern Company Service`s Wilsonville PSD Facility. The Base Program (Phases I and II) objective is to develop and demonstrate the suitability of the Westinghouse/Techniweave next generation composite candle filter for use in Pressurized Fluidized Bed Combustion (PFBC) and/or Integrated Gasification Combined Cycle (IGCC) power generation systems. The Optional Task (Phase M, Task 5) objective is to fabricate, inspect and ship to Wilsonville Hot gas particulate filters are key components for the successful commercializaion of advanced coal-based power-generation systems such as Pressurized Fluidized-bed Combustion (PFBC), including second-generation PFBC, and Integrated Gasification Combined Cycles (IGCC). Current generation monolithic ceramic filters are subject to catastrophic failure because they have very low resistance to crack propagation. To overcome this problem, a damage-tolerant ceramic filter element is needed.

  15. Series of compositions Bi{sub 2}(M'{sub x}M{sub 1-x}){sub 4}O{sub 9} (M', M=Al, Ga, Fe; 0{<=}x{<=}1) with mullite-type crystal structure: Synthesis, characterization and {sup 18}O/{sup 16}O exchange experiment

    SciTech Connect

    Debnath, T.; Ruescher, C.H.; Fielitz, P.; Ohmann, S.; Borchardt, G.

    2010-11-15

    Series of compositions Bi{sub 2}(M'{sub x}M{sub 1-x}){sub 4}O{sub 9} with x=0.0, 0.1,..., 1.0 and M'/M=Ga/Al, Fe/Al and Fe/Ga were synthesized by dissolving appropriate amounts of corresponding metal nitrate hydrates in glycerine, followed by gelation, calcination and final heating at 800 {sup o}C for 24 h. The new compositions with M'/M=Ga/Al form solid-solution series, which are isotypes to the two other series M'/M=Fe/Al and Fe/Ga. The XRD data analysis yielded in all cases a linear dependence of the lattice parameters related on x. Rietveld structure refinements of the XRD patterns of the new compounds, Bi{sub 2}(Ga{sub x}Al{sub 1-x}){sub 4}O{sub 9} reveal a preferential occupation of Ga in tetrahedral site (4 h). The IR absorption spectra measured between 50 and 4000 cm{sup -1} of all systems show systematic shifts in peak positions related to the degree of substitution. Samples treated in {sup 18}O{sub 2} atmosphere (16 h at 800 {sup o}C, 200 mbar, 95% {sup 18}O{sub 2}) for {sup 18}O/{sup 16}O isotope exchange experiments show a well-separated IR absorption peak related to the M-{sup 18}O{sub c}-M vibration, where O{sub c} denotes the common oxygen of two tetrahedral type MO{sub 4} units. The intensity ratio of M-{sup 18}O{sub c}/M-{sup 16}O{sub c} IR absorption peaks and the average crystal sizes were used to estimate the tracer diffusion coefficients of polycrystalline Bi{sub 2}Al{sub 4}O{sub 9} (D=2x10{sup -22} m{sup 2}s{sup -1}), Bi{sub 2}Fe{sub 4}O{sub 9} (D=5x10{sup -21} m{sup 2}s{sup -1}), Bi{sub 2}(Ga/Al){sub 4}O{sub 9} (D=2x10{sup -21} m{sup 2}s{sup -1}) and Bi{sub 2}Ga{sub 4}O{sub 9} (D=2x10{sup -20} m{sup 2}s{sup -1}). - Graphical abstract: Fig. Perspective view of the mullite-type Bi{sub 2}(M'{sub x}M{sub 1-x}){sub 4}O{sub 9} unit cell (M', M=Al, Ga, Fe). Display Omitted

  16. Processing of a Mullite Matrix, Molybdenum Disilicide Reinforced Composite

    DTIC Science & Technology

    1991-01-01

    concentration is that of the dispersion medium. The Debye - Huckel length is used to give the thickness of the double layer and is of the order 3/Kc to...Stem layer potential K = Debye - Huckel length * H particle-particle separation S 10 S Having defined the attractive and repulsive energies (VA, VR...potential. The double layer theory is important because it gives a picture of what is happening between dispersed particles and between the particles and

  17. Mullite fiber reinforced reaction bonded Si3N4 composites

    NASA Technical Reports Server (NTRS)

    Saleh, T.; Sayir, A.; Lightfoot, A.; Haggerty, J.

    1996-01-01

    Fracture toughnesses of brittle ceramic materials have been improved by introducing reinforcements and carefully tailored interface layers. Silicon carbide and Si3N4 have been emphasized as matrices of structural composites intended for high temperature service because they combine excellent mechanical, chemical, thermal and physical properties. Both matrices have been successfully toughened with SiC fibers, whiskers and particles for ceramic matrix composite (CMC) parts made by sintering, hot pressing or reaction forming processes. These SiC reinforced CMCs have exhibited significantly improved toughnesses at low and intermediate temperature levels, as well as retention of properties at high temperatures for selected exposures; however, they are vulnerable to attack from elevated temperature dry and wet oxidizing atmospheres after the matrix has cracked. Property degradation results from oxidation of interface layers and/or reinforcements. The problem is particularly acute for small diameter (-20 tim) polymer derived SiC fibers used for weavable toes. This research explored opportunities for reinforcing Si3N4 matrices with fibers having improved environmental stability; the findings should also be applicable to SiC matrix CMCs.

  18. Crystal chemical characterization of mullite-type aluminum borate compounds

    NASA Astrophysics Data System (ADS)

    Hoffmann, K.; Hooper, T. J. N.; Zhao, H.; Kolb, U.; Murshed, M. M.; Fischer, M.; Lührs, H.; Nénert, G.; Kudějová, P.; Senyshyn, A.; Schneider, H.; Hanna, J. V.; Gesing, Th. M.; Fischer, R. X.

    2017-03-01

    Al-rich aluminum borates were prepared by different synthesis routes using various Al/B ratios, characterized by diffraction methods, spectroscopy and prompt gamma activation analysis. The 11B NMR data show a small amount of BO4 species in all samples. The chemical analysis indicates a trend in the Al/B ratio instead of a fixed composition. Both methods indicate a solid solution Al5-xB1+xO9 where Al is substituted by B in the range of 1-3%. The structure of B-rich Al4B2O9 (C2/m, a=1488 pm, b=553 pm, c=1502 pm, ß=90.6°), was re-investigated by electron diffraction methods, showing that structural details vary within a crystallite. In most of the domains the atoms are orderly distributed, showing no signal for the postulated channel oxygen atom O5. The absence of O5 is supported by density functional theory calculations. Other domains show a probable disordered configuration of O5 and O10, indicated by diffuse scattering along the b direction.

  19. Silicon Carbide Fiber/Mullite Composites from Rapidly Solidified Aluminosilicate Powder.

    DTIC Science & Technology

    1984-04-01

    was the ~60 weight % Al20 3 , ~40 weight % Sio 2 Fiberfrax H insulating fibers fabricated by the Carborundum Company. By milling, these fibers were...obtained by dry ball milling Carborundum’s high temperature insulation known as Fiberfrax H. This is a fibrous material that is produced in commercial

  20. Dielectric Properties of Strontium Titanate Filled Mullite Composites in Microwave Region

    NASA Astrophysics Data System (ADS)

    See, Alex; Hassan, Jumiah; Hashim, Mansor; Yusoff, W. Mohd. Daud Wan

    2008-05-01

    This research was designed to form better dielectric composite material using one steady state dielectric with a good dielectric material. Distinct dielectric composite was successfully produced using locally sourced kaolinite clay. The samples were made using kaolinite as the base matrix and Strontium Titanate (ST) added in varying ratios. Strontium Titanate were synthesized via solid-state reaction using Strontium Carbonate and rutile Titanium (IV) Oxide with sintering at 1300 °C. Local white kaolinite was used to fuse the barium titanate material in varying weight ratios. The powders were dry-mixed and made into pellets for calcination at 1000 °C. The dielectric measurements were carried out using the HP 4291B Impedance Analyzer dielectric setup. Three samples were prepared, namely 10%ST, 20%ST and 30%ST. The dielectric measurements were carried out at room temperature. Microwave region measurements showed steady state and linear dielectric relaxation ranging from 7 in the control sample and dropping down to 5 in 30%ST. The responses indicate linear relation between ST addition and microwave region dielectric permittivity

  1. Coated article and method of making

    NASA Technical Reports Server (NTRS)

    Wang, Hongyu (Inventor); Lee, Kang Neung (Inventor)

    2002-01-01

    An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.

  2. Coated article and method of making

    NASA Technical Reports Server (NTRS)

    Wang, Hongyu (Inventor); Lee, Kang Neung (Inventor)

    2003-01-01

    An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.

  3. Effect of Steam Environment on Creep Behavior of Nextel720/Alumina-Mullite Ceramic Matrix Composite at Elevated Temperature

    DTIC Science & Technology

    2009-03-01

    exhaust nozzles. 2. ground ba sed ga s t urbine a nd a utomotive components s uch a s combustors, first and second stage turbine vanes and blades 3...Aircraft applications [5]. TYPE COMPONENT TYPICAL GOALS Land based gas turbines Combustor Turbine vanes operating at > 1600 °C for 25.000...TYPE COMPONENT TYPICAL GOALS Civil Aircraft Gas Turbines Compressor Combustor turbine For both components > 1300 °C for > 10.000 hrs

  4. Effects of Environment on Creep Behavior of Nextel 720/Alumina-Mullite Ceramic Composite at 1200 deg C

    DTIC Science & Technology

    2008-03-01

    propulsion. Ceramic matrix composites are ideal candidate materials for components in turbine engines such as combustor walls where structural materials...process. The specimens were first rinsed with alcohol, and then placed in an ultrasonic cleaner for 15 min. Once removed from the ultrasonic bath, the...close around the specimen without interference. A small hole was made in the back of the insulation to allow for gas feeding tubes and a slot was cut

  5. Effects of Environment On Creep Behavior of Nextel720/Alumina-Mullite Ceramic Composite With 45 Deg. Fiber Orientation at 1200 Deg. C

    DTIC Science & Technology

    2009-03-01

    Contract F49620-02-1-0128. 26. Jurf RA, Butner SC. Advances in oxide-oxide CMC. Trans ASME J Eng Gas Turbines Power 1999;122(2):202-205...maintaining excellent strength and fracture toughness at high temperatures continue to attract attention as candidate materials for aerospace turbine ...strength and fracture toughness at high temperatures continue to attract attention as candidate materials for aerospace turbine engine applications

  6. First principles study of the Mn-doping effect on the physical and chemical properties of mullite-family Al2SiO5.

    PubMed

    Wang, Qingbo; Liang, Chaoping; Zheng, Yongping; Ashburn, Nickolas; Oh, Young Jun; Kong, Fantai; Zhang, Chenxi; Nie, Yifan; Sun, Jian; He, Kaihua; Ye, Yu; Chen, Rong; Shan, Bin; Cho, Kyeongjae

    2017-09-06

    Transition metal (TM) modification is a common strategy for converting an earth-abundant mineral into a cost-effective catalyst for industrial applications. Among a variety of minerals, Al2SiO5, which has three phases, andalusite, sillimanite and kyanite, is emerging as a promising candidate for new catalyst development. In this paper, we use Mn to demonstrate the rationale of 3d TM doping at the Al sites in each of these three phases through first-principles calculations and the cluster expansion method. The results of cluster expansion show that Mn has a strong site preference for the six-coordinated Al octahedral chains in the andalusite and sillimanite phases, while distributing randomly in the kyanite phase. Moreover, Mn can only replace Al in sillimanite and kyanite in low concentrations; however, higher concentrations of Mn can replace Al in andalusite. We found that the concentration sensitivity is due to the Jahn-Teller distortion and 3d orbital splitting. This finding can also explain the low doping concentrations of other 3d TMs (Fe, Cr and V) in Al2SiO5 compounds. Based on the calculated Helmholtz free energy, we constructed a (MnxAl1-x)AlSiO5 temperature-composite phase diagram, which explains the physical mechanisms behind the results for 3d transition metal doping and phase transitions in Al2SiO5. This work could shed light on the related physics, chemistry, and geoscience of (MnxAl1-x)AlSiO5, and more importantly, a design rationale for the engineering of cheap catalysts.

  7. Characterization of RSI coating

    NASA Technical Reports Server (NTRS)

    Miller, A. D.; Garofalini, S. H.; Smiser, L. W.; Mueller, J. I.

    1973-01-01

    X-ray diffraction analyses on mullite, silica, and ceramic mullite fiber coating materials to investigate the effects of thermal cycling, show that ceramic mullite fiber coating porosity is little affected by cycling to 1250 C and that material pores are mostly smaller than 15 nm. Some mullite coatings experience a slight increase in crystobalite with somewhat increased porosity. Silica coatings show a marked tendency to precipitate cristobalite with increased porosity and dimensional instability.

  8. Emittance of RSI Coatings Determined from Radiation Measurements in Arc Jet Tests

    NASA Technical Reports Server (NTRS)

    Wakefield, R. M.; Stewart, D. A.

    1973-01-01

    Simultaneous measurements were made on three surface insulation coatings for total surface radiation and radiation at discrete wavelengths between 0.88 and 4.5 microns. The mullite coating radiated all the applied heat at convective heat rates of 204 and 295 kw/sq m. Radiation from the ceramic mullite fiber coating was 170 kw/sq m at a heat rate of 454 kw/sq m. Effective total emissivity and spectral emissivity values were evaluated; all three coatings were significantly non-grey. Effective total emissivity values were 0.79 for mullite, 0.50 for ceramic mullite fiber, and 0.78 for silica composite.

  9. Interfacial Studies of Chemical Vapor Infiltrated (CVI) Ceramic Matrix Composites

    DTIC Science & Technology

    1990-03-31

    methyldichlorosilane (MDS), methyltrichlorosilane (MTS), and dimethyldichlorosilane (DMDS). The fibers utilized were Nicalon SiC and Nextel 440 mullite. During the... methyltrichlorosilane (MTS), and dimethyldichlorosilane (DMDS). The fibers utilized were Nicalon SiC and Nextel 440 mullite. The chemistry and...MOS), methyltrichlorosilane (MTS), and dimethyldichloro- silane (DMDS). The fiber/matrix interface was tailored by means of introducing a carbon, BN, or

  10. Environmental Barrier Coatings Having a YSZ Top Coat

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Gray, Hugh (Technical Monitor)

    2002-01-01

    Environmental barrier coatings (EBCs) with a Si bond coat, a yttria-stabilized zirconia (YSZ) top coat, and various intermediate coats were investigated. EBCs were processed by atmospheric pressure plasma spraying. The EBC durability was determined by thermal cycling tests in water vapor at 1300 C and 1400 C, and in air at 1400 C and 1500 C. EBCs with a mullite (3Al2O3 (dot) 2SiO2) + BSAS (1 - xBaO (dot) xSrO (dot) Al2O3 (dot) 2SiO2) intermediate coat were more durable than EBCs with a mullite intermediate coat, while EBCs with a mullite/BSAS duplex intermediate coat resulted in inferior durability. The improvement with a mullite + BSAS intermediate coat was attributed to enhanced compliance of the intermediate coat due to the addition of a low modulus BSAS second phase. Mullite + BSAS/YSZ and BSAS/YSZ interfaces produced a low melting (less than 1400 C) reaction product, which is expected to degrade the EBC performance by increasing the thermal conductivity. EBCs with a mullite + BSAS / graded mullite + YSZ intermediate coat showed the best durability among the EBCs investigated in this study. This improvement was attributed to diffused CTE (Coefficient of Thermal Expansion) mismatch stress and improved chemical stability due to the compositionally graded mullite+YSZ layer.

  11. Thin-wall hollow ceramic spheres from slurries. Quarterly project status report, 1 January--31 March 1991

    SciTech Connect

    Chapman, A.T.; Cochran, J.K.

    1991-12-31

    The hollow sphere materials were alumina, mullite, and mullite- ZrO{sub 2} (the Zr reduced the high-temperature thermal conductivity). During this phase, three major tasks were emphasized: Use of opacifiers (Zr oxide) to reduce the high-temperature thermal conductivity of the sphere, convert the slurries from organic-based to aqueous-based, and technology transfer to industry.

  12. Degradation Of Environmental Barrier Coatings (EBC) Due To Chemical and Thermal Expansion Incompatibility

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; King, Deboran (Technical Monitor)

    2001-01-01

    Current environmental barrier coatings (EBCs) consist of multiple layers, with each layer having unique properties to meet the various requirements for successful EBCs. As a result, chemical and thermal expansion compatibility between layers becomes an important issue to maintaining durability. Key constituents in current EBCs are mullite (3Al2O3-2SiO2), BSAS (BaO(1-x)-SrO(x)-Al2O3-2SiO2), and YSZ (ZrO2-8 wt.% Y2O3). The mullite-BSAS combination appears benign although significant diffusion occurs. Mullite-YSZ and BSAS-YSZ combinations do not react up to 1500 C. Thermally grown SiO2- BSAS and mullite-BSAS-YSZ combinations are most detrimental, forming low melting glasses. Thermal expansion mismatch between YSZ and mullite or BSAS causes severe cracking and delamination.

  13. Chemical and morphological changes of reusable surface insulation coatings as a function of convectively heated cyclic testing

    NASA Technical Reports Server (NTRS)

    Leiser, D. B.; Stewart, D. A.; Goldstein, H. E.

    1973-01-01

    The effects of convective heating upon reusable surface insulation coatings were studied utilizing scanning electron microscopy, X-ray fluorescence, and X-ray diffraction. Samples of coated silica, mullite, and ceramic mullite fiber were cycled in an arc plasma stream up to 15 times for 15 minutes per cycle at surface temperatures simulating those on the space shuttle vehicle. The surfaces of ceramic mullite fiber and mullite coatings were roughened substantially by the convectively heated environment while the silica was significantly smoothed after testing. Scanning electron microscopy also showed surface cracking of varying degrees in all of the coatings. The surface chemistry of the coatings as examined by X-ray fluorescence revealed that significant changes in composition were occurring during cycling, particularly within the mullite coating.

  14. Multilayer article having stabilized zirconia outer layer and chemical barrier layer

    NASA Technical Reports Server (NTRS)

    Lee, Kang N. (Inventor); Bansal, Narottam P. (Inventor)

    2004-01-01

    A multilayer article includes a substrate that includes at least one of a ceramic compound and a Si-containing metal alloy. An outer layer includes stabilized zirconia. Intermediate layers are located between the outer layer and the substrate and include a mullite-containing layer and a chemical barrier layer. The mullite-containing layer includes 1) mullite or 2) mullite and an alkaline earth metal aluminosilicate. The chemical barrier layer is located between the mullite-containing layer and the outer layer. The chemical barrier layer includes at least one of mullite, hafnia, hafnium silicate and rare earth silicate (e.g., at least one of RE.sub.2 SiO.sub.5 and RE.sub.2 Si.sub.2 O.sub.7 where RE is Sc or Yb). The multilayer article is characterized by the combination of the chemical barrier layer and by its lack of a layer consisting essentially of barium strontium aluminosilicate between the mullite-containing layer and the chemical barrier layer. Such a barium strontium aluminosilicate layer may undesirably lead to the formation of a low melting glass or unnecessarily increase the layer thickness with concomitant reduced durability of the multilayer article. In particular, the chemical barrier layer may include at least one of hafnia, hafnium silicate and rare earth silicate.

  15. Radiant Heat Transfer in Reusable Surface Insulation

    NASA Technical Reports Server (NTRS)

    Hughes, T. A.; Linford, R. M. F.; Chmitt, R. J.; Christensen, H. E.

    1973-01-01

    During radiant testing of mullite panels, temperatures in the insulation and support structure exceeded those predicted on the basis of guarded hot plate thermal conductivity tests. Similar results were obtained during arc tunnel tests of mullite specimens. The differences between effective conductivity and guarded hot plate values suggested that radiant transfer through the mullite was occurring. To study the radiant transport, measurements were made of the infrared transmission through various insulating materials and fibers of interest to the shuttle program, using black body sources over the range of 780 to 2000 K. Experimental data were analyzed and scattering coefficients were derived for a variety of materials, fiber diameters, and source temperature.

  16. Transformation toughened ceramics for the heavy duty diesel engine technology program, phase 2

    NASA Technical Reports Server (NTRS)

    Musikant, S.; Samanta, S. C.; Architetto, P.; Feingold, E.

    1985-01-01

    The objective of this program is to develop an insulating structural ceramic for application in a heavy duty adiabatic diesel engine. The approach is to employ transformation toughening (TT) by additions of zirconia-hafnia solid solution (ZHSS). The feasibility of using ZHSS as a toughening agent in mullite and alumina has been demonstrated in Phase 1 of this work. Based on Phase 1 results, a decision was made to concentrate the Phase 2 effort on process optimization of the TT mullite. A strong factor in that decision was the low thermal conductivity and high thermal shock resistance of the mullite. Results of the Phase 2 effort indicate that optimum toughening of mullite by additions of ZHSS is difficult to achieve due to apparent sensitivity to morphology. The 48 ksi room temperature modulus-of-rupture (MOR) achieved in selected specimens is approximately 50% of the original strength target. The MOR deteriorated to 34 ksi at 800 C.

  17. Chemical species in fly ash from coal-burning power plants

    SciTech Connect

    Hulett, L.D. Jr.; Weinberger, A.J.; Northcutt, K.J.; Ferguson, M.

    1980-12-19

    Fly ash specimens from four power plants in the Tennessee Valley Authority system have been separated into three matrices: glass, mullite-quartz, and magnetic spinel. Chemical species of trace elements are defined to a large extent by the matrices that contain them. The magnetic component of fly ash is ferrite. The mullit-quartz phase is relatively pure and can be recovered as a resource.

  18. Highly Refractory Porous Ceramics,

    DTIC Science & Technology

    1979-03-14

    under the names " Fiberfrax ", "Kaowool", "Triton Kaowool", "Refrosil" and others, of kaolin and mullite composition based on the pure oxides SiO2 and...configuration of the thermal insulation is required (254, 255). The fiber " Fiberfrax " of mullite composition retains the thermoinsula- ting properties to...abovementioned fibrous materials, "Refrosil" and " Fiberfrax " (250, 251); the $latter can also find application for the purification of hot gases in

  19. Crystallization of a barium-aluminosilicate glass

    NASA Technical Reports Server (NTRS)

    Drummond, C. H., III; Lee, W. E.; Bansal, N. P.; Hyatt, M. J.

    1989-01-01

    The crystallization of a celsian glass composition was investigated as a possible high-temperature ceramic matrix material. Heat treatments invariably resulted in crystallization of the hexaclesian phase unless a flux, such as lithia, was added or a nucleating agent used (e.g., celsian seeds). TEM analysis revealed complex microstructures. Glasses with Mo additions contained hexacelsian, mullite, and an Mo-rich glass. Li2O additions stabilized celsian but mullite and Mo-rich glass were still present.

  20. TEM characterization of Al/Al{sub 2}O{sub 3} composite fabricated by reactive metal infiltration

    SciTech Connect

    Gao, Y.; Jia, J.; Loehman, R.E.; Ewsuk, K.G.

    1994-12-31

    The microstructure of Al/{alpha}-Al{sub 2}0{sub 3} composites made by infiltrating Al into dense mullite preforms has been characterized using transmission electron microscopy. Observations revealed that the formation of the Al/Al{sub 2}0{sub 3} composites involves three stages. Initially, Al infiltrates into a dense mullite preform through grain boundary diffusion, and reacts with mullite at grain boundaries to form a partial reaction zone. Then, a complete reaction takes place in the reaction region between the partial reaction zone and the full reaction zone to convert the dense mullite preform to a composite of {alpha}-Al{sub 2}0{sub 3} (matrix) and an Al-Si phase (thin channels). Finally, the reduced Si from the reaction diffuses out of the Al/Al{sub 2}0{sub 3} composite through the metal channels, whereas Al from the molten Al pool is continuously drawn to the reaction region until the mullite preform is consumed or the sample is removed from the molten Al pool. Based on the observed microstructure, infiltration mechanisms have been discussed, and a growth model of the composites is proposed in which the process involves repeated nucleation of Al{sub 2}0{sub 3} grains and grain growth.

  1. Evaluation of reusable surface insulation for space shuttle over a range of heat-transfer rate and surface temperature

    NASA Technical Reports Server (NTRS)

    Chapman, A. J.

    1973-01-01

    Reusable surface insulation materials, which were developed as heat shields for the space shuttle, were tested over a range of conditions including heat-transfer rates between 160 and 620 kW/sq m. The lowest of these heating rates was in a range predicted for the space shuttle during reentry, and the highest was more than twice the predicted entry heating on shuttle areas where reusable surface insulation would be used. Individual specimens were tested repeatedly at increasingly severe conditions to determine the maximum heating rate and temperature capability. A silica-base material experienced only minimal degradation during repeated tests which included conditions twice as severe as predicted shuttle entry and withstood cumulative exposures three times longer than the best mullite material. Mullite-base materials cracked and experienced incipient melting at conditions within the range predicted for shuttle entry. Neither silica nor mullite materials consistently survived the test series with unbroken waterproof surfaces. Surface temperatures for a silica and a mullite material followed a trend expected for noncatalytic surfaces, whereas surface temperatures for a second mullite material appeared to follow a trend expected for a catalytic surface.

  2. Microwave-assisted rapid discharge sintering of a bioactive glass-ceramic.

    PubMed

    O'Flynn, Kevin P; Twomey, Barry; Breen, Aidan; Dowling, Denis P; Stanton, Kenneth T

    2011-07-01

    Bioactive glass-ceramics have been developed as successful bone graft materials. Although conventional sintering in an electrically-heated furnace is most commonly used, an alternative microwave plasma batch processing technique, known as rapid discharge sintering (RDS), is examined to crystallise the metastable base glass to form one or more ceramic phases. Apatite-mullite glass-ceramics (AMGC) were examined to elucidate the effects of RDS on the crystallization of a bioactive glass-ceramic. By increasing the fluorine content of the glass, the fluorapatite (FAp) and mullite crystallization onset temperatures can be reduced. Samples were sintered in a hydrogen and hydrogen/nitrogen discharge at temperatures of ≈800 and 1000 °C respectively with the higher sintering temperature required to form mullite. Results show that the material can be densified and crystallised using RDS in a considerably shorter time than conventional sintering due to heating and cooling rates of ≈400 °C/min.

  3. The geochemistry and bioreactivity of fly-ash from coal-burning power stations.

    PubMed

    Jones, Timothy; Wlodarczyk, Anna; Koshy, Lata; Brown, Patrick; Shao, Longyi; BéruBé, Kelly

    2009-07-01

    Fly-ash is a byproduct of the combustion of coal in power stations for the generation of electricity. The fly-ash forms from the melting of incombustible minerals found naturally in the coal. The very high coal combustion temperatures result in the formation of microscopic glass particles from which minerals such as quartz, haematite and mullite can later recrystallize. In addition to these minerals, the glassy fly-ash contains a number of leachable metals. Mullite is a well-known material in the ceramics industry and a known respiratory hazard. Macroscopically mullite can be found in a large range of morphologies; however microscopic crystals appear to favour a fibrous habit. Fly-ash is a recognized bioreactive material in rat lung, generating hydroxyl radicals, releasing iron, and causing DNA damage. However, the mechanisms of the bioreactivity are still unclear and the relative contributions of the minerals and leachable metals to that toxicity are not well known.

  4. Oxidation-resistant interfacial coatings for continuous fiber ceramic composites

    SciTech Connect

    Stinton, D.P.; Besmann, T.M.; Bleier, A.; Shanmugham, S.; Liaw, P.K.

    1995-08-01

    Continuous fiber ceramic composites mechanical behavior are influenced by the bonding characteristics between the fiber and the matrix. Finite modeling studies suggest that a low-modulus interfacial coating material will be effective in reducing the residual thermal stresses that are generated upon cooling from processing temperatures. Nicalon{trademark}/SiC composites with carbon, alumina and mullite interfacial coatings were fabricated with the SiC matrix deposited using a forced-flow, thermal gradient chemical vapor infiltration process. Composites with mullite interfacial coatings exhibited considerable fiber pull-out even after oxidation and have potential as a composite system.

  5. Pillared smectite clay coatings for ceramic-matrix composites

    SciTech Connect

    Jagota, S.; Harmer, M.A.; Lemon, M.F.; Jagota, A.; McCarron, E.M. III.

    1995-08-01

    This paper describes a novel route for the low-temperature formation of mullite, from pillared smectite clay precursors, for use as fiber coatings in ceramic-matrix composites. In particular, alumina-pillared bentonite converts in part to mullite at the unusually low temperature of about 800 C. The clay precursors display excellent film-forming capability and have been coated onto silicon carbide fibers. Mechanical tests on composites of the coated fibers and a borosilicate glass demonstrate their success as debond coatings, suggesting that this approach is a viable and simple route to oxide coatings for fibers.

  6. Mechanistic Studies of Superplasticity of Structural Ceramics

    DTIC Science & Technology

    1992-02-01

    residing on grain corners . composition. Y-TZP with up to 80 vol% Data from fine-grained zirconia/mullite of alumina or mullite are superplastic and and...have proposed a picture to envision the scaling relationship by assuming pinning particles residing on every grain corner . 18l Since a...studied two other TZPs with trivalent stabi-STEM, we find Ca , Mg2 , and In segregate strongly, Sc3+ lizers . These are a Sc-TZP with 6.2 mol% SeO 1s

  7. Refractory Oxide Coatings on Sic Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Jacobson, Nathan S.; Miller, Robert A.

    1994-01-01

    Silicon carbide with a refractory oxide coating is potentially a very attractive ceramic system. It offers the desirable mechanical and physical properties of SiC and the environmental durability of a refractory oxide. The development of a thermal shock resistant plasma-sprayed mullite coating on SiC is discussed. The durability of the mullite/SiC in oxidizing, reducing, and molten salt environments is discussed. In general, this system exhibits better behavior than uncoated SiC. Areas for further developments are discussed.

  8. Examination of ERDA-10 Grout Specimens at Different Ages.

    DTIC Science & Technology

    1981-08-01

    patterns there appeared to be an unresolved peak on the low angle shoulder of the 7.84-R peak; it is likely that this represented the presence of the alpha ...were quartz, mullite, calcium oxide, and hematite . Those in the clay material used in the salt gel were mainly palygorskite clay with small amounts of

  9. Investigation on cell assemblies for mantle rheology

    NASA Astrophysics Data System (ADS)

    Long, H.; Li, L.; Chen, J.; Leinenweber, K.; Wang, L.; Liu, Z.; Vaughan, M. T.; Yang, Y.; Weidner, D. J.

    2004-12-01

    Several types of cell assemblies are being tested on large volume press apparatus at Sam85, NSLS to determine their suitability for high pressure rheology experiments, with present focus on the influence of different cells on water fugacity and the thermal efficiency. SanCarlos olivine, both lab dry and super dry, is being used as the testing material. Three types of pressure media including mullite, MgO and boron:epoxy (BE) are used for both DIA and T-cup apparatus in the test. For lab dry sample assemblies, 2¡ª3 hours heating at 130C in the vacuum environment is applied before experiment in order to drive off the absorptive water. Different pressure media in each apparatus are carried out at the same P-T path. After experiments the recovered samples are examined on the synchrotron infrared (IR) spectrometer at U2A beamline of NSLS to evaluate the water concentration. IR results suggest that mullite cell offers an acceptable dry environment for the rheology study. Among the tested cell assemblies, mullite cell has a comparable thermal efficiency as BE cell does. Both of them show much higher heating efficiency than MgO cell does. This preliminary study suggests that mullite has great potential as the pressure medium for the high pressure and high temperature experiment.

  10. Article Including Environmental Barrier Coating System

    NASA Technical Reports Server (NTRS)

    Lee, Kang N. (Inventor)

    2015-01-01

    An enhanced environmental barrier coating for a silicon containing substrate. The enhanced barrier coating may include a bond coat doped with at least one of an alkali metal oxide and an alkali earth metal oxide. The enhanced barrier coating may include a composite mullite bond coat including BSAS and another distinct second phase oxide applied over said surface.

  11. Ceramic-bonded abrasive grinding tools

    DOEpatents

    Holcombe, C.E. Jr.; Gorin, A.H.; Seals, R.D.

    1994-11-22

    Abrasive grains such as boron carbide, silicon carbide, alumina, diamond, cubic boron nitride, and mullite are combined with a cement primarily comprised of zinc oxide and a reactive liquid setting agent and solidified into abrasive grinding tools. Such grinding tools are particularly suitable for grinding and polishing stone, such as marble and granite.

  12. Ceramic-bonded abrasive grinding tools

    SciTech Connect

    Holcombe, Jr., Cressie E.; Gorin, Andrew H.; Seals, Roland D.

    1994-01-01

    Abrasive grains such as boron carbide, silicon carbide, alumina, diamond, cubic boron nitride, and mullite are combined with a cement primarily comprised of zinc oxide and a reactive liquid setting agent and solidified into abrasive grinding tools. Such grinding tools are particularly suitable for grinding and polishing stone, such as marble and granite.

  13. Phase equilibrium and preparation, crystallization and viscous sintering of glass in the alumina-silica-lanthanum phosphate system

    NASA Astrophysics Data System (ADS)

    He, Feng

    The phase equilibrium, viscosity of melt-quenched glasses, and processing of sol-gel glasses of the alumina-silica-lanthanum phosphate system were studied. These investigations were directed towards serving the objective of synthesizing nano-structured ceramic-matrix-composites via controlled crystallization of glass precursors. The thermal stability, phase equilibrium, and liquidus temperatures of the alumina- and mullite-lanthanum phosphate systems are determined. An iridium wire heater was constructed to anneal samples up to 2200°C. Phosphorus evaporation losses were significant at high temperatures, especially over 1800°C. The tentative phase diagrams of the two quasi-binary systems were presented. The viscosity of the melt-quenched mullite-lanthanum phosphate glasses was measured by three different methods, including viscous sintering of glass powder compacts, neck formation between two Frenkel glass beads, and thermal analysis of the glass transition. Improved methodologies were developed for applying the interpretative mathematical models to the results of the sintered powder and thermal analytical experiments. Good agreement was found between all three methods for both absolute values and temperature dependence. A sol-gel process was developed as a low temperature route to producing glasses. A unique, single phase mullite gel capable of low temperature (575°C) mullitization was made from tetraethoxysilane and aluminum isopropoxide at room temperature in three days. Low temperature crystallization was attributed to the avoidance of phase segregation during gel formation and annealing. This was greatly enhanced by a combination of low temperature preheating in the amorphous state, a high heating rate during crystallization and low water content. The Al2O3 content in mullite (61-68 mol%) depended on the highest annealing temperature. Two mullite-lanthanum phosphate gels were made based upon modifying the chemical procedures used for the homogeneous single

  14. Abundances and distribution of minerals and elements in high-alumina coal fly ash from the Jungar Power Plant, Inner Mongolia, China

    USGS Publications Warehouse

    Dai, S.; Zhao, L.; Peng, S.; Chou, C.-L.; Wang, X.; Zhang, Y.; Li, D.; Sun, Y.

    2010-01-01

    The fly ash from the Jungar Power Plant, Inner Mongolia, China, is unique because it is highly enriched in alumina (Al2O3>50%). The fly ash mainly consists of amorphous glass and mullite and trace amounts of corundum, quartz, char, calcite, K-feldspar, clay minerals, and Fe-bearing minerals. The mullite content in fly ash is as high as 37.4% because of high boehmite and kaolinite contents in feed coal. Corundum is a characteristic mineral formed during the combustion of boehmite-rich coal.Samples from the economizer were sieved into six size fractions (<120, 120-160, 160-300, 300-360, 360-500, and >500 mesh) and separated into magnetic, mullite+corundum+quartz (MCQ) and glass phases for mineralogical and chemical analysis. The corundum content increases but amorphous glass decreases with decreasing particle size. Fractions of small particle sizes are relatively high in mullite, probably because mullite was formed from fine clay mineral particles under high-temperature combustion condition. Similarly, fine corundum crystals formed in the boiler from boehmite in feed coal. The magnetic phase consists of hematite, magnetite, magnesioferrite, and MgFeAlO4 crystals. The MCQ phase is composed of 89% mullite, 6.1% corundum, 4.5% quartz, and 0.5% K-feldspar.Overall, the fly ash from the power plant is significantly enriched in Al2O3 with an average of 51.9%, but poor in SiO2, Fe2O3, CaO, MgO, Na2O, P2O5, and As. Arsenic, TiO2, Th, Al2O3, Bi, La, Ga, Ni, and V are high in mullite, and the magnetic matter is enriched in Fe2O3, CaO, MnO, TiO2, Cs, Co, As, Cd, Ba, Ni, Sb, MgO, Zn, and V. The remaining elements are high in the glass fraction. The concentration of K2O, Na2O, P2O5, Nb, Cr, Ta, U, W, Rb, and Ni do not clearly vary with particle size, while SiO2 and Hg decrease and the remaining elements clearly increase with decreasing particle size. ?? 2009 Elsevier B.V.

  15. Thermal/chemical stability of ceramic cross flow filter materials

    SciTech Connect

    Alvin, M.A.; Bahovchin, D.M.; Lippert, T.E.; Tressler, R.E.; McNerney, K.B.

    1992-01-01

    Westinghouse has undertaken a two phase program to determine possible long-term, high temperature influence that advanced coal-based power system environments may have on the stability of the ceramic cross flow filter elements. During the past year, we have principally focused our efforts on developing an understanding of the stability of the alumina/mullite filter material at high temperature (i.e., 870, 980, and 1100[degrees]C) under oxidizing conditions which contain gas phase alkali species. The alumina/mullite cross flow liter material that has consistently been used throughout the flow-through gas phase alkali testing segment of this program, consists of mullite rods or needles that are embedded within an amorphous phase which contains corundum (Al[sub 2]O[sub 3]) and anorthite (CaAl[sub 2]Si[sub 2]O[sub 8]). Due to the rapid cooling rate that was used to produce the alumina/mullite filter disc material from high fire, the matrix consists of 59.6 wt% mullite, 30.5 wt% amorphous, 5.1 wt% anorthite, and 4.8 wt% alumina. The relatively low, as-fabricated, hot strength of this material (841[plus minus]259 psi at 870[degrees]C) is a direct result of the high amorphous content which softens at temperatures of 870[degrees]C. Load versus deflection curves as a function of temperature indicate that this material is relatively brittle up to temperatures of 600[degrees]C. Both a loss of strength, as well as plastic deformation of the matrix occurs at [approximately]700[degrees]C. If cross flow filters are manufactured from an alumina/mullite matrix that contains an [approximately]30.5 wt% amorphous content, we suspect that the plastic nature of the glass phase could potentially serve as a substrate for fines collection during initial filter operation at 700[degrees]C. Similarly the plastic nature could potentially cause deformation of the liter under load.

  16. Thermal/chemical stability of ceramic cross flow filter materials

    SciTech Connect

    Alvin, M.A.; Bahovchin, D.M.; Lippert, T.E.; Tressler, R.E.; McNerney, K.B.

    1992-11-01

    Westinghouse has undertaken a two phase program to determine possible long-term, high temperature influence that advanced coal-based power system environments may have on the stability of the ceramic cross flow filter elements. During the past year, we have principally focused our efforts on developing an understanding of the stability of the alumina/mullite filter material at high temperature (i.e., 870, 980, and 1100{degrees}C) under oxidizing conditions which contain gas phase alkali species. The alumina/mullite cross flow liter material that has consistently been used throughout the flow-through gas phase alkali testing segment of this program, consists of mullite rods or needles that are embedded within an amorphous phase which contains corundum (Al{sub 2}O{sub 3}) and anorthite (CaAl{sub 2}Si{sub 2}O{sub 8}). Due to the rapid cooling rate that was used to produce the alumina/mullite filter disc material from high fire, the matrix consists of 59.6 wt% mullite, 30.5 wt% amorphous, 5.1 wt% anorthite, and 4.8 wt% alumina. The relatively low, as-fabricated, hot strength of this material (841{plus_minus}259 psi at 870{degrees}C) is a direct result of the high amorphous content which softens at temperatures of 870{degrees}C. Load versus deflection curves as a function of temperature indicate that this material is relatively brittle up to temperatures of 600{degrees}C. Both a loss of strength, as well as plastic deformation of the matrix occurs at {approximately}700{degrees}C. If cross flow filters are manufactured from an alumina/mullite matrix that contains an {approximately}30.5 wt% amorphous content, we suspect that the plastic nature of the glass phase could potentially serve as a substrate for fines collection during initial filter operation at 700{degrees}C. Similarly the plastic nature could potentially cause deformation of the liter under load.

  17. Interfacial and colloidal aspects of aqueous suspensions containing oxidic powders. Final report

    SciTech Connect

    Bleier, Alan

    1984-01-01

    This program addressed ceramics and colloid science research needs that underscore the physicochemical principles which govern the processing of oxide ceramic powders. Materials systems emphasized silica, alumina, zirconia, and mullite. The surface charge characteristics of the cited solids were determined using potentiometric techniques. Interfacial chemical reactions were thermodynamically evaluated. Zeta potential trends and values for silica and alumina systems were predicted reasonably well. Some surface behavior of mullite could be predicted from those of the constituent, silicon and aluminum oxides. Guidelines were generated for these problems and for a more complete description of the electrical double layers surrounding oxide ceramic powders in aqueous media. These efforts ultimately indicated that charge regulation is important to the processing of ceramics. A charge regulation model suggests that the electrostatic stabilizing effect of surface charge may critically depend on the volume concentration of powder.

  18. High temperature insulation for ceramic matrix composites

    DOEpatents

    Merrill, Gary B.; Morrison, Jay Alan

    2004-01-13

    A ceramic composition is provided to insulate ceramic matrix composites under high temperature, high heat flux environments. The composition comprises a plurality of hollow oxide-based spheres of various dimensions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere. The spheres may be any combination of Mullite spheres, Alumina spheres, or stabilized Zirconia spheres. The filler powder may be any combination of Alumina, Mullite, Ceria, or Hafnia. Preferably, the phosphate binder is Aluminum Ortho-Phosphate. A method of manufacturing the ceramic insulating composition and its application to CMC substrates are also provided.

  19. High temperature insulation for ceramic matrix composites

    DOEpatents

    Merrill, Gary B.; Morrison, Jay Alan

    2001-01-01

    A ceramic composition is provided to insulate ceramic matrix composites under high temperature, high heat flux environments. The composition comprises a plurality of hollow oxide-based spheres of various dimensions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere. The spheres may be any combination of Mullite spheres, Alumina spheres, or stabilized Zirconia spheres. The filler powder may be any combination of Alumina, Mullite, Ceria, or Hafnia. Preferably, the phosphate binder is Aluminum Ortho-Phosphate. A method of manufacturing the ceramic insulating composition and its application to CMC substrates are also provided.

  20. High temperature insulation for ceramic matrix composites

    DOEpatents

    Merrill, Gary B.; Morrison, Jay Alan

    2000-01-01

    A ceramic composition is provided to insulate ceramic matrix composites under high temperature, high heat flux environments. The composite comprises a plurality of hollow oxide-based spheres of varios dimentions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere. The spheres may be any combination of Mullite spheres, Alumina spheres, or stabilized Zirconia spheres. The filler powder may be any combination of Alumina, Mullite, Ceria, or Hafnia. Preferably, the phosphate binder is Aluminum Ortho-Phosphate. A method of manufacturing the ceramic insulating composition and its application to CMC substates are also provided.

  1. Topical report to Morgantown Energy Technology Center for the interfacial coatings for ceramic-matrix composites

    SciTech Connect

    1997-01-09

    This report summarizes the task conducted to examine various activities on interface development for ceramic-matrix composites (CMCs) intended for high-temperature applications. While several articles have been published on the subject of CMC interfaces, the purpose of this report is to describe the various ongoing efforts on interface concepts, material selection, and issues related to processing methods employed for developing interface coatings. The most exciting and new development in the field is the discovery of monazite as a potential interface material for mullite- and alumina-based composites. Monazite offers two critical properties to the CMC system; a weakly bonded layer due to its non-wetting behavior and chemical compatibility with both alumina and mullite up to very high temperatures (> 1,600 C). A description of the Department of Energy-related activities and some thoughts on processing issues, interface testing, and effects of processing on fiber strength are given.

  2. Protective coating for alumina-silicon carbide whisker composites

    DOEpatents

    Tiegs, Terry N.

    1989-01-01

    Ceramic composites formed of an alumina matrix reinforced with silicon carbide whiskers homogenously dispersed therein are provided with a protective coating for preventing fracture strength degradation of the composite by oxidation during exposure to high temperatures in oxygen-containing atmospheres. The coating prevents oxidation of the silicon carbide whiskers within the matrix by sealing off the exterior of the matrix so as to prevent oxygen transport into the interior of the matrix. The coating is formed of mullite or mullite plus silicon oxide and alumina and is formed in place by heating the composite in air to a temperature greater than 1200.degree. C. This coating is less than about 100 microns thick and adequately protects the underlying composite from fracture strength degradation due to oxidation.

  3. Assembly of acid and sintering resistant honeycomb washcoat and catalytically active phase using sols of silica, zirconia, and platinum

    SciTech Connect

    Felthouse, T.R. |; Berkel, D.A.; Jost, S.R.

    1995-12-01

    Development of high performance honeycomb catalysts containing platinum active phase for gas phase air oxidation of sulfur dioxide is described. Stepwise assembly of these washcoated honeycombs consists of: (1) selection of honeycomb composition (mullite substrate) and cell density based on pressure drop requirements; (2) identification of washcoat slurry composition (silica-precursor sol, silica powder, and surfactants if needed); (3) processing of the washcoat-substrate by dip coating, drying, and calcining; (4) loading of the platinum active phase through a facilitated adsorption technique followed by drying and activation steps; and (5) reactor loading and evaluation. Details of these steps will be presented that include thermal and chemical stability tests. Characterization by transmission electron microscopy of the final Pt/(ZrO{sub 2}-SiO{sub 2}) composite attached to the mullite substrate will be reported.

  4. Internally Cooled Monolithic Silicon Nitride Aerospace Components

    NASA Technical Reports Server (NTRS)

    Best, Jonathan E.; Cawley, James D.; Bhatt, Ramakrishna T.; Fox, Dennis S.; Lang, Jerry (Technical Monitor)

    2000-01-01

    A set of rapid prototyping (RP) processes have been combined with gelcasting to make ceramic aerospace components that contain internal cooling geometry. A mold and core combination is made using a MM6Pro (Sanders Prototyping, Inc.) and SLA-250/40 (3Dsystems, Inc.). The MM6Pro produces cores from ProtoBuild (trademarked) wax that are dissolved in room temperature ethanol following gelcasting. The SLA-250/40 yields epoxy/acrylate reusable molds. Parts produced by this method include two types of specimens containing a high density of thin long cooling channels, thin-walled cylinders and plates, as well as a model hollow airfoil shape that can be used for burner rig evaluation of coatings. Both uncoated and mullite-coated hollow airfoils has been tested in a Mach 0.3 burner rig with cooling air demonstrating internal cooling and confirming the effectiveness of mullite coatings.

  5. Stress-corrosion resistant proppant for oil and gas wells

    SciTech Connect

    Khaund, A.K.

    1987-01-27

    This patent describes a proppant medium composed of spherical particles of a sintered composition of alumina, silica, and the impurities associated with bauxite, such impurities selected from the group consisting of alkali and alkaline earth, oxides, iron oxide, and titanium oxide. The improvement described here is wherein there is at least 15% silica in the composition and zirconium oxide is present in the ratio of between one part of zirconia per twenty parts of silica to one part of zirconia per six parts of silica by weight, the proppant spheres as fired, consisting essentially of mullite, alumina, and glass. The silica content in the weight ratio is calculated as SiO/sub 2/ combined in the mullite phase and SiO/sub 2/ in the glass phase, and zirconia content is calculated as ZrO/sub 2/ and is present in the glass phase.

  6. Early development of ceramic fiber insulation for the Space Shuttle

    NASA Technical Reports Server (NTRS)

    Buckley, J. D.; Strouhal, G.; Gangler, J. J.

    1981-01-01

    The evolution of reusable surface insulation is described, with attention to the mullite and other aluminosilicates, zirconia, and silicon carbide-coated carbon compositions experimented with in the late 1960s and early 1970s. Evaluation and development concentrated in this period on such aspects of design and material properties as cold soak performance, attachment, shock impingement, surface coating cracks, and tile gap design and heating. In addressing the central problem of heat-shield thermal conductivity, it was found that for a given density, silica fibers had a lower conductivity than those of mullite. This was due to the one-micron, as opposed to 4.7-micron, diameter of the silica fibers, which resulted in smaller pores and therefore less convective and radiative heat transfer. Attention is also given to tile coating materials and the high-temperature processes by which they were applied.

  7. Carbon dioxide compensation values in citronella and lemongrass.

    PubMed

    Herath, H M; Ormrod, D P

    1977-04-01

    Carbon dioxide compensation values of mature leaves from 10 selections of citronella (Cymbopogon nardus [L.] Rendle) grown at 32/27 or 27/21 C day/night temperatures and three strains of lemongrass (Cymbopogon citratus [D.C.] Stapf. and Cymbopogon flexuosus [D.C.] Stapf.) grown at 8- or 15-hour photoperiods were measured in a controlled environment at 25 C. All leaves had low compensation values but citronella varied from 1.3 to 9.7 mul/liter and lemongrass from 0.7 to 3.5 mul/liter. Lower growing temperature generally resulted in lower compensation values for citronella but there was no consistent photoperiod effect on lemongrass.

  8. Dip coating process: Silicon sheet growth development for the large-area silicon sheet task of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    Heaps, J. D.; Maciolek, R. B.; Harrison, W. B.; Wolner, H. A.; Hendrickson, G.; Nelson, L. D.

    1976-01-01

    To date, an experimental dip-coating facility was constructed. Using this facility, relatively thin (1 mm) mullite and alumina substrates were successfully dip-coated with 2.5 - 3.0 ohm-cm, p-type silicon with areas of approximately 20 sq cm. The thickness and grain size of these coatings are influenced by the temperature of the melt and the rate at which the substrate is pulled from the melt. One mullite substrate had dendrite-like crystallites of the order of 1 mm wide and 1 to 2 cm long. Their axes were aligned along the direction of pulling. A large variety of substrate materials were purchased or developed enabling the program to commence a substrate definition evaluation. Due to the insulating nature of the substrate, the bottom layer of the p-n junction may have to be made via the top surface. The feasibility of accomplishing this was demonstrated using single crystal wafers.

  9. Growth and feeding response of Pseudoplusia includens (Lepidoptera:Noctuidae) to host plants grown in controlled carbon dioxide atmospheres

    SciTech Connect

    Lincoln, D.E.; Sionit, N.; Strain, B.R.

    1984-12-01

    Rising atmospheric carbon dioxide may alter plant/herbivore interactions. The projected rise in atmospheric carbon dioxide is expected to increase plant productivity, but little evidence is available regarding effects on insect feeding or growth. Leaves of soybean plants grown under three carbon dioxide regimes (350, 500, and 650 ..mu..l/liter) were fed to soybean looper larvae. Larvae fed at increasingly higher rates on plants from elevated carbon dioxide atmospheres: 80% greater rates on leaves from the 650 ..mu..l/liter treatment than on leaves from the 350 ..mu..l/litter treatment. Variation in larval feeding was related to the leaf content of nitrogen and water and to the leaf-specific weight, each of which was altered by the carbon dioxide growth regime of the soybean plants. This study suggests that the impact of herbivores may increase as the level of atmospheric carbon dioxide rises.

  10. Effect of the Filter Surface Chemistry on the Filtration of Aluminum

    NASA Astrophysics Data System (ADS)

    Voigt, Claudia; Fankhänel, Beate; Jäckel, Eva; Aneziris, Christos G.; Stelter, Michael; Hubálková, Jana

    2015-04-01

    The influence of the filter surface chemistry of alumina skeletons on the filtration effect was tested with five different oxide coating materials (Al2O3, spinel, mullite, TiO2, and SiO2). All prepared filters were casted successfully under industrial conditions. The casted aluminum samples showed no contamination caused by the filters. The evaluation of the casted filters by means of SEM and EDX showed that the amount of inclusions in the area of the run in is larger than in the middle and the run out of the filter. The most non-metallic inclusions were found in the casted filters Al2O3+Al2O3 and Al2O3+spinel. The wetting experiments yielded for all tested materials a non-wetting behavior whereby Al2O3 and spinel showed higher wetting angle than mullite, TiO2, and SiO2.

  11. Theoretical study of production of unique glasses in space. [kinetic relationships describing nucleation and crystallization phenomena

    NASA Technical Reports Server (NTRS)

    Larsen, D. C.; Sievert, J. L.

    1975-01-01

    The potential of producing the glassy form of selected materials in the weightless, containerless nature of space processing is examined through the development of kinetic relationships describing nucleation and crystallization phenomena. Transformation kinetics are applied to a well-characterized system (SiO2), an excellent glass former (B2O3), and a poor glass former (Al2O3) by conventional earth processing methods. Viscosity and entropy of fusion are shown to be the primary materials parameters controlling the glass forming tendency. For multicomponent systems diffusion-controlled kinetics and heterogeneous nucleation effects are considered. An analytical empirical approach is used to analyze the mullite system. Results are consistent with experimentally observed data and indicate the promise of mullite as a future space processing candidate.

  12. Ceramic joining

    SciTech Connect

    Loehman, R.E.

    1996-04-01

    This paper describes the relation between reactions at ceramic-metal interfaces and the development of strong interfacial bonds in ceramic joining. Studies on a number of systems are described, including silicon nitrides, aluminium nitrides, mullite, and aluminium oxides. Joints can be weakened by stresses such as thermal expansion mismatch. Ceramic joining is used in a variety of applications such as solid oxide fuel cells.

  13. Strength and Toughness of Tailored Ceramic Microstructures

    DTIC Science & Technology

    1990-12-30

    Ceramics Program, under contract number AFOSR-87-0396. Also, helpful and stimulating discussions with W. Gust and F. Lange are gratefully acknowledged...phase specimens for mecanical testing. Composition Tem eratureC Time, hours Al 1650 3 AZi0 1650 9 c-ZrO2 1500 2 RESULTS AND DISCUSSION Figure 1 shows...sufficient ligament size to span the crack opening. This is where the alumina-mullite system may have a significant advantage over other dual phase

  14. Material for a luminescent solar concentrator

    DOEpatents

    Andrews, L.J.

    1984-01-01

    A material for use in a luminescent solar concentrator, formed by ceramitizing the luminescent ion Cr/sup 3 +/ with a transparent ceramic glass containing mullite. The resultant material has tiny Cr/sup 3 +/-bearing crystallites dispersed uniformly through an amorphous glass. The invention combines the high luminescent efficiency of Cr/sup 3 +/ in the crystalline phase with the practical and economical advantages of glass technology.

  15. Rare Earth Aluminophosphosilicate Glass Precursors for Ceramic-Matrix-Composites (REAPS CMC’s)

    DTIC Science & Technology

    2008-07-11

    DATES COVERED (From - To) 1 APRIL 2007 - 30 NOVEMBER 2007 4. TITLE AND SUBTITLE RARE EARTH ALUMINOPHOSPHOSILICATE GLASS PRECURSORS FOR CERAMIC -MATRIX...fabricating ceramic -matrixcomposites of mullite (Al6Si2013) and monazite (LaP04). The specific objective was to investigate selected issues for devising...strategies of low-temperature pathways of viscous sintering of glass powders and crystallization anneals to produce dense monolithic ceramics of very

  16. Innovative Processing of Composites for Ultra-High Temperature Applications. Book 3

    DTIC Science & Technology

    1993-11-01

    order to created MoSi 2/SiC composites. (Molybdenum disilicide has much better mechanical properties at high temperatures than silicon.) Investigations...technology necessary to fabricate ceramic-matrix, internetallic-matrix, and metal-matrix composites with superior mechanical properties in high temperature...Book I Section 1 Processing and Properties of Silicon Carbide Fibers Principal Investigators: C.D. Batich M.D. Sacks Section 2 Processing of Mullite

  17. Mechanical analysis of a cross flow filter

    SciTech Connect

    Alvin, M.A.; Lippert, T.E.; Attaar, M.H.; McNerney, K.R.

    1992-12-01

    Material properties have also been generated at the Argonne National Laboratories which detail the fracture toughness, Weibull modulus, and critical flaw size for a specifically fabricated lot of P-100A alumina/mullite cross flow filters.(Singh, 1990) The critical flaw size within the P-100A matrix was estimated to be {approximately}500 {mu},m which includes both large interconnected pores, as well as potentially debonded areas along the mid-rib or gas channel seams. Critical flaws are generally considered as potential failure initiation sites within the ceramic matrix. In addition maximum filter element stress levels induced by the process system have been estimated at ANL through the use of finite element computer analyses. These efforts project that the highest stresses result within the flange region of the cross flow filter. As a result of these projections, efforts at Coors Ceramics were directed to improving the overall strength of the alumina/mullite material which is used for cross flow filter fabrication. The results of the efforts at Coors Ceramics provide a significant improvement in the hot strength of the P-100A alumina/mullite filter matrix. Westinghouse assessed the existing nondestructive evaluation (NDE) techniques in terms of identifying methods for detecting critical flaws within the cross flow filter body. To date viable, cost effective methods for detecting critical flaws within the P-100A alumina/mullite matrix, or along the mid-rib bonds or gas channel seams in the full-scale, porous ceramic cross flow filter element are not readily available. As an alternate approach, Westinghouse focused its attention on developing NDE techniques as inspection methods for evaluating the extent of bonding along the mid-rib bonds and gas channel seams which results during the various fabrication stages of the cross flow filter element.

  18. Mechanical analysis of a cross flow filter

    SciTech Connect

    Alvin, M.A.; Lippert, T.E.; Attaar, M.H.; McNerney, K.R.

    1992-01-01

    Material properties have also been generated at the Argonne National Laboratories which detail the fracture toughness, Weibull modulus, and critical flaw size for a specifically fabricated lot of P-100A alumina/mullite cross flow filters.(Singh, 1990) The critical flaw size within the P-100A matrix was estimated to be [approximately]500 [mu],m which includes both large interconnected pores, as well as potentially debonded areas along the mid-rib or gas channel seams. Critical flaws are generally considered as potential failure initiation sites within the ceramic matrix. In addition maximum filter element stress levels induced by the process system have been estimated at ANL through the use of finite element computer analyses. These efforts project that the highest stresses result within the flange region of the cross flow filter. As a result of these projections, efforts at Coors Ceramics were directed to improving the overall strength of the alumina/mullite material which is used for cross flow filter fabrication. The results of the efforts at Coors Ceramics provide a significant improvement in the hot strength of the P-100A alumina/mullite filter matrix. Westinghouse assessed the existing nondestructive evaluation (NDE) techniques in terms of identifying methods for detecting critical flaws within the cross flow filter body. To date viable, cost effective methods for detecting critical flaws within the P-100A alumina/mullite matrix, or along the mid-rib bonds or gas channel seams in the full-scale, porous ceramic cross flow filter element are not readily available. As an alternate approach, Westinghouse focused its attention on developing NDE techniques as inspection methods for evaluating the extent of bonding along the mid-rib bonds and gas channel seams which results during the various fabrication stages of the cross flow filter element.

  19. Hydridosiloxanes as precursors to ceramic products

    DOEpatents

    Blum, Yigal D.; Johnson, Sylvia M.; Gusman, Michael I.

    1997-01-01

    A method is provided for preparing ceramic precursors from hydridosiloxane starting materials and then pyrolyzing these precursors to give rise to silicious ceramic materials. Si--H bonds present in the hydridosiloxane starting materials are catalytically activated, and the activated hydrogen atoms may then be replaced with nonhydrogen substituents. These preceramic materials are pyrolyzed in a selected atmosphere to give the desired ceramic product. Ceramic products which may be prepared by this technique include silica, silicon oxynitride, silicon carbide, metal silicates, and mullite.

  20. Microstructure Study For Optimization Of Dielectric Property Of Electrical Porcelain

    SciTech Connect

    Tak, S. K.; Shekhawat, M. S.; Mangal, R.

    2010-06-29

    Five sample mixtures of kaolin, ball clay, feldspar and Quartz were formulated and porcelain samples fabricated. Crystalline phases and mullite morphology were studied using XRD and SEM respectively. A composition of 30% kaolin, 15% ball clay, 30% feldspar and 25% quartz yielded a body with high dielectric strength of 19 kV/mm compare to an ISO graded product having dielectric strength 14.6 KV/mm after firing at 1225 deg. C.

  1. Low cost silicon-on-ceramic photovoltaic solar cells

    NASA Technical Reports Server (NTRS)

    Koepke, B. G.; Heaps, J. D.; Grung, B. L.; Zook, J. D.; Sibold, J. D.; Leipold, M. H.

    1980-01-01

    A technique has been developed for coating low-cost mullite-based refractory substrates with thin layers of solar cell quality silicon. The technique involves first carbonizing one surface of the ceramic and then contacting it with molten silicon. The silicon wets the carbonized surface and, under the proper thermal conditions, solidifies as a large-grained sheet. Solar cells produced from this composite silicon-on-ceramic material have exhibited total area conversion efficiencies of ten percent.

  2. Influence of Impurities on High-Temperature Reactions of Kaolinite

    SciTech Connect

    Johnson, Sylvia M.; Pask, Joseph A.; Moya, Jose S.

    1982-01-01

    On heating kaolinite in DTA the second exothermic peak (~1275°C) is due to growth of mullite crystals accelerated by formation of a liquid phase. The third exothermic peak (~1460°C) is due to crystallization of cristobalite, Addition or presence of impurity oxides causes the second peak to shift in temperature, and accelerates the formation of cristobalite so that the third peak could appear as low as the second exothermic peak temperature.

  3. Extruded ceramic honeycomb and method

    DOEpatents

    Day, J. Paul

    1995-04-04

    Extruded low-expansion ceramic honeycombs comprising beta-spodumene solid solution as the principal crystal phase and with less than 7 weight percent of included mullite are produced by compounding an extrusion batch comprising a lithium aluminosilicate glass powder and a clay additive, extruding a green honeycomb body from the batch, and drying and firing the green extruded cellular honeycomb to crystallize the glass and clay into a low-expansion spodumene ceramic honeycomb body.

  4. Mechanical Properties of 3-D ceramic matrix composites

    SciTech Connect

    Moore, E.H.; Folsom, C.A.; Keller, K.A.; Mah, T.

    1995-12-01

    The mullite-alumina system has been investigated with the goal of fabricating ceramic matrix composites (CMC) for use in turbine engine exhaust components over a range of temperatures from below ambient to 1200{degrees}C. Turbine engine components of interest include flaps and seals, and liners. These CMC are expected to be strong, tough, near-net fabricable and able to retain these properties over their entire range of use.

  5. Kinetics and Mechanisms of Primary and Steady State Creep in B- and Al- Containing Alpha Silicon Carbide

    DTIC Science & Technology

    1989-07-01

    silicon carbide , devoid of sintering aids, creeps by dislocation motion and climb. Silicon carbide containing...impurity substitution in the sintered silicon carbide . Experimental measurements of grain boundary sliding offsets on polycrystalline silicon carbide have... carbide whisker reinforcement has no beneficial effect on the creep resistance of Si3N4, whereas, in the more easily deformed mullite, silicon carbide whisker reinforcement does result in a reduced steady state

  6. Hydridosiloxanes as precursors to ceramic products

    DOEpatents

    Blum, Y.D.; Johnson, S.M.; Gusman, M.I.

    1997-06-03

    A method is provided for preparing ceramic precursors from hydridosiloxane starting materials and then pyrolyzing these precursors to give rise to silicious ceramic materials. Si-H bonds present in the hydridosiloxane starting materials are catalytically activated, and the activated hydrogen atoms may then be replaced with nonhydrogen substituents. These preceramic materials are pyrolyzed in a selected atmosphere to give the desired ceramic product. Ceramic products which may be prepared by this technique include silica, silicon oxynitride, silicon carbide, metal silicates, and mullite.

  7. Chemical Vapor Deposited Diamond

    DTIC Science & Technology

    1991-09-27

    forming substrates such as silicon or molybdenum. Diamond can also be grown on other substrates such as silicon carbide, silicon nitride , mullite...thermal expansion of diamond with several substrate materials. Silicon nitride has a good z 0.010 alumina -,- - 0.006Cm Si, -diamond LJ 0.002 , 0...The authors checked the accuracy of their measurements by performing the measurements on specimens of copper, silver, aluminum, and aluminum nitride

  8. The study of aluminum loss and consequent phase transformation in heat-treated acid-leached kaolin

    SciTech Connect

    Foo, Choo Thye; Mahmood, Che Seman; Mohd Salleh, Mohamad Amran

    2011-04-15

    This study investigates the effect of Al leaching during Fe removal from kaolin to mullite. Heat-treated kaolin was obtained by heating natural kaolin at 400, 500, 600, 700, 800 and 900 deg. C. The heat-treated kaolin was then leached at 100 deg. C with 4 M, 3 M, 2 M, 1 M, 0.2 M solution of H{sub 2}SO{sub 4} and 0.2 M solution of oxalic acid. The dried samples were sintered to 1300 deg. C for 4 h at a heating rate of 10 deg. C min{sup -1}. X-ray diffractometry and differential thermal analysis were used to study the phase transformation of kaolin to mullite. It was found that 700 deg. C is the optimum preheat-treatment temperature to leach out Fe and also Al for both types of the acids used. The majority of the 4 M sulfuric acid-treated kaolins formed the cristobalite phase when sintered. On the other hand, 1 M, 0.2 M sulfuric acid and 0.2 M oxalic acid leached heat-treated kaolin formed mullite and quartz phase after sintering. - Research Highlights: {yields} Preheat-treatment of kaolin improves the leachability of unwanted iron. {yields} The optimum preheat-treatment temperature is 700 deg. C. {yields} Sintered 4 M sulfuric acid-treated kaolin majorly formed the cristobalite phase. {yields} Sintered 0.2 M oxalic acid-treated kaolin formed lesser amorphous silicate phase.

  9. Sintering and Interface Strain Tolerance of Plasma-Sprayed Thermal and Environmental Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Leissler, George W.; Miller, Robert A.

    2003-01-01

    Ceramic thermal and environmental barrier coatings will be more aggressively designed to protect gas turbine engine hot section SiC/SiC Ceramic Matrix Composite (CMC) components in order to meet future engine higher fuel efficiency and lower emission goals. A coating system consisting of a zirconia-based oxide topcoat (thermal barrier) and a mullite/BSAS silicate inner coat (environmental barrier) is often considered a model system for the CMC applications. However, the coating sintering, and thermal expansion mismatch between the zirconia oxide layer and the silicate environmental barrier/CMC substrate will be of major concern at high temperature and under thermal cycling conditions. In this study, the sintering behavior of plasma-sprayed freestanding zirconia-yttria-based thermal barrier coatings and mullite (and/or barium-strontium-aluminosilicate, i.e., BSAS) environmental barrier coatings was determined using a dilatometer in the temperature range of 1200-1500 C. The effects of test temperature on the coating sintering kinetics were systematically investigated. The plasma-sprayed zirconia-8wt.%yttria and mullite (BSAS) two-layer composite coating systems were also prepared to quantitatively evaluate the interface strain tolerance of the coating system under thermal cycling conditions based on the dilatomentry. The cyclic response of the coating strain tolerance behavior and interface degradation as a function of cycle number will also be discussed.

  10. Comprehensive Study on Ceramic Membranes for Low-Cost Microbial Fuel Cells.

    PubMed

    Pasternak, Grzegorz; Greenman, John; Ieropoulos, Ioannis

    2016-01-08

    Microbial fuel cells (MFCs) made with different types of ceramic membranes were investigated to find a low-cost alternative to commercially available proton exchange membranes. The MFCs operated with fresh human urine as the fuel. Pyrophyllite and earthenware produced the best performance to reach power densities of 6.93 and 6.85 W m(-3), respectively, whereas mullite and alumina achieved power densities of 4.98 and 2.60 W m(-3), respectively. The results indicate the dependence of bio-film growth and activity on the type of ceramic membrane applied. The most favourable conditions were created in earthenware MFCs. The performance of the ceramic membranes was related to their physical and chemical properties determined by environmental scanning electron microscopy and energy dispersive X-ray spectroscopy. The cost of mullite, earthenware, pyrophyllite and alumina was estimated to be 13.61, 4.14, 387.96 and 177.03 GBP m(-2), respectively. The results indicate that earthenware and mullite are good substitutes for commercially available proton exchange membranes, which makes the MFC technology accessible in developing countries. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  11. The Morphology and Chemistry Evolution of Inclusions in Fe-Si-Al-O Melts

    NASA Astrophysics Data System (ADS)

    Kwon, Youjong; Choi, Juhan; Sridhar, Seetharaman

    2011-08-01

    This study aims to elucidate the process of inclusion precipitation in Fe-Si and Fe-Si-Al melts. Deoxidation experiments were carried out in a vacuum induction furnace (VIF) at 1873 K (1600 °C). In the Si-deoxidation experiments, spherical SiO2 of 1~2 μm diameter was dominant. When 3 wt pct Si and 300 ppm Al were added, such that Al2O3 and mullite were thermodynamically stable, the resulting inclusions depended on the addition sequence. When aluminum was added before silicon, spherical aluminum oxides were dominant after the Al addition, but after the Si addition, the number and size of alumina decreased and Al-Si oxides and mullite appeared with increasing time. When silicon was added before aluminum, spherical SiO2 was dominant after the Si addition, but after the Al addition, spherical and polygonal alumina inclusions were dominant. When Al/Si was added simultaneously, polygonal alumina inclusions were dominant initially, but with time, Al-Si oxide and mullite inclusions increased in numbers. If the Al amount in the Al/Si addition was increased to 600 ppm, only alumina was found. This study shows how, under similar thermodynamic conditions, the transient evolution of inclusions in iron melts in the Si-Al-O system differ depending on the alloy addition sequence.

  12. Comprehensive Study on Ceramic Membranes for Low‐Cost Microbial Fuel Cells

    PubMed Central

    Pasternak, Grzegorz; Greenman, John

    2016-01-01

    Abstract Microbial fuel cells (MFCs) made with different types of ceramic membranes were investigated to find a low‐cost alternative to commercially available proton exchange membranes. The MFCs operated with fresh human urine as the fuel. Pyrophyllite and earthenware produced the best performance to reach power densities of 6.93 and 6.85 W m−3, respectively, whereas mullite and alumina achieved power densities of 4.98 and 2.60 W m−3, respectively. The results indicate the dependence of bio‐film growth and activity on the type of ceramic membrane applied. The most favourable conditions were created in earthenware MFCs. The performance of the ceramic membranes was related to their physical and chemical properties determined by environmental scanning electron microscopy and energy dispersive X‐ray spectroscopy. The cost of mullite, earthenware, pyrophyllite and alumina was estimated to be 13.61, 4.14, 387.96 and 177.03 GBP m−2, respectively. The results indicate that earthenware and mullite are good substitutes for commercially available proton exchange membranes, which makes the MFC technology accessible in developing countries. PMID:26692569

  13. Kinetics and Properties of Micro Arc Oxidation Coatings Deposited on Commercial Al Alloys

    NASA Astrophysics Data System (ADS)

    Krishna, L. Rama; Purnima, A. Sudha; Wasekar, Nitin P.; Sundararajan, G.

    2007-02-01

    The micro arc oxidation (MAO) technique is being increasingly recognized as a novel and ecofriendly means of depositing dense ceramic oxide coatings on Al and its alloys. In the present study, the deposition kinetics, surface roughness, morphology, phase distribution and the microhardness of the MAO coatings deposited on ten different commercially available Al substrates having widely differing chemical composition has been investigated. Further, the tribological properties of the coatings obtained on different Al alloys in comparison with the bare substrates have also been evaluated using dry sand abrasion, solid-particle erosion and pin-on-disc dry sliding wear tests. The results clearly demonstrate that the alloying elements added to the Al substrate substantially influence the MAO coating deposition kinetics and coating properties. In the case of Al-Si alloys, the coating deposition kinetics is non-linear and the Al6Si2O13 (mullite) is observed to form. With increasing Si content, the corresponding mullite phase also increases. Increasing mullite content in the coating adversely affects the tribological performance. Excepting Al-Si alloys, all other alloys investigated including commercial purity Al exhibit linear coating deposition kinetics. Of all the alloys investigated, Al-Li alloy exhibits the highest coating deposition rate and the 6061 T6 Al alloy exhibits the best coating properties.

  14. Evaluation of Interfacial Interactions Between Ti-6Al-4V and Mold Use Ti-Added Backup Coat in Investment Casting

    NASA Astrophysics Data System (ADS)

    Cheng, Xu; Chai, Lianjing; Wu, Guoqing; Wang, Hong; Nan, Hai

    2016-05-01

    In this article, the chemical inertness of shell using Ti-added mullite backup coat against molten Ti-6Al-4V (Ti64) alloy was investigated. The metal/shell interfacial microstructures and compositions were characterized using an optical microscope, scanning electron microscope, roughness tester, and X-ray diffractometer; the hardened layer thickness was evaluated using a microhardness tester. By adding titanium powder into the mullite backup coat, the alpha case and hardened layer thickness of the Ti64 castings were largely reduced with good surface finishing. Silicon ions, from the backup coat, penetrated into the alloy and coarsened the β lath at the metal/shell interfacial area. The Ti powder in the mullite backup coat oxidized and interacted with silica during mold firing and casting, which reduced the silicon and oxygen concentrations at the metal/shell interfacial area. The oxygen penetration depth is thicker than the alpha case layer thickness, and around 0.26 wt pct, oxygen can obviously coarsen the alpha lath at the metal/shell interfacial area during investment casting.

  15. The influence of crystallography and kinetics on phengite breakdown reactions in a low-pressure metamorphic aureole

    NASA Astrophysics Data System (ADS)

    Worden, R. H.; Droop, G. T. R.; Champness, P. E.

    1992-04-01

    A natural example of phengite that had undergone partial thermal decomposition at a pressure of about 0.5 kbar and a temperature of about 680° C in a contact aureole was exmined in the transmission electron microscope (TEM). Partially pseudomorphed phengites were found to consist of combinations of phengite, biotite, K-feldspar, mullite, sillimanite, spinel and cordierite. Different areas within individual, partially pseudomorphed, phengite grains show various degrees of reaction and different reaction products; the cores are the least reacted and the margins have reacted most. In the cores the assemblage Al-, Mg-enriched phengite+biotite +K-feldspar+mullite±spinel has formed, whereas the assemblage K-feldspar+mullite+sillimanite+spinel +biotite+cordierite has formed at the edges. According to our thermodynamic calculations, the breakdown of phengite should have produced cordierite+spinel +corundum+K-feldspar in regions isolated from the influx of SiO2 and cordierite+andalusite+quartz+K-feldspar in regions near the edge of the grains that were essentially saturated with SiO2. Chemical equilibrium was not achieved in any part of the partially pseudomorphed phengites on a micron scale or larger. Breakdown theoretically should have been complete by about 550° C; the reaction temperature was overstepped by at least 130° C for 20 25 years. The variations in the degree and type of reaction are probably due partly to the availability of suitable nucleation sites in different regions, partly to the need to remove H2O from reaction sites and partly to the influence of SiO2, which diffused into the grains during metamorphism. The presence of SiO2 lowers the equilibrium temperatures. Thus there is a higher driving force for breakdown near the grain boundaries than in the cores. Most of the products show an orientation relationship with the parent phengite and have consistent habit planes; they have their closest-packed planes and closest-packed directions parallel to one

  16. Selection of fluxing agent for coal ash and investigation of fusion mechanism: a first-principles study

    SciTech Connect

    Jie Li; Mei-Fang Du; Zhong-Xiao Zhang; Rong-Qing Guan; Yu-Shuang Chen; Ting-Yu Liu

    2009-01-15

    An approach based on the ab initio quantum chemical modeling (CASTEP, generalized gradient approximation (GGA), and density functional theory (DFT)) was first employed to guide the selection of the appropriate fluxing agent to reduce the coal ash melting temperature. Two kinds of typical Chinese coal ash A and B with a high-melting temperature were chosen as the investigated subjects. Result of the calculation shows that mullite mineral, which is the main component of coal ash, is easier to combine with an electron acceptor than with an electron donor. Because the cations of borax (Na{sub 2}B{sub 4}O{sub 7}10H{sub 2}O) and limestone can act as electron acceptors, borax and limestone were selected as the fluxing agents in our experiment. Results of the experiment show that the melting temperatures of coal ash A and B are both decreased by borax and limestone, respectively. Moreover, borax has a better fluxing effect than limestone under the same conditions. The further numerical study on the coal ash fusing mechanism indicates that the Na{sup +} and Ca{sup 2+} cations, as acceptors, can enter into the crystal lattice of mullite mainly through O(7) and O(8) and then cause the Al(6)-O(8) and Al(5)-O(7) bonds to rupture in the (AlO{sub 6})-octahedron. From this, mullite is forced to transform to feldspar and corundum minerals that have a low binding energy. Because of the phase change of minerals in the coal ash, the coal ash melting temperature is decreased by adding borax and limestone. 27 refs., 8 figs., 3 tabs.

  17. Novel, inorganic composites using porous, alkali-activated, aluminosilicate binders

    NASA Astrophysics Data System (ADS)

    Musil, Sean

    Geopolymers are an inorganic polymeric material composed of alumina, silica, and alkali metal oxides. Geopolymers are chemical and fire resistant, can be used as refractory adhesives, and are processed at or near ambient temperature. These properties make geopolymer an attractive choice as a matrix material for elevated temperature composites. This body of research investigated numerous different reinforcement possibilities and variants of geopolymer matrix material and characterized their mechanical performance in tension, flexure and flexural creep. Reinforcements can then be chosen based on the resulting properties to tailor the geopolymer matrix composites to a specific application condition. Geopolymer matrix composites combine the ease of processing of polymer matrix composites with the high temperature capability of ceramic matrix composites. This study incorporated particulate, unidirectional fiber and woven fiber reinforcements. Sodium, potassium, and cesium based geopolymer matrices were evaluated with cesium based geopolymer showing great promise as a high temperature matrix material. It showed the best strength retention at elevated temperature, as well as a very low coefficient of thermal expansion when crystallized into pollucite. These qualities made cesium geopolymer the best choice for creep resistant applications. Cesium geopolymer binders were combined with unidirectional continuous polycrystalline mullite fibers (Nextel(TM) 720) and single crystal mullite fibers, then the matrix was crystallized to form cubic pollucite. Single crystal mullite fibers were obtained by the internal crystallization method and show excellent creep resistance up to 1400°C. High temperature flexural strength and flexural creep resistance of pollucite and polycrystalline/single-crystal fibers was evaluated at 1000-1400°C.

  18. Copper sludge from printed circuit board production/recycling for ceramic materials: a quantitative analysis of copper transformation and immobilization.

    PubMed

    Tang, Yuanyuan; Lee, Po-Heng; Shih, Kaimin

    2013-08-06

    The fast development of electronic industries and stringent requirement of recycling waste electronics have produced a large amount of metal-containing waste sludge. This study developed a waste-to-resource strategy to beneficially use such metal-containing sludge from the production and recycling processes of printed circuit board (PCBs). To observe the metal incorporation mechanisms and phase transformation processes, mixtures of copper industrial waste sludge and kaolinite-based materials (kaolinite and mullite) were fired between 650 and 1250 °C for 3 h. The different copper-hosting phases were identified by powder X-ray diffraction (XRD) in the sintered products, and CuAl2O4 was found to be the predominant hosting phase throughout the reactions, regardless of the strong reduction potential of copper expected at high temperatures. The experimental results indicated that CuAl2O4 was generated more easily and in larger quantities at low-temperature processing when using the kaolinite precursor. Maximum copper transformations reached 86% and 97% for kaolinite and mullite systems, respectively, when sintering at 1000 °C. To monitor the stabilization effect after thermal process, prolonged leaching tests were carried out using acetic acid with an initial pH value of 2.9 to leach the sintered products for 20 days. The results demonstrated the decrease of copper leachability with the formation of CuAl2O4, despite different sintering behavior in kaolinite and mullite systems. This study clearly indicates spinel formation as the most crucial metal stabilization mechanism when sintering copper sludge with aluminosilicate materials, and suggests a promising and reliable technique for reusing metal-containing sludge as ceramic materials.

  19. Devitrification of ionomer glass and its effect on the in vitro biocompatibility of glass-ionomer cements.

    PubMed

    Hurrell-Gillingham, K; Reaney, I M; Miller, C A; Crawford, A; Hatton, P V

    2003-08-01

    The effects of devitrification of an ionomer glass with a molar composition 4.5SiO(2).3Al(2)O(3).1.5P(2)O(5).3CaO.2CaF(2) on cement formation and in vitro biocompatibility were investigated. Differential thermal analysis was used to study the phase evolution in the glass, and to determine the heat treatments for production of glass-ceramics. X-ray diffraction patterns from glass frit heat-treated at 750 degrees C for 2h contained peaks corresponding to apatite (JCPDS 15-876), whereas for samples heat-treated at 950 degrees C for 2h apatite and mullite (JCPDS 15-776) were the major phases detected. Transmission electron microscopy (TEM) confirmed that apatite and apatite-mullite phases were present after heat treatments at 750 degrees C and 950 degrees C respectively. Glass and glass-ceramics were ground to prepare <45microm powders and glass ionomer cements were produced using a ratio of 1g powder: 0.2g PAA: 0.3g 10% m/v tartaric acid solution in water. In vitro biocompatibility was evaluated using cultured rat osteosarcoma (ROS) cells. Scanning electron microscopy (SEM) showed that cells colonised the surfaces of cements prepared using untreated ionomer glass and glass crystallised to form apatite (750 degrees C/2h). However, quantitative evaluation using MTT and total protein assays indicated that more cell growth occurred in the presence of cements prepared using ionomer glasses crystallised to apatite than cements prepared using untreated glass. The least cell growth and respiratory activity was observed on cements made with crystallised glass containing both apatite and mullite. It was concluded that the controlled devitrification of ionomer glasses could be used to produce GIC bone cements with improved biocompatibility.

  20. The physicochemistry and toxicology of CFA particles.

    PubMed

    Jones, Tim; Brown, Patrick; BéruBé, Kelly; Wlodarczyk, Anna; Longyi, Shao

    2010-01-01

    The term "technogenic particles" is used to describe airborne particulate matter (PM) produced during industrial processes. The most common of these is "fly ash" produced during combustion of solid and liquid fossil fuels. Coal fly ash is derived from the mineral and metal contaminants within coal in which particles (1) are distinctly spherical in shape, (2) are composed of 60-90% glass, and (3) often contain a range of contaminant metals. In addition, particles may contain recrystallized minerals, mainly quartz, mullite, and hematite; both quartz and mullite are recognized respiratory hazards. Fly ash particles from both UK and Chinese coal-burning power stations were characterized by field emission-scanning electron microscopy (morphology and size), x-ray diffraction (crystallinity and minerals), and inductively coupled plasma-mass spectroscopy (elemental composition). PM(10) samples were separated from bulk fly ash by a dry dust separator system. The plasmid scission assay (PSA) was used to measure damage produced by fly ash to plasmid bacteriophage PhiX174 RF DNA. The supercoiled DNA was either damaged or severely damaged by reactive oxygen species (ROS) generated by the fly ash at different concentrations. Geochemical analyses confirmed that the fly ash particles are predominantly glass, with a minor component of the minerals quartz, hematite, and mullite. Fly ash particles also contained a range of metals contaminants; however, these were mostly bound into the glass with only a small proportion potentially bioaccessible. PSA data showed that fly ash exhibited significant oxidative capacity when compared to negative control (MB H(2)O), indicating that ROS are likely to be the driving force underlying fly ash bioreactivity.

  1. Contribution of Aluminas and Aluminosilicates to the Formation of PCDD/Fs on Fly Ashes

    PubMed Central

    Potter, Phillip M.; Dellinger, Barry; Lomnicki, Slawomir M.

    2015-01-01

    Chlorinated aromatics undergo surface-mediated reactions with metal oxides to form Environmentally Persistent Free Radicals (EPFRs) which can further react to produce polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). Previous work using laboratory-made fly ash surrogates composed of transition metal oxides deposited on silica powder has confirmed their ability to mimic fly ash in the production of PCDD/Fs. However, little is known about the propensity of aluminas and aluminosilicates, other components of fly ash, to form PCDD/Fs. A fly ash sample containing both alumina and mullite, an aluminosilicate, was tested for PCDD/F formation ability and compared to PCDD/F yields from the thermal degradation of 2-monochlorophenol (2-MCP) precursor over γ-alumina, α-alumina, and mullite. A packed-bed flow reactor was used to investigate the thermal degradation of 2-MCP over the various catalysts at 200–600 °C. Fly ash gave similar PCDD/F yields to surrogates made with similar transition metal content. γ-alumina, which is thermodynamically unfavorable, was very catalytically active and gave low PCDD/F yields despite a high destruction of 2-MCP. Mullite and α-alumina, the thermodynamically favorable form of alumina, yielded higher concentrations of dioxins and products with a higher degree of chlorine substitution than γ-alumina. The data suggest that certain aluminas and aluminosilicates, commonly found in fly ash, are active catalytic surfaces in the formation of PCDD/Fs in the post-flame cool zones of combustion systems and should be considered as additional catalytic surfaces active in the process. PMID:26615490

  2. Trace-element and phase relations in fly ash

    SciTech Connect

    Hulett, L.D.; Weinberger, A.J.; Ferguson, N.M.; Northcutt, K.J.; Lyon, W.S.

    1981-05-01

    Chemical forms of elements have been studied in fly ash specimens collected from four Tennessee Valley Authority steam plants. Matrix components have been isolated and individually analyzed to determine trace element distributions. After particle sizing and extraction of magnetic components, the aluminosilicate phases were etched in 1% HF to remove glasses comingled with mullite and quartz. Neutron activation and atomic absorption analyses showed that most of the +1- and +2-valent elements, rare earths, and certain transition metals were concentrated in the glass phases. Cr, V, Ti, Fe, Ga, and Zr, which are trivalent and tetravalent, were concentrated in the crystal phases. X-ray diffraction and elemental analyses show that the main components of the magnetic phase are ferrite compounds with compositions of approximately Fe/sub 2/ /sub 3/Al/sub 0/ /sub 7/O/sub 4/. First-row transition elements, V, Cr, Mn, Co, Cu, Ni, and Zn are concentrated by factors as high as 50 in the magnetic phases. This infers that they occur as isomorphic substitutions in the magnetic spinel lattice since such compounds are well known. Because the spinel is magnetic, a magnetic separation could be used to remove spinel, along with its associated transition metals. Scanning electron microscopy studies of mullite phases remaining after 1% etching suggest that they have resource value. As mullite and quartz crystallize during the solidification of fly ash particles, they purify themselves of trace elements by freezing them out into interstitial glass phases. An analytic scheme for routine chemical specification and pollution hazard assessment of fly ash is suggested. Studies of fly ash exposed to sluice pond waters show tht iron in the magnetic spinel phases is oxidized and subsequently adsorbed on alumino-silicate and other particles. Arsenic and molybdenum are translocated and concentrated into these iron-rich surface phases.

  3. Development of low dielectric constant alumina-based ceramics for microelectronic substrates

    SciTech Connect

    Wu, Shun Jackson

    1993-05-01

    The performance of high speed computers depends not only on IC chips, but also on the signal propagation speed between these chips. The signal propagation delay in a computer is determined by the dielectric constant of the substrate material to which the IC chips are attached. In this study, a ceramic substrate with a low dielectric constant (k ≈ 5.0) has been developed. When compared with the traditional alumina substrate (k ≈ 10.0), the new material corresponds to a 37% decrease in the signal propagation delay. Glass hollow spheres are used to introduce porosity (k = 1.0) to the alumina matrix in a controlled manner. A surface coating technique via heterogeneous nucleation in aqueous solution has been used to improve the high temperature stability of these spheres. After sintering at 1,400 C, isolated spherical pores are uniformly distributed in the almost fully dense alumina matrix; negligible amounts of matrix defects can be seen. All pores are isolated from each other. Detailed analyses of the chemical composition find that the sintered sample consists of α-alumina, mullite and residual glass. Mullite is the chemical reaction product of alumina and the glass spheres. Residual glass exists because current firing conditions do not complete the mullitization reaction. The dielectric constant of the sintered sample is measured and then compared with the predicted value using Maxwell`s model. Mechanical strength is evaluated by a four-point bending test. Although the flexural strength decreases exponentially with porosity, samples with 34% porosity (k ≈ 5.0) still maintain adequate mechanical strength for the proper operation of a microelectronic substrate.

  4. Phase transformations in 40-60-GPa shocked gneisses from the Haughton Crater (Canada): An Analytical Transmission Electron Microscopy (ATEM) study

    NASA Technical Reports Server (NTRS)

    Martinez, I.; Guyot, F.; Schaerer, U.

    1992-01-01

    In order to better understand phase transformations, chemical migration, and isotopic disequilibrium in highly shocked rocks, we have performed a microprobe and an ATEM study on gneisses shocked up to 60 GPa from the Haughton Crater. This study reveals the following chemical and structural characteristics: (1) SiO2 dominant areas are formed by a mixture of pure SiO2 polycrystalline quartz identified by electron diffraction pattern and chemical analysis and a silica-rich amorphous phase containing minor amounts of aluminium, potassium, and iron; (2) Areas with biotitelike composition are formed by less than 200-nm grains of iron-rich spinels embedded in a silica-rich amorphous phase that is very similar to the one described above; (3) Layers with feldsparlike composition are constituted by 100-200-nm-sized alumina-rich grains (the indexation of the crystalline structure is under progress) and the silica-rich amorphous phase; (4) Zones characterized by the unusual Al/Si ratio close to 1 are formed by spinel grains (200-nm-sized) embedded in the same silica-rich amorphous phase; and (5) The fracturated sillimanites contain domains with a lamellar structure, defined by the intercalation of 100-nm-wide lamellae of mullite crystals and of a silica-rich amorphous phase. These mullite crystals preserved the crystallographical orientation of the preshock sillimanite. All compositional domains, identified at the microprobe scale, can thus be explained by a mixture in different proportion between the following phases: (1) a silica-rich amorphous phase, with minor Al and K; (2) quartz crystals; (3) spinel crystals and alumina-rich crystals; (4) sillimanite; and (5) mullite. Such mixtures of amorphous phases and crystals in different proportions explain disturbed isotope systems in these rocks and chemical heterogeneities observed on the microprobe.

  5. Rigid separator lead acid batteries

    SciTech Connect

    Cannone, A.G.; Salkind, A.J.; Stempin, J.L.; Wexell, D.R.

    1996-11-01

    Lead acid cells assembled with extruded separators displayed relatively uniform capacity and voltage parameters through 100{sup +} cycles of charge/discharge. This contrasts to failure of control cells with glass mat separators after 60 cycles. The mullite/alumina separators with 50, 60, and 70% porosity separators appear suitable for both flooded and sealed lead acid cell applications. The advantages of the rigid ceramic separators over fiber mat materials are in the uniformity of capacity and voltage, the ease of cell assembly, and the probability that firm stacking pressure on the active material will yield greater cycle life, especially at elevated temperatures.

  6. Interfacial Studies of Chemical Vapor Infiltrated (CVI) Ceramic Matrix Composites

    DTIC Science & Technology

    1988-10-01

    methyldichlorosilane (MDS), methyltrichlorosilane (MTS), and dimethyldichlorosilane (DMDS). The fibers utilized were Nicalon SiC and Nextel 440 mullite. The...transference of the saturated carrier to the reactor over long distances without heated lines. Methyltrichlorosilane (MTS), CH 3 SiCI 3 (B.P.= 66.4 0C), is...used extensively by other researchers to deposit SiC and was also used in this program along with dimethyldichlorosilane (DMDS), (CH3)2SiCI 2 (B.P

  7. Determination of anisotropy and multimorphology in fly ash based geopolymers

    SciTech Connect

    Khan, M. Irfan Azizli, Khairun Sufian, Suriati Man, Zakaria Siyal, Ahmer Ali Ullah, Hafeez

    2015-07-22

    In this study, Malaysian coal fly ash-based geopolymers were investigated for its morphology and chemical composition using scanning electron microscopy coupled with energy dispersive X-rays (SEM-EDX). Geopolymer was synthesized using sodium hydroxide as activator. SEM studies revealed multiphasous structure of the material, composed of geopolymeric gel, partially reacted fly ashparticles and selectively leached particles. EDX analysis confirmed the chemical composition of different regions. Infra red spectroscopic studies supported the SEM-EDX analysis by confirming presence of unreacted quartzite and mullite in geopolymers. It is concluded that geopolymers possese a non uniform chemistry through out the structure.

  8. Method of depositing a coating on Si-based ceramic composites

    NASA Technical Reports Server (NTRS)

    Wang, Hongyu (Inventor); Lau, Yuk-Chiu (Inventor); Spitsberg, Irene (Inventor); Henry, Arnold T. (Inventor)

    2004-01-01

    A process of depositing a coating system suitable for use as an environmental barrier coating on various substrate materials, particularly those containing silicon and intended for high temperature applications such as the hostile thermal environment of a gas turbine engine. The process comprises depositing a first coating layer containing mullite, and preferably a second coating layer of an alkaline earth aluminosilicate, such as barium-strontium-aluminosilicate (BSAS), by thermal spraying while maintaining the substrate at a temperature of 800.degree. C. or less, preferably 500.degree. C. or less, by which a substantially crack-free coating system is produced with desirable mechanical integrity.

  9. Thermal Conductivity and Thermal Gradient Cyclic Behavior of Refractory Silicate Coatings on SiC/SiC Ceramic Matrix Composites

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

    2001-01-01

    Plasma-sprayed mullite and BSAS coatings have been developed to protect SiC/SiC ceramic matrix composites from high temperature environmental attack. In this study, thermal conductivity and thermal barrier functions of these coating systems are evaluated using a laser high-heat-flux test rig. The effects of water vapor on coating thermal conductivity and durability are studied by using alternating furnace and laser thermal gradient cyclic tests. The influence of laser high thermal-gradient cycling on coating failure modes is also investigated.

  10. Development of low-expansion ceramics for diesel engine applications

    SciTech Connect

    Brown, J.J. Jr. . Center for Advanced Ceramic Materials)

    1992-04-01

    The need for stable fabricable low thermal expansion ceramics for use in advanced heat engines was first recognized in the Department of Energy Advanced Gas Turbine (AGT) technology programs. More recently, the need for ceramic materials having low thermal expansion for use in components of advanced low heat rejection diesel engines has also been recognized. This investigation concentrated on (1) synthesis, (2) property characterization, and (3) fabrication of candidate low thermal expansion ceramics from four systems based upon aluminum phosphate, silica, mullite, and zircon. The NZP (zircon - NaZr{sub 2}(PO{sub 4}){sub 3}) structures clearly represent a new class of high melting, thermal shock-resistant ceramics.

  11. Development of low-expansion ceramics for diesel engine applications. Final report: DOE/ORNL Ceramic Technology Project

    SciTech Connect

    Brown, J.J. Jr.

    1992-04-01

    The need for stable fabricable low thermal expansion ceramics for use in advanced heat engines was first recognized in the Department of Energy Advanced Gas Turbine (AGT) technology programs. More recently, the need for ceramic materials having low thermal expansion for use in components of advanced low heat rejection diesel engines has also been recognized. This investigation concentrated on (1) synthesis, (2) property characterization, and (3) fabrication of candidate low thermal expansion ceramics from four systems based upon aluminum phosphate, silica, mullite, and zircon. The NZP [zircon - NaZr{sub 2}(PO{sub 4}){sub 3}] structures clearly represent a new class of high melting, thermal shock-resistant ceramics.

  12. Radiative contribution to the thermal conductivity of fibrous insulations

    NASA Technical Reports Server (NTRS)

    Linford, R. M. F.; Schmitt, R. J.; Hughes, T. A.

    1974-01-01

    An approach is shown for using a simple two-flux model to interpret infrared transmission data for a variety of reuseable surface insulations materials and to calculate the radiation transmission. A description is given of preliminary experiments on mullite and silica-based materials. The calculated parameters are compared with the measured values of the total thermal conductivity, as determined on guarded hot plate equipment. It is pointed out that for many samples the newly developed four-flux model must be utilized because the scattering properties of the fibers are often dependent on the wavelength of the radiation.

  13. Sliding wear of oxide ceramics at elevated temperatures

    SciTech Connect

    Senda, Tetsuya; Drennan, J.; McPherson, R.

    1995-11-01

    Sliding wear tests of sintered alumina and mullite consistently showed that the wear loss significantly decreased at 800 C and above by an order of magnitude. Microscopy of the room-temperature wear surfaces revealed a feature suggesting material removal by brittle fracture. Microscopy of the wear surface at 1,000 C revealed that the immediate vicinity of the wear surface consisted of a very fine grain size polycrystalline structure. The zone below this consisted of heavily deformed grains containing dense dislocation networks forming a cellular structure. The results suggest that, at high temperatures, dynamic recrystallization at the wear surface forms the fine grain size structure which suppresses further material removal.

  14. High Temperature Aerogels in the Al2O3-SiO2 System

    NASA Technical Reports Server (NTRS)

    Hurwitz, Frances I.; Aranda, Denisse V.; Gallagher, Meghan E.

    2008-01-01

    Al2O3-SiO2 aerogels are of interest as constituents of thermal insulation systems for use at high temperatures. Al2O3 and mullite aerogels are expected to crystallize at higher temperatures than their SiO2 counterparts, hence avoiding the shrinkages that accompany the formation of lower temperature SiO2 phases and preserving pore structures into higher temperature regimes. The objective of this work is to determine the influence of processing parameters on shrinkage, gel structure (including surface area, pore size and distribution) and pyrolysis behavior.

  15. Method for making lightweight proppant for oil and gas wells

    SciTech Connect

    Rumpf, D.S.; Lemieux, P.R.

    1990-12-11

    This paper discuses a method for making a low density proppant. It comprises calcining kaolin clay at a temperature below that which would cause the transformation of any significant portion of the kaolin clay to mullite or crystobalite for a time sufficient to reduce the LOI thereof to 12% or less, when tested at 1400{degrees}C.; mixing the calcined kaolin clay with amorphous to microcrystalline silica; pelletizing the mixture to form pellets in a selected size range; and sintering the pellets to form proppant particles having a dry specific gravity of less than 2.70.

  16. Life of refractories in the lining of a cyclone reactor

    SciTech Connect

    Pitak, N.V.

    1985-09-01

    Tests of refractories in the linings of cyclone reactors for the production of industrial carbon showed that mullite-corundum, corundum, and zirconium-containing refractories, which are recommended for wide use, possess the longest life. Alumina-silicon carbide, kaolin-base chamotte, chamotte-graphite, and silicon carbide parts fail rapidly in the reactor linings and are not suitable for these service conditions. Disthene-sillimanite and kaolin-base chamotte parts showed satisfactory results in service and occupy an intermediate place in life between the first and second groups of refractories.

  17. Refractories for lining blast furnaces

    SciTech Connect

    Fedoruk, R.M.; Baksheeva, V.S.; Karyakina, E.L.; Khmelenko, T.P.; Pitak, N.V.

    1986-01-01

    The authors develop and introduce a technology for the production of chamotte kaolin refractories with a porosity of not more than 12% and a mass proportion of not less than 42% A1/sub 2/O/sub 3/ on the basis of chamotte from high-grade Polozhe kaolin, and also additions to the batch of finely milled mullite-corundum chamotte. Using the new technology, a batch of goods designated ShPD-42 was produced for lining the shafts, bosh, and upper parts of blast furnaces of large capacity.

  18. Oxidation-resistant interface coatings for Nicalon/SiC composites

    SciTech Connect

    Stinton, D.P.; Besmann, T.M.; Lowden, R.A.; Liaw, P.K.; Shanmugham, S.

    1997-12-01

    Nicalon/SiC composites with thin C and C/oxide/C interfaces were fabricated. The oxide layers, mullite and Al{sub 2}O{sub 3}-TiO{sub 2}, were deposited by a sol-gel process, while the C layer was deposited by a chemical vapor infiltration method. The fabricated composites were flexure tested in both as-processed and oxidized conditions. Composites with C and C/oxide/C interfaces retained graceful failure even after 500 h oxidation at 1000 C, but with reduced flexural strengths.

  19. Oxidation behavior in reaction-bonded aluminum-silicon alloy/alumina powder compacts

    SciTech Connect

    Yokota, Shari Hanayo

    1992-12-01

    Goal of this research is to determine the feasibility of producing low-shrinkage mullite/alumina composites by applying the reaction-bonded alumina (RBAO) process to an aluminum-silicon alloy/alumina system. Mirostructural and compositional changes during heat treatment were studied by removing samples from the furnace at different steps in the heating schedule and then using optical and scanning electron microscopy, EDS and XRD to characterize the powder compacts. Results suggest that the oxidation behavior of the alloy compact is different from the model proposed for the pure Al/alumina system.

  20. Effect of mineralizers on the sintering of porcelain bodies (a review)

    SciTech Connect

    Maslennikova, G.N.; Koneshova, T.I.

    1987-11-01

    The authors assess the effects of a wide range of mineralizing agents on the structure formation of porcelain in order to arrive at optimal crystallization and structure parameters for the resulting porcelain crystals and to determine those agents which best contribute to the energy efficiency of the sintering process. The assessment is carried out specifically for the kinetics of mullite formation. Reagents tested include salts of sodium, potassium, lithium, calcium, magnesium, zinc, and aluminum, and the oxides of chromium, titanium, iron, zirconium, molybdenum, boron, and tin.

  1. Oxidation behavior in reaction-bonded aluminum-silicon alloy/alumina powder compacts

    SciTech Connect

    Yokota, S.H.

    1992-12-01

    Goal of this research is to determine the feasibility of producing low-shrinkage mullite/alumina composites by applying the reaction-bonded alumina (RBAO) process to an aluminum-silicon alloy/alumina system. Mirostructural and compositional changes during heat treatment were studied by removing samples from the furnace at different steps in the heating schedule and then using optical and scanning electron microscopy, EDS and XRD to characterize the powder compacts. Results suggest that the oxidation behavior of the alloy compact is different from the model proposed for the pure Al/alumina system.

  2. Reaction mechanisms and microstructures of ceramic-metal composites made by reactive metal penetration

    SciTech Connect

    Fahrenholtz, W.F.; Ewsuk, K.G.; Loehman, R.E.

    1996-12-31

    Ceramic-metal composites can be made by reactive penetration of molten metals into dense ceramic performs. The metal penetration is driven by a large negative Gibbs energy for reaction, which is different from the more common physical infiltration of porous media. Reactions involving Al can be written generally as (x+2)Al + (3/y)MO{sub y} {yields} Al{sub 2}O{sub 3} + M{sub 3/y}Al{sub x}, where MO{sub y} is an oxide that is wet by molten Al. In low Po{sub 2} atmospheres and at temperature above about 900{degrees}c, molten Al reduces mullite to produce Al{sub 2}O{sub 3} + M{sub 3/y}Al{sub x}, where MO is an oxide that is wet by molten Al. In low Po{sub 2} atmospheres and at temperatures above about 900{degrees}C, molten al reduces mullite to produce Al{sub 2}O{sub 3} and Si. The Al/mullite reaction has a {Delta}G{sub r}{degrees} (1200K) of -1014 kJ/mol and, if the mullite is fully dense, the theoretical volume change on reaction is less than 1%. A microstructure of mutually-interpenetrating metal and ceramic phases generally is obtained. Penetration rate increases with increasing reaction temperature from 900 to 1150{degrees}C, and the reaction layer thickness increases linearly with time. Reaction rate is a maximum at 1150{degrees}C; above that temperature the reaction slows and stops after a relatively short period of linear growth. At 1300{degrees}C and above, no reaction layer is detected by optical microscopy. Observations of the reaction front by TEM show only al and Al{sub 2}O{sub 3} after reaction at 900{degrees}C, but Si is present in increasing amounts as the reaction temperature increases to 1100{degrees}C and above. The kinetic and microstructural data suggest that the deviation from linear growth kinetics at higher reaction temperatures and longer times is due to Si build-up and saturation at the reaction front. The activation energy for short reaction times at 900 to 1150{degrees}C varies from {approximately}90 to {approximately}200 kJ/mole.

  3. Synthesis of hydroxy sodalite from coal fly ash using waste industrial brine solution.

    PubMed

    Musyoka, Nicholas M; Petrik, Leslie F; Balfour, Gillian; Gitari, Wilson M; Hums, Eric

    2011-01-01

    The effect of using industrial waste brine solution instead of ultra pure water was investigated during the synthesis of zeolites using three South African coal fly ashes as Si feedstock. The high halide brine was obtained from the retentate effluent of a reverse osmosis mine water treatment plant. Synthesis conditions applied were; ageing of fly ash was at 47 ° C for 48 hours, and while the hydrothermal treatment temperature was set at 140 ° C for 48 hours. The use of brine as a solvent resulted in the formation of hydroxy sodalite zeolite although unconverted mullite and hematite from the fly ash feedstock was also found in the synthesis product.

  4. Development of refractory concrete for extreme conditions

    NASA Astrophysics Data System (ADS)

    Pundiene, I.; Antonovich, V.; Stonys, R.; Demidova-Buiziniene, I.

    2011-12-01

    Comparative analysis is provided for the properties of medium-cement refractory concrete with microsilica based on mullite filler in relation to different type of deflocculant. The effect of different deflocculants on refractory concrete structure formation, hydration, rheology, strength and heat resistance is discussed. Corrosion resistance test, determined that samples with hybrid deflocculant showed better resistance for slag penetration than samples with only the sodium tripolyphosphate or polycarboxylate ether deflocculant. Moreover, a composition of hybrid deflocculant let to control the rate of the hydration process and to get features of refractory refractory concrete.

  5. Determination of anisotropy and multimorphology in fly ash based geopolymers

    NASA Astrophysics Data System (ADS)

    Khan, M. Irfan; Azizli, Khairun; Sufian, Suriati; Man, Zakaria; Siyal, Ahmer Ali; Ullah, Hafeez

    2015-07-01

    In this study, Malaysian coal fly ash-based geopolymers were investigated for its morphology and chemical composition using scanning electron microscopy coupled with energy dispersive X-rays (SEM-EDX). Geopolymer was synthesized using sodium hydroxide as activator. SEM studies revealed multiphasous structure of the material, composed of geopolymeric gel, partially reacted fly ashparticles and selectively leached particles. EDX analysis confirmed the chemical composition of different regions. Infra red spectroscopic studies supported the SEM-EDX analysis by confirming presence of unreacted quartzite and mullite in geopolymers. It is concluded that geopolymers possese a non uniform chemistry through out the structure.

  6. Automatic control during microwave heating of ceramics

    SciTech Connect

    Li, M.; Beale, G.O.; Tian, Yong Lai

    1995-12-31

    This paper presents results on the development of a feedback control system for regulating temperature in ceramic samples being heated by microwave energy for the purpose of joining. The main objective of the control system is to prevent thermal runaway in the ceramic samples during heating. Microwave power level and the positions of a movable iris and plunger are the variables being controlled. Results obtained from heating mullite and silicon carbide are presented. These results indicate the ability of the control system to prevent thermal runaway during microwave heating of the samples.

  7. Crystallization paths in SiO2-Al2O3-CaO system as a genotype of silicate materials

    NASA Astrophysics Data System (ADS)

    Lutsyk, V. I.; Zelenaya, A. E.

    2013-12-01

    The phases trajectories in the fields of primary crystallization of cristobalite (SiO2cr), tridymite (SiO2tr), mullite (3Al2O3-2SiO2) and in a field of liquid immiscibility are analyzed on a basis of computer model for T-x-y diagram of SiO2-Al2O3-CaO system. The concentration fields with unique set of microconstituents and the fields without individual crystallization schemes and microconstituents are revealed.

  8. High Temperature Liquid and Glass Precursors for Oxyphosphate Ceramic Composites

    DTIC Science & Technology

    2007-07-01

    model . We also mapped out the general liquidus surfaces for the ternary A120 3- A16SiEO 1 3-LaPO4 system , although refinements are needed. 2. We...temperatures for the binary AI20 3-LaPO4 (alumina-monazite) and A16Si 20 13-LaPO4 (mullite-monazite) systems were determined and fitted to a thermodynamic...determined the glass transition and crystallization temperatures for the A16Si 20 3- LaPO4 system as a function of composition and have identified the

  9. The oxidation behavior of Co-15 wt % Cr alloy containing dispersed oxides formed by internal oxidation

    SciTech Connect

    Hou, P.Y.; Shui, Z.R. ); Stringer, J. )

    1991-12-01

    Internal oxidation pretreatments of Co-15wt%Cr and Co-15wt%Cr-1wt%Ti were carried out using a Rhines pack in quartz, in mullite and in alumina. A dispersion of titanium oxide particles formed in the Ti-containing alloy as a result of the internal oxidation. However, silicon also diffused into all treated specimens when the pretreatments were carried out in quartz or in mullite. The effect of various pretreatments on the subsequent oxidation of these alloys was studied at 1000{degree}C, and compared with that of Co-15wt%Cr-1wt%Si alloy. The main purpose of this study was to determine the relative effectiveness of the dispersed oxide particles and the contaminated silicon on the selective oxidation of chromium. It was found that the oxidation behavior of both treated alloys were strongly affected by the degree of silicon contamination. Selective oxidation of chromium to form a nearly continuous protective Cr{sub 2}O{sub 3} scale was achieved with greater than 0.4wt% silicon. The presence of dispersed particles reduced initial oxidation rate, but was ineffective in promoting Cr{sub 2}O{sub 3} scale formation.

  10. Dip coating process: Silicon sheet growth development for the large-area silicon sheet task of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    Heaps, J. D.; Maciolek, R. B.; Zook, J. D.; Harrison, W. B.; Scott, M. W.; Hendrickson, G.; Wolner, H. A.; Nelson, L. D.; Schuller, T. L.; Peterson, A. A.

    1976-01-01

    The technical and economic feasibility of producing solar cell quality sheet silicon by dip-coating one surface of carbonized ceramic substrates with a thin layer of large grain polycrystalline silicon was investigated. The dip-coating methods studied were directed toward a minimum cost process with the ultimate objective of producing solar cells with a conversion efficiency of 10% or greater. The technique shows excellent promise for low cost, labor-saving, scale-up potentialities and would provide an end product of sheet silicon with a rigid and strong supportive backing. An experimental dip-coating facility was designed and constructed, several substrates were successfully dip-coated with areas as large as 25 sq cm and thicknesses of 12 micron to 250 micron. There appears to be no serious limitation on the area of a substrate that could be coated. Of the various substrate materials dip-coated, mullite appears to best satisfy the requirement of the program. An inexpensive process was developed for producing mullite in the desired geometry.

  11. Magnesia-ammonium phosphate-bonded cordierite refractory castables: Phase evolution on heating and mechanical properties

    SciTech Connect

    Hipedinger, Nora E.; Scian, Alberto N.; Aglietti, Esteban F

    2004-01-01

    A cordierite refractory castable was developed using the MgO-NH{sub 4}H{sub 2}PO{sub 4} reaction. This castable was made with cordierite-mullite aggregates from scrap refractory material and a cement paste based on magnesia, calcined alumina, silica fume, and ammonium dihydrogen phosphate, which forms cordierite (2MgO{center_dot}2Al{sub 2}O{sub 3}{center_dot}5SiO{sub 2}) during heating at high temperature. The mix with water was cast into steel molds; the cold setting occurs within 30 min. The set castables were thermally treated and the evolution of the phases was observed. Struvite (NH{sub 4}{center_dot}MgPO{sub 4}{center_dot}6H{sub 2}O) was identified at room temperature; between 110 and 750 deg. C, the present phosphates were amorphous to X-ray diffraction (XRD). At 1100 deg. C, magnesium orthophosphate (Mg{sub 3}(PO{sub 4}){sub 2}) and aluminum orthophosphate (AlPO{sub 4}) were present. At 1350 deg. C, the main crystalline phases were cordierite and mullite. Cold and hot flexural strength, thermal shock resistance, and physical properties were measured. The properties of magnesia-phosphate-bonded cordierite castables were compared with cordierite material obtained by conventional slip-casting method from aggregates, clay, talc, and calcined alumina.

  12. Filtration Efficiency of Functionalized Ceramic Foam Filters for Aluminum Melt Filtration

    NASA Astrophysics Data System (ADS)

    Voigt, Claudia; Jäckel, Eva; Taina, Fabio; Zienert, Tilo; Salomon, Anton; Wolf, Gotthard; Aneziris, Christos G.; Le Brun, Pierre

    2017-02-01

    The influence of filter surface chemistry on the filtration efficiency of cast aluminum alloys was evaluated for four different filter coating compositions (Al2O3—alumina, MgAl2O4—spinel, 3Al2O3·2SiO2—mullite, and TiO2—rutile). The tests were conducted on a laboratory scale with a filtration pilot plant, which facilitates long-term filtration tests (40 to 76 minutes). This test set-up allows the simultaneous use of two LiMCAs (before and after the filter) for the determination of the efficiency of inclusion removal. The four tested filter surface chemistries exhibited good thermal stability and mechanical robustness after 750 kg of molten aluminum had been cast. All four filter types exhibited a mean filtration efficiency of at least 80 pct. However, differences were also observed. The highest filtration efficiencies were obtained with alumina- and spinel-coated filter surfaces (>90 pct), and the complete removal of the largest inclusions (>90 µm) was observed. The efficiency was slightly lower with mullite- and rutile-coated filter surfaces, in particular for large inclusions. These observations are discussed in relation to the properties of the filters, in particular in terms of, for example, the surface roughness.

  13. Microstructural characterization and influence of manufacturing parameters on technological properties of vitreous ceramic materials

    SciTech Connect

    Njoya, D.; Hajjaji, M.; Bacaoui, A.; Njopwouo, D.

    2010-03-15

    Microstructure of vitreous ceramic samples manufactured from kaolinitic-clay and feldspars raw materials from Cameroon was investigated in the range 1150-1250 deg. C by X-ray diffraction and scanning electron microscopy and by measuring some technological properties. Moreover, the simultaneous influence of feldspars content, heating temperature and soaking time on water absorption and firing shrinkage was evaluated by adopting the response surface methodology (Doehlert matrix), using the New Efficient Methodology for Research using Optimal Design (NEMROD) software. The results show that a spinel phase, mullite, glassy phase and some amount of hematite were formed. However, the spinel phase and potassic feldspar, as compared to the sodic one, disappeared at moderate firing temperature and soaking time. Apparently, mullite developed from spinel phase, which is formed from the demixion of metakaolin. On the other hand, it is found that the effects of fluxing content and firing temperature on the measured properties were almost similar and more influent than soaking time. Antagonistic and synergetic interactions existed between the considered parameters, and their importance differed for the considered properties. By using this mathematical tool, suitable operating conditions for manufacturing vitreous bodies were determined.

  14. Microstructure, Tensile Adhesion Strength and Thermal Shock Resistance of TBCs with Different Flame-Sprayed Bond Coat Materials Onto BMI Polyimide Matrix Composite

    NASA Astrophysics Data System (ADS)

    Abedi, H. R.; Salehi, M.; Shafyei, A.

    2017-08-01

    In this study, thermal barrier coatings (TBCs) composed of different bond coats (Zn, Al, Cu-8Al and Cu-6Sn) with mullite top coats were flame-sprayed and air-plasma-sprayed, respectively, onto bismaleimide matrix composites. These polyimide matrix composites are of interest to replace PMR-15, due to concerns about the toxicity of the MDA monomer from which PMR-15 is made. The results showed that pores and cracks appeared at the bond coat/substrate interface for the Al-bonded TBC because of its high thermal conductivity and diffusivity resulting in transferring of high heat flux and temperature to the polymeric substrate during top coat deposition. The other TBC systems due to the lower conductivity and diffusivity of bonding layers could decrease the adverse thermal effect on the polymer substrate during top coat deposition and exhibited adhesive bond coat/substrate interfaces. The tensile adhesion test showed that the adhesion strength of the coatings to the substrate is inversely proportional to the level of residual stress in the coatings. However, the adhesion strength of Al bond-coated sample decreased strongly after mullite top coat deposition due to thermal damage at the bond coat/substrate interface. TBC system with the Cu-6Sn bond coat exhibited the best thermal shock resistance, while Al-bonded TBC showed the lowest. It was inferred that thermal mismatch stresses and oxidation of the bond coats were the main factors causing failure in the thermal shock test.

  15. Improvement of Reusable Surface Insulation (RSI) materials

    NASA Technical Reports Server (NTRS)

    Blome, J. C.

    1972-01-01

    The mullite fiber based hardened compacted fibers (HCF) type of reusable surface insulation was further developed for use in the Space Shuttle Program. Two hundred fifty formulations of fiber mixtures, fillers, binders, and organic processing aids were made using mullite fibers as the basic ingredient. Most of the work was accomplished on 15-lb/cu ft material. It was established that higher density materials are stronger with strength values as high as 250 lb/sq in. in tension. New measurement techniques and equipment were developed for accurate determination of strength and strain to failure. Room temperature to 2300 F stress-strain relationships were made. The room temperature tensile modulus of elasticity is 61,700 lb/sq in. and the strain at failure is 0.165 percent, typically, when measured longitudinally parallel to the long axes of the fibers. Thermal insulating effectiveness was increased 20 percent by reducing the diameter of some of the fibers in the material. Improvements were made in density uniformity and strength uniformity in a block of HCF by mixing improvements and by the use of organic additives. Specifications were established on the materials and processes used in making the insulation.

  16. Corrosion protection of SiC-based ceramics with CVDMullite coatings

    SciTech Connect

    Sarin, V.; Auger, M.

    1997-05-01

    Silicon carbide ceramics are the leading candidate materials for use as heat exchangers in advanced combined cycle power plants because of their unique combination of high temperature strength, high thermal conductivity, excellent thermal shock resistance, and good high temperature stability and oxidation resistance. Ceramic coatings are being considered for diesel engine cylinder liners, piston caps, valve faces and seats, piston rings, and for turbine components such as combustors, blades, stators, seals, and bearings. Under such conditions ceramics are better suited to high temperature environments than metals. For the first time, adherent crystalline mullite coatings have been chemically vapor deposited onto SiC substrates to enhance its corrosion/oxidation resistance. Thermodynamic and kinetic considerations have been utilized to produce mullite coatings with a variety of growth rates, compositions, and morphologies. The flexibility of processing can be exploited to produce coated ceramics with properties tailored to specific applications and varied corrosive environments. These corrosive environments include thermal, Na{sub 2}SO{sub 4}, O{sub 2} and coal slag.

  17. Thermal Conductivity of Ceramic Thermal Barrier and Environmental Barrier Coating Materials

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Bansal, Narottam P.; Lee, Kang N.; Miller, Robert A.

    2001-01-01

    Thermal barrier and environmental barrier coatings (TBC's and EBC's) have been developed to protect metallic and Si-based ceramic components in gas turbine engines from high temperature attack. Zirconia-yttria based oxides and (Ba,Sr)Al2Si2O8(BSAS)/mullite based silicates have been used as the coating materials. In this study, thermal conductivity values of zirconia-yttria- and BSAS/mullite-based coating materials were determined at high temperatures using a steady-state laser heat flux technique. During the laser conductivity test, the specimen surface was heated by delivering uniformly distributed heat flux from a high power laser. One-dimensional steady-state heating was achieved by using thin disk specimen configuration (25.4 mm diam and 2 to 4 mm thickness) and the appropriate backside air-cooling. The temperature gradient across the specimen thickness was carefully measured by two surface and backside pyrometers. The thermal conductivity values were thus determined as a function of temperature based on the 1-D heat transfer equation. The radiation heat loss and laser absorption corrections of the materials were considered in the conductivity measurements. The effects of specimen porosity and sintering on measured conductivity values were also evaluated.

  18. Microstructure, Tensile Adhesion Strength and Thermal Shock Resistance of TBCs with Different Flame-Sprayed Bond Coat Materials Onto BMI Polyimide Matrix Composite

    NASA Astrophysics Data System (ADS)

    Abedi, H. R.; Salehi, M.; Shafyei, A.

    2017-10-01

    In this study, thermal barrier coatings (TBCs) composed of different bond coats (Zn, Al, Cu-8Al and Cu-6Sn) with mullite top coats were flame-sprayed and air-plasma-sprayed, respectively, onto bismaleimide matrix composites. These polyimide matrix composites are of interest to replace PMR-15, due to concerns about the toxicity of the MDA monomer from which PMR-15 is made. The results showed that pores and cracks appeared at the bond coat/substrate interface for the Al-bonded TBC because of its high thermal conductivity and diffusivity resulting in transferring of high heat flux and temperature to the polymeric substrate during top coat deposition. The other TBC systems due to the lower conductivity and diffusivity of bonding layers could decrease the adverse thermal effect on the polymer substrate during top coat deposition and exhibited adhesive bond coat/substrate interfaces. The tensile adhesion test showed that the adhesion strength of the coatings to the substrate is inversely proportional to the level of residual stress in the coatings. However, the adhesion strength of Al bond-coated sample decreased strongly after mullite top coat deposition due to thermal damage at the bond coat/substrate interface. TBC system with the Cu-6Sn bond coat exhibited the best thermal shock resistance, while Al-bonded TBC showed the lowest. It was inferred that thermal mismatch stresses and oxidation of the bond coats were the main factors causing failure in the thermal shock test.

  19. High temperature alkali corrosion of ceramics in coal gas: Final report

    SciTech Connect

    Pickrell, G.R.; Sun, T.; Brown, J.J. Jr.

    1994-12-31

    There are several ceramic materials which are currently being considered for use as structural elements in coal combustion and coal conversion systems because of their thermal and mechanical properties. These include alumina (refractories, membranes, heat engines); silicon carbide and silicon nitride (turbine engines, internal combustion engines, heat exchangers, particulate filters); zirconia (internal combustion engines, turbine engines, refractories); and mullite and cordierite (particulate filters, refractories, heat exchangers). High temperature alkali corrosion has been known to cause premature failure of ceramic components used in advanced high temperature coal combustion systems such as coal gasification and clean-up, coal fired gas turbines, and high efficiency heat engines. The objective of this research is to systematically evaluate the alkali corrosion resistance of the most commonly used structural ceramics including silicon carbide, silicon nitride, cordierite, mullite, alumina, aluminum titanate, and zirconia. The study consists of identification of the alkali reaction products and determination of the kinetics of the alkali reactions as a function of temperature and time. 145 refs., 29 figs., 12 tabs.

  20. On the Enclathration of NaB(OH)4 in the β-Cages of Sodalite: Crystallization Kinetics and Crystal Structure

    NASA Astrophysics Data System (ADS)

    Buhl, J.-Ch.; Mundus, C.; Löns, J.; Hoffmann, W.

    1994-12-01

    The hydrothermal formation of sodium hydroxyborate enclathrated sodalite synthesized from an initial ternary mixture of mullite, cristobalite and corundum has been investigated. Depending on temperature and pressure the compound Na7.5[AlSiO4]6[B(OH)4]1.5 · 2H2O could be synthesized in form of polycrystalline powder as well as in form of single crystals. The kinetics of the sodalite growth could be determined at 423 K and 473 K. 29Si-and 27Al MAS NMR was shown to be the preferred method to describe the conversion into sodalite quantitatively. Evidence for the first formation of polycrystalline sodalite has been found after the total dissolution of mullite and cristobalite. Single crystal X-ray diffraction data were used for the structure determination and refinement. The position and orientation of the hydroxyborate anions within the sodalite's /β-cages could only be found in the course of a "rigid body" refinement with constraints for the B(OH)4 tetrahedron. The boron atoms are located in an off-centre position within the sodalite cages. One out of the four oxygen atoms of the hydroxyborate group is positioned near the centre of a face of the sodium tetrahedron, whereas the three remaining oxygen atoms are near to the middle of its edges.

  1. The internal microstructure and fibrous mineralogy of fly ash from coal-burning power stations.

    PubMed

    Brown, Patrick; Jones, Tim; BéruBé, Kelly

    2011-12-01

    Coal fly ash (CFA) is a significant environmental pollutant that presents a respiratory hazard when airborne. Although previous studies have identified the mineral components of CFA, there is a paucity of information on the structural habits of these minerals. Samples from UK, Polish and Chinese power stations were studied to further our understanding of the factors that affect CFA geochemistry and mineralogy. ICP-MS, FE-SEM/EDX, XRD, and laser diffraction were used to study physicochemical characteristics. Analysis revealed important differences in the elemental compositions and particle size distributions of samples between sites. Microscopy of HF acid-etched CFA revealed the mullite present possesses a fibrous habit; fibres ranged in length between 1 and 10 μm. Respirable particles (<10 μm) were frequently observed to contain fibrous mullite. We propose that the biopersistence of these refractory fibres in the lung environment could be contributing towards chronic lung diseases seen in communities and individuals continually exposed to high levels of CFA.

  2. Lightweight proppants for deep-gas-well stimulation. Third annual report, July 1, 1981-June 30, 1982

    SciTech Connect

    Cutler, R.A.; Enniss, D.O.; Swartz, G.C.; Jones, A.H.

    1983-04-01

    The need exists for lower-density, less-expensive proppants for use in hydraulic-fracturing treatments. Ceramics, fabricated as fully sintered or hollow spheres, are the best materials for obtaining economical proppants with adequate strength. Fabrication techniques are described for fabricating solid-porcelain proppants and hollow-ceramic proppants. Porcelain proppants made by mix-pelletization techniques have good characteristics for propping wells with closure stresses to 96.5 MPa (14,000 psi). The properties of porcelain proppants are compared with twelve commercially available or experimental proppants. Several of the proppants evaluated had adequate conductivity for most hydraulic-fracturing jobs and are less expensive than bauxite. A single-fluid nozzle, counter-current spray-drying technique was used to make hollow, spherical proppants. Alumina was used as the ceramic raw material for these spray-drying experiments, but the same technique can be used with other ceramic materials. Hollow proppants with strengths comparable to sand have been spray dried but further optimization of spray drying parameters is needed to achieve proppants with concentric voids and improved strength. Bauxite, mullite, alumina and mullite rods were fast fired in a plasma in order to see if it is feasible to sinter these materials rapidly. Fast firing appears to be an alternative method of sintering proppants and may reduce costs, thereby making proppants more cost competitive with sand. 42 figures, 20 tables.

  3. Development of oxide based diffusion barrier coatings for CFC components applied in modern furnaces

    NASA Astrophysics Data System (ADS)

    Bobzin, Kirsten; Zhao, Lidong; Schlaefer, Thomas; Warda, Thomas

    2011-12-01

    Carbon fibre reinforced carbon (CFC) materials show a high potential for usage in furnaces as sample carriers for example, which is due to their excellent thermal stability compared to steel carriers. Only their tendency to react with different metals at high temperatures by Cdiffusion is a disadvantage, which can be solved by application of diffusion barriers. In order to enable the utilization of CFC-carriers for e.g. brazing furnaces, within the frame of this study thermally sprayed diffusion barrier coatings were developed. Coatings of mullite and ZrO2-7% Y2O3 (YSZ) were prepared by air plasma spraying (APS). The coatings were investigated in terms of their microstructure and thermal shock behaviour. In order to prove the suitability of the coatings for the application in brazing furnaces, the wettability of the coating surfaces by a Ni-based brazing alloy was investigated. The results showed that both mullite and YSZ could be deposited on CFC substrates with a bond coat of W or SiC. Both coatings exhibited good thermal shock behaviour and an excellent non-wetting behaviour against the used Ni-based braze alloy.

  4. Illinois basin coal fly ashes. 2. Equilibria relationships and qualitative modeling of ash-water reactions

    USGS Publications Warehouse

    Roy, W.R.; Griffin, R.A.

    1984-01-01

    Alkaline and acidic Illinois Basin coal fly ash samples were each mixed with deionized water and equilibrated for about 140 days to simulate ash ponding environments. Common to both equilibrated solutions, anhydrite solubility dominated Ca2+ activities, and Al3+ activities were in equilibrium with both matrix mullite and insoluble aluminum hydroxide phases. Aqueous silica activities were controlled by both mullite and matrix silicates. The pH of the extract of the acidic fly ash was 4.1 after 24 h but increased to a pH value of 6.4 as the H2SO4, assumed to be adsorbed to the particle surfaces, was exhausted by the dissolution of matrix iron oxides and aluminosilicates. The activities of aqueous Al3+ and iron, initially at high levels during the early stages of equilibration, decreased to below analytical detection limits as the result of the formation of insoluble Fe and Al hydroxide phases. The pH of the extract of the alkaline fly ash remained above a pH value of 10 during the entire equilibration interval as a result of the hydrolysis of matrix oxides. As with the acidic system, Al3+ activities were controlled by amorphous aluminum hydroxide phases that began to form after about 7 days of equilibration. The proposed mechanisms and their interrelations are discussed in addition to the solubility diagrams used to deduce these relationships. ?? 1984 American Chemical Society.

  5. [Fly ash and its biological effects. I. Production, utilization and physico-chemical properties of fly ash].

    PubMed

    Woźniak, H; Wiecek, E; Tenerowicz, B

    1988-01-01

    The paper includes the results of Part I of the studies designed to evaluate occupational risk of power engineering workers, i.e. people employed in plants producing fly-ashes, as well as those working in lightweight concrete plants where fly-ashes are applied as raw materials. The authors have found out that fly-ashes included mainly quartz, orthoclase and mullite. In dust samples, particles of fibrous structure have been found (probably--mullite). The content of free crystalline silica came to 31.6% in total dust and 8.9% in respirable dust. Fly-ashes contained:--naturally radioactive elements K40, Ra226, Th228 (maximum values were, respectively: 1070 Bq/kg, 222 Bq/kg, 142 Bq/kg of dust),--aromatic hydrocarbons (benzene-soluble fraction) in the amount of 0.001 to 0.003 microgram/mg, as well as admixtures of heavy metals in amounts varying largely. The dust concentrations at workplaces ranged from 1 mg/m3 to 200 mg/m3, depending on the type of work (inspection, repair of boilers). The results demonstrate that in the working environment of power engineering and lightweight concrete plants there occur agents of potentially fibrogenic and cancerogenic properties.

  6. Evaluation of ceramic filter material, selection for application

    SciTech Connect

    Alvin, M.A.; Tressler, R.E.; Lippert, T.E.; Diaz, E.S.

    1993-09-01

    Field testing in several of the Westinghouse Advanced Particulate Filtration (APF) systems has indicated that the oxide-based materials are more susceptible to thermal shock which results from system transients (i.e., combustion of char or reducing gases; system startup/turbine transients). The current clay bonded silicon carbide filter materials have a higher thermal shock resistance, but appear to be more susceptible to high temperature creep, as well as to changes that occur within the binder phase(s). Strength has frequently been used to assess what effects advanced coal fired process systems have on the stability and projected life of the various porous ceramic filter materials (Tables 1 and 2). Based on the numerous phase changes that occur, and the influence of pulse cleaning on the thermal fatigue characteristics of both the alumina/mullite and clay bonded silicon carbide filter materials, alternate material properties as thermal conductivity, thermal coefficient of expansion, elastic modulus, fracture toughness, and emissivity as a function of thermal/chemical aging are now being considered as critical factors for projecting filter durability and operating life. Table 3 provides a summary of the as-manufactured material properties for the alumina/mullite and clay bonded silicon carbide filter materials which have been used in the Westinghouse`s APF systems. Effort is currently being directed to determine how these properties change during thermal aging of the filters in various subpilot and pilot plant systems.

  7. Testing of the Westinghouse hot gas filter at Ahlstrom Pyropower Corporation

    SciTech Connect

    Lippert, T.; Alvin, M.A.; Bruck, G.J.; Isaksson, J.; Dennis, R.A.; Brown, R.A.

    1995-12-31

    A single cluster Westinghouse hot gas filter has been tested for over 2050 hours on Ahlstrom Pyropower Corporation`s Pressurized Circulating Fluidized Bed (PCFB) 10 MW test facility at Karhula, Finland. This filter system, which houses 128 ceramic candles in three plenums, takes the full flow from the PCFB. Two candle types, an alumina/mullite candle manufactured by Coors Ceramics and a clay bonded SiC candle manufactured by Refractron Corporation were evaluated over a range of filtration face velocities, dust loadings, coal types and temperatures. Both candle systems allowed less than 3 ppmw to exit the candles with inlet dust loadings as high as 18,000 ppm. Stable pressure drop across the filter in the steady state was achieved with less than 60 in wg (150 mbar) for either candle system. Pulse cleaning air pressure was less than 435 psi (30 bar) when the plant was operated at 145 to 175 psi (10 to 12 bar). Improvements to the flow distribution in the filter housing and fine tuning of the pulsing system were incorporated. The alumina/mullite candles accumulated around 750 hours at operating temperatures to 1,650 F (900 C). The SiC accumulated about 1,300 hours at temperatures to 1,560 F (850 C). Strength measurements and SEM examination of the candle material have been conducted to help evaluate long-term ceramic candle filter material stability. All metal structures within the filter assembly performed as designed.

  8. Effect of thermal treatment on the nano-structure and phase transformation of metakaolin-based geopolymers.

    PubMed

    Kim, Yongsung; Kang, Seunggu

    2014-11-01

    Enhancement of the mechanical strength of metakaolin-based geopolymers activated with NaOH was attempted by calcining metakaolin at a higher temperature than that commonly reported. Increasing the calcination temperature from 750 degrees C to 1150 degrees C promoted the recrystallization of mullite. Two type of zeolite of sodium aluminum silicate hydrates were found in the geopolymers made of metakaolin calcined at 750 degrees C-1050 degrees C. The h-zeolite [Na6(AlSiO4)6 x H2O] was not found in the geopolymer made of metakaolin calcined above 900 degrees C, while Z-zeolite [Na2O x Al2O3 x SiO2 x H2O] remained in specimens calcined at up to 1050 degrees C, All zeolite disappeared above 1150 degrees C. The pozzolanic reaction generates very small particles of 10-30 nm on the surface of metakaolin grains of 0.2-0.6 μm, rendering the matrix denser by binding the grains. The maximum compressive strength was revealed with the geopolymer made of metakaolin calcined at 1050 degrees C. The reason for the increased strength of the geopolymer obtained using higher calcination temperature is thought to be the combined effects of matrix hardening by geopolymeric reaction and reinforcement by mullite crystal phases.

  9. Processing and characterization of multi-cellular monolithic bioceramics for bone regenerative scaffolds

    NASA Astrophysics Data System (ADS)

    Ari-Wahjoedi, Bambang; Ginta, Turnad Lenggo; Parman, Setyamartana; Abustaman, Mohd Zikri Ahmad

    2014-10-01

    Multicellular monolithic ceramic body is a ceramic material which has many gas or liquid passages partitioned by thin walls throughout the bulk material. There are many currently known advanced industrial applications of multicellular ceramics structures i.e. as supports for various catalysts, electrode support structure for solid oxide fuel cells, refractories, electric/electronic materials, aerospace vehicle re-entry heat shields and biomaterials for dental as well as orthopaedic implants by naming only a few. Multicellular ceramic bodies are usually made of ceramic phases such as mullite, cordierite, aluminum titanate or pure oxides such as silica, zirconia and alumina. What make alumina ceramics is excellent for the above functions are the intrinsic properties of alumina which are hard, wear resistant, excellent dielectric properties, resists strong acid and alkali attacks at elevated temperatures, good thermal conductivities, high strength and stiffness as well as biocompatible. In this work the processing technology leading to truly multicellular monolithic alumina ceramic bodies and their characterization are reported. Ceramic slip with 66 wt.% solid loading was found to be optimum as impregnant to the polyurethane foam template. Mullitic ceramic composite of alumina-sodium alumino disilicate-Leucite-like phases with bulk and true densities of 0.852 and 1.241 g cm-3 respectively, pore linear density of ±35 cm-1, linear and bulk volume shrinkages of 7-16% and 32 vol.% were obtained. The compressive strength and elastic modulus of the bioceramics are ≈0.5-1.0 and ≈20 MPa respectively.

  10. Direct acid dissolution of aluminum and other metals from fly ash

    SciTech Connect

    Kelmers, A.D.; Egan, B.Z.; Seeley, F.G.; Campbell, G.D.

    1981-01-01

    Fly ash could provide a significant domestic source of alumina and thus supply a large part of the US needs for aluminum and possibly also several other metals. The aluminum and other metals can be solubilized from fly ash by acid dissolution methods. The aluminum may be present in any or all of three solid phases: (1) crystalline; (2) glassy amorphous; and (3) irregular, spongy amorphous. The chemistry of these phases controls the solubilization behavior. The aluminum in high-calcium western ashes is primarily found in the amorphous phases, and much of it can be solubilized by using short-time, ambient-temperature leaching. Little of the aluminum in the low-calcium eastern ashes is solubilized under ambient-temperature conditions, and only a portion can be solubilized even at reflux temperature conditions. Some of the aluminum in these eastern ashes is present as mullite, while some is found in the amorphous material. The fraction contained in mullite is relativey acid insoluble, and only partial solubilization can be achieved even under vigorous acid leach conditions.

  11. Friction and wear of oxide-ceramic sliding against IN-718 nickel base alloy at 25 to 800 C in atmospheric air

    NASA Technical Reports Server (NTRS)

    Sliney, Harold E.; Deadmore, Daniel L.

    1989-01-01

    The friction and wear of oxide-ceramics sliding against the nickel base alloy IN-718 at 25 to 800 C were measured. The oxide materials tested were mullite (3Al2O3.2SiO2); lithium aluminum silicate (LiAlSi(x)O(y)); polycrystalline monolithic alpha alumina (alpha-Al2O3); single crystal alpha-Al2O3 (sapphire); zirconia (ZrO2); and silicon carbide (SiC) whisker-reinforced Al2O3 composites. At 25 C the mullite and zirconia had the lowest friction and the polycrystalline monolithic alumina had the lowest wear. At 800 C the Al2O3-8 vol/percent SiC whisker composite had the lowest friction and the Al2O3-25 vol/percent SiC composite had the lowest wear. The friction of the Al2O3-SiC whisker composites increased with increased whisker content while the wear decreased. In general, the wear-resistance of the ceramics improve with their hardness.

  12. Coating system to permit direct brazing of ceramics

    DOEpatents

    Cadden, Charles H.; Hosking, F. Michael

    2003-01-01

    This invention relates to a method for preparing the surface of a ceramic component that enables direct brazing using a non-active braze alloy. The present invention also relates to a method for directly brazing a ceramic component to a ceramic or metal member using this method of surface preparation, and to articles produced by using this brazing method. The ceramic can be high purity alumina. The method comprises applying a first coating of a silicon-bearing oxide material (e.g. silicon dioxide or mullite (3Al.sub.2 O.sub.3.2SiO.sub.2) to the ceramic. Next, a thin coating of active metal (e.g. Ti or V) is applied. Finally, a thicker coating of a non-active metal (e.g. Au or Cu) is applied. The coatings can be applied by physical vapor deposition (PVD). Alternatively, the active and non-active metals can be co-deposited (e.g. by sputtering a target made of mullite). After all of the coatings have been applied, the ceramic can be fired at a high temperature in a non-oxidizing environment to promote diffusion, and to enhance bonding of the coatings to the substrate. After firing, the metallized ceramic component can be brazed to other components using a conventional non-active braze alloy. Alternatively, the firing and brazing steps can be combined into a single step. This process can replace the need to perform a "moly-manganese" metallization step.

  13. Processing and mechanical behavior of Nicalon/SiC and Nextel/SiC composites with sol-gel derived oxide interfacial coatings

    NASA Astrophysics Data System (ADS)

    Shanmugham, Subramaniam

    Mullite and aluminum titanate precursor sols were developed for coating applications. High temperature X-ray diffraction studies in air identified that mullite crystallizes between 950sp°C and 1050sp°C, while aluminum titanate forms between 1200sp°C and 1400sp°C. The crystallization temperature of mullite was lowered by 100sp°C compared to those reported in the literature. Nicalon tows are embrittled during the formation of mullite at 1000sp°C, and hence, there is a need to protect the fibers by a relatively inert material during the sol-gel oxide processing. The aluminum titanate formation temperature is high and would damage Nicalon and Nextel fibers. However, Nicalon fibers dip-coated in an aluminum titanate sol and heat-treated at 1000sp°C for up to 10 h in air, forming an alumina-titania (Alsb2Osb3-TiOsb2) mixture, were not embrittled. Based on the non-embrittlement of the fibers, the Alsb2Osb3-TiOsb2 mixture was chosen as an alternative to aluminum titanate for an interface material. To study the effect of protecting the fibers by an inert material during sol-gel oxide coating, oxide/C, and C/oxide/C interfaces were considered for Nicalon/SiC and Nextel/SiC composites. Since composites with C/oxide/C interfaces exhibited higher flexural strengths than composites with oxide/C interfaces in the as-processed condition, C/oxide/C interfaces were studied. Also, Nicalon/SiC composites with C/oxide/C interfaces retained damage-tolerant behavior and substantial amount of their as-processed strengths even after 24 h oxidation at 1000sp°C in air than Nextel/SiC composites with C/oxide/C interfaces. On these basis, Nicalon/SiC composites with C/oxide/C interfaces were chosen for further investigation. Transmission electron microscopy studies identified that the obtained oxide coatings were very thin ($73%). Nicalon/SiC composites with C/oxide/C interfaces performed poorly at 750spcircC, so Nicalon/SiC composites with BN/oxide/BN interfaces were fabricated and

  14. Mineralogy and thermal properties of kaolin from the San José (Oruro, Bolivia)

    NASA Astrophysics Data System (ADS)

    Alfonso, Pura; Garcia-Valles, Maite; Martínez, Salvador; Amando Penedo, Lucio; Elvys Trujillo, Juan

    2016-04-01

    The San José mine, Oruro, Bolivia is known for provided a broad diversity of minerals. The San José Sn deposit is a Sn-Ag deposit composed of veins hosted in a complex of Miocene domes from monzonitic to dioritic composition within rhyolitic volcanic rocks hosted in Tertiary sedimentary rocks. Advanced argillitic alteration. is widespread in the surroundings of the deposit. Kaolinitization reach industrial importance and the kaolinitized rock is exploited, however it was not already been characterised. In this study we present a preliminary mineralogical and thermal characterization to determine the industrial applications of these kaolinitic materials. A sampling of the kaolinitized rocks in outcrops from the mining area was undertaken. The chemical composition of major and trace elements was determined by X-ray fluorescence (XRF). Mineralogy was obtained by powder diffraction X-ray (XRD) and infrared spectroscopy (FTIR). Quantitative determination of phases was obtained by the Rietveld refinement method using the Fullprof software. Thermal properties were determined by differential thermal analysis-thermo gravimetry (DTA -TG) and dilatometry. Mineral phases determined are mainly quartz (54-55 wt. %), kaolinite (7-8 wt. %), K-feldspar (8-19 wt. %), muscovite (16-17 wt. %), plagioclase up to 3 wt. %, alunite up to 8 wt% and gypsum up to 4 wt%. DTA -TG show a first endothermic event related to the dehydration of gypsum, with a loss weight of 0.4 wt%. An endothermic peak corresponding to the loss of the OH- groups of kaolinite occurs about 520 °C and an exothermic, at 980 °C, due to the crystallization of the mullite phase. The endothermic peak is attributed to the transformation of kaolinite in metakaolinite: Al2Si2O5 (OH)4  Al2Si2O7 + 2H2O and the dehydroxilation of alunite; the loss weight associated with this event is 2.9-3.2 wt%. The exothermic peak is caused by the formation of mullite: 3Al2Si2O7  Al6Si2O13 + 4SiO2. Another loss weight, of 3wt%, is

  15. Effect of microstructure (particulate size and volume fraction) and counterface material on the sliding wear resistance of particulate-reinforced aluminum matrix composites

    NASA Astrophysics Data System (ADS)

    Alpas, A. T.; Zhang, J.

    1994-05-01

    The effects of microstructure (namely, particulate volume fraction and particulate size) and the counterface materials on the dry-sliding wear resistance of the aluminum matrix composites 2014A1-SiC and 6061Al-Al2O3 were studied. Experiments were performed within a load range of 0.9 to 350 N at a constant sliding velocity of 0.2 ms-1. Two types of counterface materials, SAE 52100 bearing steel and mullite, were used. At low loads, where particles act as loadbearing constituents, the wear resistance of the 2014A1 reinforced with 15.8 µm diameter SiC was superior to that of the alloy with the same volume fraction of SiC but with 2.4 µm diameter. The wear rates of the composites worn against a steel slider were lower compared with those worn against a mullite slider because of the formation of iron-rich layers that act as in situ solid lubricants in the former case. With increasing the applied load, SiC and A12O3 particles fractured and the wear rates of the composites increased to levels comparable to those of unreinforced matrix alloys. The transition to this regime was delayed to higher loads in the composites with a higher volume percentage of particles. Concurrent with particle fracture, large strains and strain gradients were generated within the aluminum layers adjacent to contact surfaces. This led to the subsurface crack growth and delamination. Because the particles and interfaces provided preferential sites for subsurface crack initiation and growth and because of the propensity of the broken particles to act as third-body abrasive elements at the contact surfaces, no improvement of the wear resistance was observed in the composites in this regime relative to unreinforced aluminum alloys. A second transition, to severe wear, occurred at higher loads when the contact surface temperature exceeded a critical value. The transition loads (and temperatures) were higher in the composites. The alloys with higher volume fraction of reinforcement provided better

  16. Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Choi, Sung R.; Eldridge, Jeffrey I.; Lee, Kang N.; Miller, Robert A.

    2003-01-01

    In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

  17. Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Choi, Sung R.; Eldridge, Jeffrey I.; Lee, Kang N.; Miller, Robert A.

    2003-01-01

    In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

  18. Multilayer Article Characterized by Low Coefficient of Thermal Expansion Outer Layer

    NASA Technical Reports Server (NTRS)

    Lee, Kang N. (Inventor)

    2004-01-01

    A multilayer article comprises a substrate comprising a ceramic or a silicon-containing metal alloy. The ceramic is a Si-containing ceramic or an oxide ceramic with or without silicon. An outer layer overlies the substrate and at least one intermediate layer is located between the outer layer and thc substrate. An optional bond layer is disposed between thc 1 least one intermediate layer and thc substrate. The at least one intermediate layer may comprise an optional chemical barrier layer adjacent the outer layer, a mullite-containing layer and an optional chemical barrier layer adjacent to the bond layer or substrate. The outer layer comprises a compound having a low coefficient of thermal expansion selected from one of the following systems: rare earth (RE) silicates; at least one of hafnia and hafnia-containing composite oxides; zirconia-containing composite oxides and combinations thereof.

  19. Anthropogenic- and natural sources of dust in peatland during the Anthropocene

    NASA Astrophysics Data System (ADS)

    Fiałkiewicz-Kozieł, B.; Smieja-Król, B.; Frontasyeva, M.; Słowiński, M.; Marcisz, K.; Lapshina, E.; Gilbert, D.; Buttler, A.; Jassey, V. E. J.; Kaliszan, K.; Laggoun-Défarge, F.; Kołaczek, P.; Lamentowicz, M.

    2016-12-01

    As human impact have been increasing strongly over the last decades, it is crucial to distinguish human-induced dust sources from natural ones in order to define the boundary of a newly proposed epoch - the Anthropocene. Here, we track anthropogenic signatures and natural geochemical anomalies in the Mukhrino peatland, Western Siberia. Human activity was recorded there from cal AD 1958 (±6). Anthropogenic spheroidal aluminosilicates clearly identify the beginning of industrial development and are proposed as a new indicator of the Anthropocene. In cal AD 1963 (±5), greatly elevated dust deposition and an increase in REE serve to show that the geochemistry of elements in the peat can be evidence of nuclear weapon testing; such constituted an enormous force blowing soil dust into the atmosphere. Among the natural dust sources, minor signals of dryness and of the Tunguska cosmic body (TCB) impact were noted. The TCB impact was indirectly confirmed by an unusual occurrence of mullite in the peat.

  20. Prevention of trace and major element leaching from coal combustion products by hydrothermally-treated coal ash

    SciTech Connect

    Adnadjevic, B.; Popovic, A.; Mikasinovic, B.

    2009-07-01

    The most important structural components of coal ash obtained by coal combustion in 'Nikola Tesla A' power plant located near Belgrade (Serbia) are amorphous alumosilicate, alpha-quartz, and mullite. The phase composition of coal ash can be altered to obtain zeolite type NaA that crystallizes in a narrow crystallization field (SiO{sub 2}/Al{sub 2}O{sub 3}; Na{sub 2}O/SiO{sub 2}; H{sub 2}O/Na{sub 2}O ratios). Basic properties (crystallization degree, chemical composition, the energy of activation) of obtained zeolites were established. Coal ash extracts treated with obtained ion-exchange material showed that zeolites obtained from coal ash were able to reduce the amounts of iron, chromium, nickel, zinc, copper, lead, and manganese in ash extracts, thus proving its potential in preventing pollution from dump effluent waters.

  1. Strong, damage tolerant oxide-fiber/oxide matrix composites

    NASA Astrophysics Data System (ADS)

    Bao, Yahua

    cationic polyelectrolytes to have a positive surface charge and then dipped into diluted, negatively-charged AlPO4 colloidal suspension (0.05M) at pH 7.5. Amorphous AlPO4 (crystallizes to tridymite- and cristobalite-forms at 1080°C) nano particles were coated on fibers layer-by-layer using an electrostatic attraction protocol. A uniform and smooth coating was formed which allowed fiber pullout from the matrix of a Nextel 720/alumina mini-composite hot-pressed at 1250°C/20MPa. Reaction-bonded mullite (RBM), with low formation temperature and sintering shrinkage was synthesized by incorporation of mixed-rare-earth-oxide (MREO) and mullite seeds. Pure mullite formed with 7.5wt% MREO at 1300°C. Introduction of 5wt% mullite seeds gave RBM with less than 3% shrinkage and 20% porosity. AlPO4-coated Nextel 720/RBM composites were successful fabricated by EPID and pressureless sintering at 1300°C. Significant fiber pullout occurred and the 4-point bend strength was around 170MPa (with 25-30vol% fibers) at room temperature and 1100°C and a Work-of-Fracture 7KJ/m2. At 1200°C, the composite failed in shear due to the MREO-based glassy phase in the matrix. AlPO4-coated Nextel 720 fiber/aluminosilicate (no MREO) showed damage tolerance at 1200°C with a bend strength 170MPa.

  2. Ceramic thermal barrier coating for rapid thermal cycling applications

    DOEpatents

    Scharman, Alan J.; Yonushonis, Thomas M.

    1994-01-01

    A thermal barrier coating for metal articles subjected to rapid thermal cycling includes a metallic bond coat deposited on the metal article, at least one MCrAlY/ceramic layer deposited on the bond coat, and a ceramic top layer deposited on the MCrAlY/ceramic layer. The M in the MCrAlY material is Fe, Ni, Co, or a mixture of Ni and Co. The ceramic in the MCrAlY/ceramic layer is mullite or Al.sub.2 O.sub.3. The ceramic top layer includes a ceramic with a coefficient of thermal expansion less than about 5.4.times.10.sup.-6 .degree.C.sup.-1 and a thermal conductivity between about 1 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1 and about 1.7 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1.

  3. Anthropogenic- and natural sources of dust in peatland during the Anthropocene

    PubMed Central

    Fiałkiewicz-Kozieł, B.; Smieja-Król, B.; Frontasyeva, M.; Słowiński, M.; Marcisz, K.; Lapshina, E.; Gilbert, D.; Buttler, A.; Jassey, V. E. J.; Kaliszan, K.; Laggoun-Défarge, F.; Kołaczek, P.; Lamentowicz, M.

    2016-01-01

    As human impact have been increasing strongly over the last decades, it is crucial to distinguish human-induced dust sources from natural ones in order to define the boundary of a newly proposed epoch - the Anthropocene. Here, we track anthropogenic signatures and natural geochemical anomalies in the Mukhrino peatland, Western Siberia. Human activity was recorded there from cal AD 1958 (±6). Anthropogenic spheroidal aluminosilicates clearly identify the beginning of industrial development and are proposed as a new indicator of the Anthropocene. In cal AD 1963 (±5), greatly elevated dust deposition and an increase in REE serve to show that the geochemistry of elements in the peat can be evidence of nuclear weapon testing; such constituted an enormous force blowing soil dust into the atmosphere. Among the natural dust sources, minor signals of dryness and of the Tunguska cosmic body (TCB) impact were noted. The TCB impact was indirectly confirmed by an unusual occurrence of mullite in the peat. PMID:27995953

  4. Development of Refractory Silicate-YSZ Dual Layer TBCs

    NASA Technical Reports Server (NTRS)

    He, Yirong; Lee, N.; Tewari, Surendra; Miller, Robert A.

    1999-01-01

    Development of advanced thermal barrier coatings (TBCs) is the most promising approach for increasing the efficiency and performance of gas turbine engines by enhancing the temperature capability of hot section metallic components. Spallation of the yttria-stabilized zirconia (YSZ) top coat, induced by the oxidation of the bond coat coupled with the thermal expansion mismatch strain, is considered to be the ultimate failure mode for current state-of-the-art TBCS. Enhanced oxidation resistance of TBCs can be achieved by reducing the oxygen conductance of TBCs below that of thermally grown oxide (TGO) alumina scale. One approach is incorporating an oxygen barrier having an oxygen conductance lower than that of alumina scale. Mullite, rare earth silicates and glass ceramics have been selected as potential candidates for the oxygen barrier. This paper presents the results of cyclic oxidation studies of oxygen barrier/YSZ dual layer TBCs.

  5. The Microstructure and Wear Resistance of Microarc Oxidation Composite Coatings Containing Nano-Hexagonal Boron Nitride (HBN) Particles

    NASA Astrophysics Data System (ADS)

    Li, Zhenwei; Di, Shichun

    2017-04-01

    The composite coatings containing HBN were prepared on 2024 aluminum alloy by microarc oxidation in the electrolyte with nano-HBN particles. The microstructure, surface roughness, phase composition, hardness, adhesion strength and wear resistance of composite coatings were analyzed by SEM, EDS, laser confocal microscope, XRD, Vickers hardness tester, scratch test and ball-on-disc abrasive tests. The results revealed that composite coatings were mainly composed of γ-Al2O3, α-Al2O3, mullite and HBN. With increasing the content of HBN particles in the electrolyte, the size and number of the pores on the surface of composite coatings decreased significantly. Compared to the MAO coatings without HBN, the composite coatings exhibited better wear resistance, as demonstrated by the lower friction coefficient and the lower wear rate.

  6. Preparation and Oxidation of ZrB2/SiC/Zr2Al4C5 Multi-phase Ceramics with Spark Plasma Sintering

    NASA Astrophysics Data System (ADS)

    Guo, Qilong; Li, Junguo; Ma, Zhiyu; Nie, Ye; Shen, Qiang; Zhang, Lianmeng

    2013-03-01

    The ZrB2/SiC/Zr2Al4C5 multi-phase ceramics were fabricated by spark plasma sintering (SPS) at 1800 °C for 3 min under 20 MPa in an vacuum. Oxidation behavior of multi-phase ceramics were investigated using thermo gravimetric analysis (TGA) from 20 °C to 1500 °C and muffle furnace in stagnant air at 1200 °C. Samples were analyzed after oxidation by X-ray diffraction (XRD), scanning electron microscopy (SEM) along with energy dispersive spectroscopy (EDS) to determine the reaction products and to observe the microstructure. The results showed that the aluminium borate and mullite crystallize on the surface in the samples oxidized. The effect of Zr2Al4C5 content on the oxidation resistance of the ZrB2 ceramics were discussed respectively, and oxidation mechanism was also analysised.

  7. Advanced Environmental Barrier Coatings Development for Si-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Choi, R. Sung; Robinson, Raymond C.; Lee, Kang N.; Bhatt, Ramakrishna T.; Miller, Robert A.

    2005-01-01

    Advanced environmental barrier coating concepts based on multi-component HfO2 (ZrO2) and modified mullite systems are developed for monolithic Si3N4 and SiC/SiC ceramic matrix composite (CMC) applications. Comprehensive testing approaches were established using the water vapor cyclic furnace, high pressure burner rig and laser heat flux steam rig to evaluate the coating water vapor stability, cyclic durability, radiation and erosion resistance under simulated engine environments. Test results demonstrated the feasibility and durability of the environmental barrier coating systems for 2700 to 3000 F monolithic Si3N4 and SiC/SiC CMC component applications. The high-temperature-capable environmental barrier coating systems are being further developed and optimized in collaboration with engine companies for advanced turbine engine applications.

  8. Microstructures and Abrasive Properties of the Oxide Coatings on Al6061 Alloys Prepared by Plasma Electrolytic Oxidation in Different Electrolytes

    NASA Astrophysics Data System (ADS)

    Wang, Kai; Byun, Sangsik; Lee, Chan Gyu; Koo, Bon Heun; Wang, Yi Qi; Song, Jung Il

    Al2O3 coatings were prepared on T6-tempered Al6061 alloys substrate under a hybrid voltage (AC 200 V-60 Hz and DC 260 V value) by plasma electrolytic oxidation (PEO) in 30 min. The effects of different electrolytes on the abrasive behaviors of the coatings were studied by conducting dry ball-on-disk wear tests. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were used to investigate the coating microstructure. XRD analysis results show that the coatings mainly consist of α- and γ-Al2O3, and some mullite and AlPO4 phase in Na2SiO3 and Na3PO4 containing electrolytes, respectively. The wear test results show that the coatings which were PEO-treated in Na3PO4 containing electrolyte presented the most excellent abrasive resistance property.

  9. Dip-coating process: Silicon sheet growth development for the large-area silicon sheet task of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    Zook, J. D.; Heaps, J. D.; Maciolek, R. B.; Koepke, B. G.; Gutter, C. D.; Schuldt, S. B.

    1977-01-01

    The objective of this research program is to investigate the technical and economic feasibility of producing solar-cell-quality sheet silicon by coating one surface of carbonized ceramic substrates with a thin layer of large-grain polycrystalline silicon from the melt. The past quarter demonstrated significant progress in several areas. Seeded growth of silicon-on-ceramic (SOC) with an EFG ribbon seed was demonstrated. Different types of mullite were successfully coated with silicon. A new method of deriving minority carrier diffusion length, L sub n from spectral response measurements was evaluated. ECOMOD cost projections were found to be in good agreement with the interim SAMIS method proposed by JPL. On the less positive side, there was a decrease in cell performance which we believe to be due to an unidentified source of impurities.

  10. Amorphous and nanostructured silica and aluminosilicate spray-dried microspheres

    NASA Astrophysics Data System (ADS)

    Todea, M.; Turcu, R. V. F.; Frentiu, B.; Tamasan, M.; Mocuta, H.; Ponta, O.; Simon, S.

    2011-08-01

    Amorphous silica and aluminosilicate microspheres with diameters in the 0.1-20 μm range were produced by spray drying method. SEM, TEM and AFM images showed the spherical shape of the obtained particles. Based on thermal analysis data, several heat treatments have been applied on the as-prepared samples in order to check the amorphous state stability of the microspheres and to develop nanosized crystalline phases. As-prepared microspheres remain amorphous up to 1400 °C. By calcination at 1400 °C, cristobalite type nanocrystals are developed on silica sample, while in aluminosilicate sample first are developed mullite type nanocrystals and only after prolonged treatment are developed also cristobalite type nanocrystals. 29Si and 27Al MAS NMR results show that the local order around aluminum and silicon atoms strongly depend on the thermal history of the microspheres.

  11. Development of a monolithic ceramic cross flow filter

    SciTech Connect

    Larsen, D.A.

    1995-12-01

    High-temperature, high-pressure particulate control is required to protect turbine equipment and to meet environmental stack emissions standards in coal-fueled power systems. Ceramic cross flow filters have high surface area per unit volume for removing particulates from these hot gas streams. A one-piece monolithic ceramic cross flow filter is needed. Mullite bonded, porous, permeable alumina ceramics were made on a lab scale with the Blasch injection forming process. Permeability and other initial targeted property requirements were achieved: >200 cd (<1 iwg/fpm), room temperature modulus of rupture >1000 psi, particle size 100/200 mesh, pore size 20 microns. It is concluded that it is feasible to use the proprietary Blasch process to form cross flow filters.

  12. Silicon carbide whisker reinforced ceramic composites and method for making same

    DOEpatents

    Wei, George C.

    1993-01-01

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al.sub.2 O.sub.3, mullite, or B.sub.4 C. The mixtures which contain a homogeneous disperson of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600.degree. to 1950.degree. C. with pressing times varying from about 0.075 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MPa.m.sup.1/2 which represents as much as a two-fold increase over that of the matrix material.

  13. Silicon carbide whisker reinforced composites and method for making same

    DOEpatents

    Wei, G.C.

    1984-02-09

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties, especially increased fracture toughness. In the formation of these ceramic composites, the single-crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al/sub 2/O/sub 3/, mullite, or B/sub 4/C. The mixtures which contain a homogeneous dispersion of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600 to 1950/sup 0/C with pressing times varying from about 0.75 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MPa.m/sup 1/2/ which represents as much as a two-fold increase over that of the matrix material.

  14. Silicon carbide whisker reinforced ceramic composites and method for making same

    DOEpatents

    Wei, George C.

    1985-01-01

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al.sub.2 O.sub.3, mullite, or B.sub.4 C. The mixtures which contain a homogeneous dispersion of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600.degree. to 1950.degree. C. with pressing times varying from about 0.75 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MPa.m.sup.1/2 which represents as much as a two-fold increase over that of the matrix material.

  15. Silicon carbide whisker reinforced ceramic composites and method for making same

    DOEpatents

    Wei, George C.

    1989-01-24

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al.sub.2 O.sub.3, mullite, or B.sub.4 C. The mixtures which contain a homogeneous disperson of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600.degree. to 1950.degree. C. with pressing times varying from about 0.75 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MP.am.sup.1/2 which represents as much as a two-fold increase over that of the matrix material.

  16. Silicon carbide whisker reinforced ceramic composites and method for making same

    DOEpatents

    Wei, George C.

    1993-11-16

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al.sub.2 O.sub.3, mullite, or B.sub.4 C. The mixtures which contain a homogeneous disperson of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600.degree. to 1950.degree. C. with pressing times varying from about 0.075 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MPa.m.sup.1/2 which represents as much as a two-fold increase over that of the matrix material.

  17. Silicon carbide whisker reinforced ceramic composites and method for making same

    DOEpatents

    Wei, G.C.

    1989-01-24

    The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al{sub 2}O{sub 3}, mullite, or B{sub 4}C. The mixtures which contain a homogeneous dispersion of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1,600 to 1,950 C with pressing times varying from about 0.75 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness which represents as much as a two-fold increase over that of the matrix material.

  18. Thermodynamic analysis of chemical stability of ceramic materials in hydrogen-containing atmospheres at high temperatures

    NASA Technical Reports Server (NTRS)

    Misra, Ajay K.

    1990-01-01

    The chemical stability of several ceramic materials in hydrogen-containing environments was analyzed with thermodynamic considerations in mind. Equilibrium calculations were made as a function of temperature, moisture content, and total system pressure. The following ceramic materials were considered in this study: SiC, Si3N4, SiO2, Al2O3, mullite, ZrO2, Y2O3, CaO, MgO, BeO, TiB2, TiC, HfC, and ZrC. On the basis of purely thermodynamic arguments, upper temperature limits are suggested for each material for long-term use in H2-containing atmospheres.

  19. Spatio-temporal behaviour of atomic-scale tribo-ceramic films in adaptive surface engineered nano-materials.

    PubMed

    Fox-Rabinovich, G; Kovalev, A; Veldhuis, S; Yamamoto, K; Endrino, J L; Gershman, I S; Rashkovskiy, A; Aguirre, M H; Wainstein, D L

    2015-03-05

    Atomic-scale, tribo-ceramic films associated with dissipative structures formation are discovered under extreme frictional conditions which trigger self-organization. For the first time, we present an actual image of meta-stable protective tribo-ceramics within thicknesses of a few atomic layers. A mullite and sapphire structure predominates in these phases. They act as thermal barriers with an amazing energy soaking/dissipating capacity. Less protective tribo-films cannot sustain in these severe conditions and rapidly wear out. Therefore, a functional hierarchy is established. The created tribo-films act in synergy, striving to better adapt themselves to external stimuli. Under a highly complex structure and non-equilibrium state, the upcoming generation of adaptive surface engineered nano-multilayer materials behaves like intelligent systems - capable of generating, with unprecedented efficiency, the necessary tribo-films to endure an increasingly severe environment.

  20. Oxidation-resistant interface coatings for SiC/SiC composites

    SciTech Connect

    Stinton, D.P.; Kupp, E.R.; Hurley, J.W.

    1996-06-01

    The characteristics of the fiber-matrix interfaces in ceramic matrix composites control the mechanical behavior of these composites. Finite element modeling (FEM) was performed to examine the effect of interface coating modulus and coefficient of thermal expansion on composite behavior. Oxide interface coatings (mullite and alumina-titania) produced by a sol-gel method were chosen for study as a result of the FEM results. Amorphous silicon carbide deposited by chemical vapor deposition (CVD) is also being investigated for interface coatings in SiC-matrix composites. Processing routes for depositing coatings of these materials were developed. Composites with these interfaces were produced and tested in flexure both as-processed and after oxidation to examine the suitability of these materials as interface coatings for SiC/SiC composites in fossil energy applications.

  1. Oxidation-resistant interface coatings for SiC/SiC composites

    SciTech Connect

    Stinton, D.P.; Kupp, E.R.; Hurley, J.W.; Lowden, R.A.

    1996-08-01

    The characteristics of the fiber-matrix interfaces in ceramic matrix composites control the mechanical behavior of these composites. Finite element modeling (FEM) was performed to examine the effect of interface coating modulus and coefficient of thermal expansion on composite behavior. Oxide interface coatings (mullite and alumina-titania) produced by a sol-gel method were chosen for study as a result of the FEM results. Amorphous silicon carbide deposited by chemical vapor deposition (CVD) is also being investigated for interface coatings in SiC-matrix composites. Processing routes for depositing coatings of these materials were developed. Composites with these interfaces were produced and tested in flexure both as-processed and after oxidation to examine the suitability of these materials as interface coatings for SiC/SiC composites in fossil energy applications.

  2. Multilayer Article Characterized by Low Coefficient of Thermal Expansion Outer Layer

    NASA Technical Reports Server (NTRS)

    Lee, Kang N. (Inventor)

    2004-01-01

    A multilayer article comprises a substrate comprising a ceramic or a silicon-containing metal alloy. The ceramic is a Si-containing ceramic or an oxide ceramic with or without silicon. An outer layer overlies the substrate and at least one intermediate layer is located between the outer layer and thc substrate. An optional bond layer is disposed between thc 1 least one intermediate layer and thc substrate. The at least one intermediate layer may comprise an optional chemical barrier layer adjacent the outer layer, a mullite-containing layer and an optional chemical barrier layer adjacent to the bond layer or substrate. The outer layer comprises a compound having a low coefficient of thermal expansion selected from one of the following systems: rare earth (RE) silicates; at least one of hafnia and hafnia-containing composite oxides; zirconia-containing composite oxides and combinations thereof.

  3. Environmental Barrier Coatings for Silicon-Based Ceramics

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Fox, Dennis S.; Robinson, Raymond C.; Bansal, Narottam P.

    2001-01-01

    Silicon-based ceramics, such as SiC fiber-reinforced SiC (SiC/SiC ceramic matrix composites (CMC) and monolithic silicon nitride (Si3N4), are prime candidates for hot section structural components of next generation gas turbine engines. Silicon-based ceramics, however, suffer from rapid surface recession in combustion environments due to volatilization of the silica scale via reaction with water vapor, a major product of combustion. Therefore, application of silicon-based ceramic components in the hot section of advanced gas turbine engines requires development of a reliable method to protect the ceramic from environmental attack. An external environmental barrier coating (EBC) is considered a logical approach to achieve protection and CP long-term stability. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 Wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program (5). They consist of three layers, a silicon first bond coat, a mullite or a mullite + BSAS (BaO(1-x)-SrO(x)-Al2O3-2SiO2) second bond coat, and a BSAS top coat. The EPM EBCs were applied on SiC/SiC CMC combustor liners in three Solar Turbines (San Diego, CA) Centaur 50s gas turbine engines. The combined operation of the three engines has accumulated over 24,000 hours without failure (approximately 1,250 C maximum combustor liner temperature), with the engine in Texaco, Bakersfield, CA, accumulating about 14,000 hours. As the

  4. Environmental Barrier Coatings (EBC) for Ceramic Matrix Composite (CMC) Materials

    NASA Technical Reports Server (NTRS)

    Lee,Kang

    2001-01-01

    The upper use temperature of current Environmental Barrier Coatings (EBC's) based on mullite and BSAS (EPM EBC's) is limited to -255 F due to silica volatility, chemical reactions, and high thermal conductivity. Therefore, new EBC s having low CTE, good chemical compatibility, and high melting point (greater than 2700 F ) are being investigated. Sinter-resistant, low thermal conductivity EBC s are strongly desired to achieve the UEET EBC goal of 270 F EBC surface temperature and 30 F AT over long exposures (greater than 1000 hr). Key areas affecting the upper temperature limit of current EBC s as well as the ongoing efforts to develop next generation EBC s in the UEET Program will be discussed.

  5. Tailoring of Boehmite-Derived Aluminosilicate Aerogel Structure and Properties: Influence of Ti Addition

    NASA Technical Reports Server (NTRS)

    Hurwitz, Frances I.; Guo, Haiquan; Sheets, Erik J.; Miller, Derek R.; Newlin, Katy N.

    2010-01-01

    Aluminosilicate aerogels offer potential for extremely low thermal conductivities at temperatures greater than 900 C, beyond where silica aerogels reach their upper temperature limits. Aerogels have been synthesized at various Al:Si ratios, including mullite compositions, using Boehmite (AlOOH) as the Al source, and tetraethoxy orthosilicate as the Si precursor. The Boehmite-derived aerogels are found to form by a self-assembly process of AlOOH crystallites, with Si-O groups on the surface of an alumina skeleton. Morphology, surface area and pore size varies with the crystallite size of the starting Boehmite powder, as well as with synthesis parameters. Ternary systems, including Al-Si-Ti aerogels incorporating a soluble Ti precursor, are possible with careful control of pH. The addition of Ti influences sol viscosity, gelation time pore structure and pore size distribution, as well as phase formation on heat treatment.

  6. Sialons from natural aluminosilicates

    SciTech Connect

    Mukerji, J.; Bandyopadhyay, S. )

    1988-07-01

    The synthesis of the high-temperature material sialon (Si{sub 6{minus}z}Al{sub z}O{sub z}N{sub 8{minus}z}) by carbothermic reduction followed by nitridation has been examined. Kaolin, sillimanite, and pyrophillite can be converted to {beta}{prime}-sialon having z values of 2, 2.5, and 0.8, respectively. Other phases that appear in small quantities along with the sialon are mainly alumina and mullite, and trace amounts of AlN and the AlON spinel phase also form. The carbon content at {ge}90% theoretical is very sensitive to nitrogen uptake and phase composition. The uniform mixing of carbon with clay is equally important. Fireclay without an Fe{sub 2}O{sub 3} catalyst produces the same product that does kaolin with an Fe{sub 2}O{sub 3} catalyst.

  7. Hot forging to produce pore-free near-net-shape ceramic composites

    SciTech Connect

    Shulman, H.S.; Withers, J.C.; Loutfy, R.O.

    1988-08-01

    Researchers have demonstrated that it is possible to hot forge ceramic composites without damaging the whisker reinforcement and to reduce flaw size and population. Hot forging was investigated for the systems A1203, A1203/ZrO2, mullite, AlN, and SiC with reinforcements of SiCw and TiB2. The system Al203/SiCw was demonstrated to be forgeable at 1400 C which is 500 C lower than hot pressing temperatures. At high strain rates of greater than 0.1/sec, the density achieved was 99.7 percent with strength values comparable to hot pressing. The hot forging of ceramic-whisker composites offers the opportunity to produce low cost components and, because the process reduces the size and population of flaws, it can result in better mechanical properties with greater reliability.

  8. Investigation of the mineral components of porcelain raw material and their phase evolution during a firing process by using a Rietveld quantitative analysis

    NASA Astrophysics Data System (ADS)

    Kim, Jaegyeom; Heo, Eunae; Kim, Seung-Joo; Kim, Jong-Young

    2016-01-01

    A ceramic raw material for white porcelain and its phase evolution during a firing process were investigated by using Rietveld method based on powder X-ray diffraction data. The raw material was mainly composed of five mineral phases: quartz (SiO2), microcline (KAlSi3O8), albite (NaAlSi3O8), muscovite (KAl2(AlSi3O10)(OH)2), and kaolinite (Al2Si2O5(OH)4). The amount of each mineral phase could be determined by using Rietveld quantitative phase analyses. During the firing process, the microcline, albite, muscovite and kaolinite phases started to react with each other to produce the mullite phase embedded in an amorphous matrix. The amount of quartz remained nearly unchanged until a temperature above 1200 °C; then, it converted to an amorphous phase at higher temperatures.

  9. Sensors for ceramic components in advanced propulsion systems

    NASA Technical Reports Server (NTRS)

    Koller, A. C.; Bennethum, W. H.; Burkholder, S. D.; Brackett, R. R.; Harris, J. P.

    1995-01-01

    This report includes: (1) a survey of the current methods for the measurement of surface temperature of ceramic materials suitable for use as hot section flowpath components in aircraft gas turbine engines; (2) analysis and selection of three sensing techniques with potential to extend surface temperature measurement capability beyond current limits; and (3) design, manufacture, and evaluation of the three selected techniques which include the following: platinum rhodium thin film thermocouple on alumina and mullite substrates; doped silicon carbide thin film thermocouple on silicon carbide, silicon nitride, and aluminum nitride substrates; and long and short wavelength radiation pyrometry on the substrates listed above plus yttria stabilized zirconia. Measurement of surface emittance of these materials at elevated temperature was included as part of this effort.

  10. PEO of pre-anodized Al-Si alloys: Corrosion properties and influence of sealings

    NASA Astrophysics Data System (ADS)

    Mohedano, M.; Matykina, E.; Arrabal, R.; Mingo, B.; Pardo, A.

    2015-08-01

    Voltage-controlled PEO coatings were developed on A356 aluminum alloys (gravity-cast and rheocast) with a pre-anodized layer. The influence of the alloy manufacturing process and the effect of Si-rich phase on the structure and composition of the oxide layers were evaluated using SEM, EDS and XRD. The pre-anodized oxide layer preserves the microstructure of the substrate due to the presence of secondary phases that have a different behavior relative to the matrix during anodizing. PEO coatings consisted of a mixture of α-Al2O3, γ-Al2O3 and mullite. The corrosion behavior and the effectiveness of different sealing techniques based on salts of nickel, cobalt, cerium and phosphonic acid were also studied. Post-treatments improved the hydrophobic properties of the coatings and showed a beneficial effect, significantly increasing the coating impedance and thereby reducing the susceptibility to corrosion.

  11. Alumina composites for oxide/oxide fibrous monoliths

    SciTech Connect

    Cruse, T. A.; Polzin, B. J.; Picciolo, J. J.; Singh, D.; Tsaliagos, R. N.; Goretta, K. C.

    2000-03-01

    Most work on ceramic fibrous monoliths (FMs) has focused on the Si{sub 3}N{sub 4}/BN system. In an effort to develop oxidation-resistant FMs, several oxide systems have recently been examined. Zirconia-toughened alumina and alumina/mullite appear to be good candidates for the cell phase of FMs. These composites offer higher strength and toughness than pure alumina and good high-temperature stability. By combining these oxides, possibly with a weaker high-temperature oxide as the cell-boundary phase, it should be possible to product a strong, resilient FM that exhibits graceful failure. Several material combinations have been examined. Results on FM fabrication and microstructural development are presented.

  12. Alumina lightweight ceramics modified with plasma synthesized nanopowders

    NASA Astrophysics Data System (ADS)

    Zake, I.; Svinka, R.; Svinka, V.; Palcevskis, E.

    2011-12-01

    The aim of this study is to clarify possibilities of using plasma synthesized Al2O3 and SiC nanopowders as additives in alumina lightweight ceramics prepared by slip casting. Each plasma synthesized nanopowder (PSNP) was incorporated in the material by a different method, because of their diverse influence on the properties of slip. Al2O3 PSNP was introduced in the matrix in form of aqueous suspension. SiC nanopowder was added directly to raw materials. Bending strength, bulk density, apparent porosity and thermal shock resistance were determined to evaluate the influence of these additives. The effect of Al2O3 PSNP addition on the properties of material depends on the initial sintering temperature. SiC particles during sintering oxidize into SiO2 and then in the reaction with alumina form mullite. Addition of SiC considerably improves bending strength and thermal shock resistance.

  13. Nd:YAG laser cutting of advanced ceramics

    NASA Astrophysics Data System (ADS)

    Quintero, F.; Pou, Juan; Lusquinos, F.; Boutinguiza, M.; Soto, R.; Perez-Amor, Mariano

    2001-08-01

    The manufacturing of elements made of advance ceramics is done traditionally by the use of diamond coated tools. The inherent properties of those materials such as very high hardness and brittleness, made machining a very hard work; being noisy, powdery and unsafe for the worker. Thus, there is a need to introduce new processing methods in order to improve the working conditions and also the quality of the products. In this paper we present the result of the work carried out to investigate the possibilities of an optical fiber guided Nd:YAG laser to cut mullite-alumina plates. We used a 500 W pulsed Nd:YAG laser to perform different experiments in which the influence of the average laser power and the assist gas pressure on the maximum cutting speed was studied.

  14. Silver-hafnium braze alloy

    DOEpatents

    Stephens, Jr., John J.; Hosking, F. Michael; Yost, Frederick G.

    2003-12-16

    A binary allow braze composition has been prepared and used in a bonded article of ceramic-ceramic and ceramic-metal materials. The braze composition comprises greater than approximately 95 wt % silver, greater than approximately 2 wt % hafnium and less than approximately 4.1 wt % hafnium, and less than approximately 0.2 wt % trace elements. The binary braze alloy is used to join a ceramic material to another ceramic material or a ceramic material, such as alumina, quartz, aluminum nitride, silicon nitride, silicon carbide, and mullite, to a metal material, such as iron-based metals, cobalt-based metals, nickel-based metals, molybdenum-based metals, tungsten-based metals, niobium-based metals, and tantalum-based metals. A hermetic bonded article is obtained with a strength greater than 10,000 psi.

  15. Sol-gel derived aluminosilicate coatings on alumina as substrate for osteoblasts.

    PubMed

    Leivo, Jarkko; Meretoja, Ville; Vippola, Minnamari; Levänen, Erkki; Vallittu, Pekka; Mäntylä, Tapio A

    2006-11-01

    Rat bone marrow stromal cell differentiation on aluminosilicate 3Al(2)O(3)-2SiO(2) coatings was investigated. Thin ceramic coatings were prepared on alpha-alumina substrates by the sol-gel process and calcined in order to establish an amorphous aluminosilicate ceramic phase with and without nanosized transitional mullite crystals. In addition, coatings of thermally sprayed aluminosilicate and diphasic gamma-alumina-silica nanosized colloids were prepared. Cell culture testing by rat osteoblasts showed good biocompatibility for aluminosilicates with sustained normal osteoblast functions. Despite mutual disparities in physical and chemical nanostructures, the culture findings suggested fairly similar osteoblast response to all tested coatings. The results suggest that topographical frequency parameters and chemical uniformity are important parameters in determining the best conditions for osteoblasts on sol-gel derived aluminosilicate materials.

  16. Fundamental studies on the nature and properties of ceramic fiber insulation

    NASA Technical Reports Server (NTRS)

    Mueller, J. I.; Whittemore, O. J., Jr.; Scott, W. D.; Miller, A. D.; Smiser, L. W.; Leiser, D. B.

    1975-01-01

    Silica and mullite fibers used to fabricate reusable surface insulation (RSI) for the space shuttle orbiter may devitrify/recrystallize within the temperature range anticipated upon reentry. This is shown to be dependent upon impurity level, temperature, and time at temperature. It is determined that the effects of the material improvement and optimization program are positive. The degree of crystallinity is shown to have a predominant effect upon the strength of fabricated RSI tile, and limits are determined. Models are developed to predict tensile strengths and shrinkage rates of silica tile based upon readily measurable parameters. Thermal cycling which simulates reentry results in an increase in the crystallinity and in the porosity of tile coatings.

  17. Valorization of sugarcane bagasse ash: producing glass-ceramic materials.

    PubMed

    Teixeira, S R; Magalhães, R S; Arenales, A; Souza, A E; Romero, M; Rincón, J M

    2014-02-15

    Some aluminosilicates, for example mullite and wollastonite, are very important in the ceramic and construction industries. The most significant glass-ceramic for building applications has wollastonite as the main crystal phase. In this work we report on the use of sugarcane bagasse ash (SCBA) to produce glass-ceramics with silicates as the major crystalline phases. The glasses (frits) were prepared by mixing ash, limestone (calcium and magnesium carbonates) and potassium carbonate as the fluxing agent. X-ray fluorescence was used to determine the chemical composition of the glasses and their crystallization was assessed by using thermal analysis (DTA/DSC/TGA) and X-ray diffraction. The results showed that glass-ceramic material can be produced with wollastonite as the major phase, at a temperature lower than 900 °C.

  18. Mineralogical characterization of Sasol feed coals and corresponding gasification ash constituents

    SciTech Connect

    Aivo B. Hlatshwayo; Ratale H. Matjie; Zhongsheng Li; Colin R. Ward

    2009-05-15

    Feed coal and coarse ash particles (heated rock fragments and clinkers), produced from Sasol-Lurgi gasifier tests under different operating conditions, have been characterized by quantitative X-ray diffraction, electron microprobe analysis, and associated chemical techniques, as a basis for better understanding of the relations between the mineralogical and physical properties of the ash particles. Crystalline phases in the ashes include quartz particles inherited directly from the feed coal, as well as anorthite, mullite, and diopside, derived from solid-state reactions or crystallization of a silicate melt during the gasification process. Glass, cooled from the melt, is also abundant in the ash materials. The abundance of large particles of hard minerals in the coal or the ash, such as quartz, anorthite, pyrite, and diopside, has been correlated with a laboratory-determined abrasion index and may contribute significantly to wear on mechanical equipment during coal- or ash-handling operations. 21 refs., 3 figs., 9 tabs.

  19. Initiation of surface and interface edge cracks in functionally graded ceramic thermal barrier coatings

    SciTech Connect

    Kokini, K.; Case, M.

    1997-04-01

    The initiation of surface and interface edge cracks in functionally graded ceramic thermal barrier coatings resulting from the application of a thermal load is studied. For a given specimen configuration, the singular behavior of the thermal stresses is analytically determined in terms of a singularity power {beta} and pseudo-stress intensity factors K{sub 1} and K{sub 2}. Crack initiation at the surface at the interface is related to the surface temperature and the temperature difference between the surface of the coating and the substrate. The experimental results are used to provide Weibull curves for the probability of survival of plasma sprayed mullite and CoCrAlY coating systems.

  20. Adsorption of chromium ions from aqueous solution by using activated carbo-aluminosilicate material from oil shale.

    PubMed

    Shawabkeh, Reyad Awwad

    2006-07-15

    A novel activated carbo-aluminosilicate material was prepared from oil shale by chemical activation. The chemicals used in the activation process were 95 wt% sulfuric and 5 wt% nitric acids. The produced material combines the sorption properties and the mechanical strength of both activated carbon and zeolite. An X-ray diffraction analysis shows the formation of zeolite Y, Na-X, and A-types, sodalite, sodium silicate, mullite, and cancrinite. FT-IR spectrum shows the presence of carboxylic, phenolic, and lactonic groups on the surface of this material. The zero point of charge estimated at different mass to solution ratio ranged from 7.9 to 8.3. Chromium removal by this material showed sorption capacity of 92 mg/g.

  1. K-Al-based mixed oxides as high-capacity carbon dioxide adsorbents

    NASA Astrophysics Data System (ADS)

    Ikeue, Keita; Suzuki, Masashige; Sakai, Munetoshi; Chand Vagvala, Tarun; Kalousek, Vit

    2017-06-01

    K-Al-based mixed oxides (KAl6O9.5) with mullite structures were synthesized as CO2 adsorption materials using a polymerized complex method. Al3+ sites in the octahedral AlO6 units of K-Al-based mixed oxides were substituted with various metal ions with +2 or +3 valence states to enhance basicity. Among these samples, the Fe-introduced sample (KAl5.5Fe0.5O9.5) showed 130 times higher CO2 adsorption capacity than that of Li4SiO4. Raman spectra of these samples indicated that large distortions of the AlO6 unit were observed only for the Fe-introduced sample. Local polarization caused by such distortions could induce increased basicity of this sample.

  2. Thermal expansion of laminated, woven, continuous ceramic fiber/chemical-vapor-infiltrated silicon carbide matrix composites

    NASA Technical Reports Server (NTRS)

    Eckel, Andrew J.; Bradt, Richard C.

    1990-01-01

    Thermal expansions of three two-dimensional laminate, continuous fiber/chemical-vapor-infiltrated silicon carbide matrix composites reinforced with either FP-Alumina (alumina), Nextel (mullite), or Nicalon (Si-C-O-N) fibers are reported. Experimental thermal expansion coefficients parallel to a primary fiber orientation were comparable to values calculated by the conventional rule-of-mixtures formula, except for the alumina fiber composite. Hysteresis effects were also observed during repeated thermal cycling of that composite. Those features were attributed to reoccurring fiber/matrix separation related to the micromechanical stresses generated during temperature changes and caused by the large thermal expansion mismatch between the alumina fibers and the silicon carbide matrix.

  3. Ceramic technology for solar thermal receivers

    NASA Technical Reports Server (NTRS)

    Kudirka, A. A.; Smoak, R. H.

    1981-01-01

    The high-temperature capability, resistance to corrosive environments and non-strategic nature of ceramics have prompted applications in the solar thermal field whose advantages over metallic devices of comparable performance may begin to be assessed. It is shown by a survey of point-focusing receiver designs employing a variety of ceramic compositions and fabrication methods that the state-of-the-art in structural ceramics is not sufficiently advanced to fully realize the promised benefits of higher temperature capabilities at lower cost than metallic alternatives. The ceramics considered include alumina, berylia, magnesia, stabilized zirconia, fused silica, silicon nitride, silicon carbide, mullite and cordierite, processed by such methods as isostatic pressing, dry pressing, slip casting, extrusion, calendaring and injection molding.

  4. Spatio-temporal behaviour of atomic-scale tribo-ceramic films in adaptive surface engineered nano-materials

    NASA Astrophysics Data System (ADS)

    Fox-Rabinovich, G.; Kovalev, A.; Veldhuis, S.; Yamamoto, K.; Endrino, J. L.; Gershman, I. S.; Rashkovskiy, A.; Aguirre, M. H.; Wainstein, D. L.

    2015-03-01

    Atomic-scale, tribo-ceramic films associated with dissipative structures formation are discovered under extreme frictional conditions which trigger self-organization. For the first time, we present an actual image of meta-stable protective tribo-ceramics within thicknesses of a few atomic layers. A mullite and sapphire structure predominates in these phases. They act as thermal barriers with an amazing energy soaking/dissipating capacity. Less protective tribo-films cannot sustain in these severe conditions and rapidly wear out. Therefore, a functional hierarchy is established. The created tribo-films act in synergy, striving to better adapt themselves to external stimuli. Under a highly complex structure and non-equilibrium state, the upcoming generation of adaptive surface engineered nano-multilayer materials behaves like intelligent systems - capable of generating, with unprecedented efficiency, the necessary tribo-films to endure an increasingly severe environment.

  5. A new method for measurement of the vitrification rate of earthenware texture by scanning electron microscope.

    PubMed

    Moon, Eun Jung; Kim, Su Kyeong; Han, Min Su; Lee, Eun Woo; Heo, Jun Su; Lee, Han Hyoung

    2013-08-01

    A new method for determining the vitrification rate of pottery depending on the firing temperature was devised using secondary electron images (SEI) of scanning electron microscope (SEM). Several tests were performed to establish the appropriate operating conditions of SEM and reproducibility as well as to examine the applicability of the method. The grayscale values converted from each pixel of SEI were used to determine the vitrification rate of pottery, which in our study were artificially fired specimens composed of three types of clay. A comparison between the vitrification rate value and appearance temperature of minerals shows that mullite formation starts at 1,100°C, during which the vitrification rate rapidly increases by over 10%. In consequence, the result presented here demonstrates that the new method can be applied to estimate the firing temperature of pottery.

  6. Effect of hydrogen on the strength and microstructure of selected ceramics

    NASA Technical Reports Server (NTRS)

    Herbell, Thomas P.; Eckel, Andrew J.; Hull, David R.; Misra, Ajay K.

    1990-01-01

    Ceramics in monolithic form and as composite constituents in the form of fibers, matrices, and coatings are currently being considered for a variety of high-temperature applications in aeronautics and space. Many of these applications involve exposure to a hydrogen-containing environment. The compatibility of selected ceramics in gaseous high-temperature hydrogen is assessed. Environmental stability regimes for the long term use of ceramic materials are defined by the parameters of temperature, pressure, and moisture content. Thermodynamically predicted reactions between hydrogen and several monolithic ceramics are compared with actual performance in a controlled environment. Morphology of hydrogen attack and the corresponding strength degradation is reported for silicon carbide, silicon nitride, alumina, magnesia, and mullite.

  7. Fundamental alloy design of oxide ceramics and their composites

    SciTech Connect

    Chen, I.W.

    1992-01-01

    The main research was on microstructural development of oxide ceramics. Projects were completed and the publications given. Abstracts are given on: Reactive CeO[sub 2]powders by homogeneous precipitation, SiC whisker-reinforced lithium aluminosilicate composite, solute drag on grain boundary in ionic solids (space charge effect), in-situ alumina/aluminate platelet composites, exaggerated texture and grain growth of superplastic silicon nitride (SiAlON), hot extrusion of ceramics, control of grain boundary pinning in Al[sub 2]O[sub 3]/ZrO[sub 2] composites with Ce[sup 3+]/Ce[sup 4+] doping, superplastic forming of ceramic composites, computer simulation of final stage sintering (model, kinetics, microstructure, effect of initial pore size), development of superplastic structural ceramics, and superplastic flow of two-phase ceramics containing rigid inclusions (zirconia/mullite composites). A proposed research program is outlined: materials, solute drag, densification and coarsening, and grain boundary electrical behavior.

  8. Fundamental alloy design of oxide ceramics and their composites. [Annual] report, May 1, 1990--August 31, 1992

    SciTech Connect

    Chen, I.W.

    1992-12-31

    The main research was on microstructural development of oxide ceramics. Projects were completed and the publications given. Abstracts are given on: Reactive CeO{sub 2}powders by homogeneous precipitation, SiC whisker-reinforced lithium aluminosilicate composite, solute drag on grain boundary in ionic solids (space charge effect), in-situ alumina/aluminate platelet composites, exaggerated texture and grain growth of superplastic silicon nitride (SiAlON), hot extrusion of ceramics, control of grain boundary pinning in Al{sub 2}O{sub 3}/ZrO{sub 2} composites with Ce{sup 3+}/Ce{sup 4+} doping, superplastic forming of ceramic composites, computer simulation of final stage sintering (model, kinetics, microstructure, effect of initial pore size), development of superplastic structural ceramics, and superplastic flow of two-phase ceramics containing rigid inclusions (zirconia/mullite composites). A proposed research program is outlined: materials, solute drag, densification and coarsening, and grain boundary electrical behavior.

  9. Development of low-expansion ceramics with strength retention to elevated temperatures. Final report

    SciTech Connect

    Hirschfeld, D.A.; Brown, J.J. Jr.

    1994-09-01

    The development of advanced engines has resulted in the need for new ceramic compositions which exhibit thermo-mechanical properties suitable for the engine environment, e.g., low thermal expansion, stability to 1,200 C, and thermal shock resistance. To meet these goals, a two phase research program was instituted. In the first phase, new oxide ceramics were identified in the AlPO{sub 4}-{beta}-eucryptite, {beta}-cristobalite, mullite and zircon systems. This research focused on screening and property characterization of ceramics in the four systems. The most promising compositions in the AlPO{sub 4}-{beta}-eucryptite and zircon systems were then further evaluated and developed in the second phase with the goal of being ready for prototype testing in actual engines. Of the compositions, calcium magnesium zirconium phosphate (zircon system) exhibits the most desirable properties and is presently being developed for commercialization.

  10. Creep of Refractory Fibers and Modeling of Metal and Ceramic Matrix Composite Creep Behavior

    NASA Technical Reports Server (NTRS)

    Tewari, S.N.

    1995-01-01

    Our concentration during this research was on the following subprograms. (1) Ultra high vacuum creep tests on 218, ST300 and WHfC tungsten and MoHfC molybdenum alloy wires, temperature range from 1100 K to 1500 K, creep time of 1 to 500 hours. (2) High temperature vacuum tensile tests on 218, ST300 and WHfC tungsten and MoHfC molybdenum alloy wires. (3) Air and vacuum tensile creep tests on polycrystalline and single crystal alumina fibers, such as alumina-mullite Nextel fiber, yttrium aluminum ganet (YAG) and Saphikon, temperature range from 1150 K to 1470 K, creep time of 2 to 200 hours. (4) Microstructural evaluation of crept fibers, TEM study on the crept metal wires, SEM study on the fracture surface of ceramic fibers. (5) Metal Matrix Composite creep models, based on the fiber creep properties and fiber-matrix interface zone formation.

  11. The Microstructure and Wear Resistance of Microarc Oxidation Composite Coatings Containing Nano-Hexagonal Boron Nitride (HBN) Particles

    NASA Astrophysics Data System (ADS)

    Li, Zhenwei; Di, Shichun

    2017-03-01

    The composite coatings containing HBN were prepared on 2024 aluminum alloy by microarc oxidation in the electrolyte with nano-HBN particles. The microstructure, surface roughness, phase composition, hardness, adhesion strength and wear resistance of composite coatings were analyzed by SEM, EDS, laser confocal microscope, XRD, Vickers hardness tester, scratch test and ball-on-disc abrasive tests. The results revealed that composite coatings were mainly composed of γ-Al2O3, α-Al2O3, mullite and HBN. With increasing the content of HBN particles in the electrolyte, the size and number of the pores on the surface of composite coatings decreased significantly. Compared to the MAO coatings without HBN, the composite coatings exhibited better wear resistance, as demonstrated by the lower friction coefficient and the lower wear rate.

  12. Comparison of Refractory Performance in Black Liquor Gasifiers and a Smelt Test System

    SciTech Connect

    Peascoe, RA

    2001-09-25

    Prior laboratory corrosion studies along with experience at the black liquor gasifier in New Bern, North Carolina, clearly demonstrate that serious material problems exist with the gasifier's refractory lining. Mullite-based and alumina-based refractories used at the New Bern facility suffered significant degradation even though they reportedly performed adequately in smaller scale systems. Oak Ridge National Laboratory's involvement in the failure analysis, and the initial exploration of suitable replacement materials, led to the realization that a simple and reliable, complementary method for refractory screening was needed. The development of a laboratory test system and its suitability for simulating the environment of black liquor gasifiers was undertaken. Identification and characterization of corrosion products were used to evaluate the test system as a rapid screening tool for refractory performance and as a predictor of refractory lifetime. Results from the test systems and pl ants were qualitatively similar.

  13. Low temperature environmental degradation of zirconia ceramics

    NASA Astrophysics Data System (ADS)

    Zhao, Zhenbo

    2005-11-01

    The low temperature environmental degradation (LTED) of yttria-stabilized tetragonal zirconia polycrystal (Y-TZP) has been prevented, or at least retarded, by using both bulk doping and surface doping methods with either cation, or anion, stabilizers. The introduction of both mullite and alumina into 3Y-TZP by a bulk-doping method was found to be effective in suppressing the tetragonal-->monoclinic transformation induced by water during hydrothermal treatment thus giving rise to better mechanical properties. The beneficial effects of alumina on the phase stability of the 3Y-TZP ceramic are considered to be due to the increase in the elastic modulus of the constraining matrix, as well as to the segregation of A12O3 at grain boundaries. The LTED transformation kinetics as determined by x-ray diffraction (XRD) and White Light Interferometer (WLI) analysis showed that the isothermal tetragonal-to-monoclinic transformation starts from the surface and has an incubation-nucleation-growth mechanism which can be described by the Johnson-Mehl-Avrami equation. The degradation of Y-TZP ceramic after hydrothermal treatment can be effectively overcome by surface doping by a solid diffusion method with tetravalent dopants: CeO2 and GeO2; with trivalent dopants: La2O 3 and Fe2O3; and with divalent dopants: CuO and MgO. For surface CeO2-, GeO2- and Fe2O 3-doping, this degradation inhibition behaviour is attributed to a localized increase in cation stabilizer content which satisfies the requirements for stabilization of the tetragonal phase. However, in each case, the stability mechanisms are different. For surface La2O3doping, surface doping overcomes the formation of La2O3 and La 2Zr2O7 since the extra La2O3 can further diffuse to the center of the 3Y-TZP ceramic. For CuO-doping, small amounts of CuO form a liquid that can act as a conduit for the re-distribution of yttria. In the case of surface MgO modification, the stabilization results from the isolated nature of the

  14. Anthropogenic- and natural sources of dust in peatland during the Anthropocene.

    PubMed

    Fiałkiewicz-Kozieł, B; Smieja-Król, B; Frontasyeva, M; Słowiński, M; Marcisz, K; Lapshina, E; Gilbert, D; Buttler, A; Jassey, V E J; Kaliszan, K; Laggoun-Défarge, F; Kołaczek, P; Lamentowicz, M

    2016-12-20

    As human impact have been increasing strongly over the last decades, it is crucial to distinguish human-induced dust sources from natural ones in order to define the boundary of a newly proposed epoch - the Anthropocene. Here, we track anthropogenic signatures and natural geochemical anomalies in the Mukhrino peatland, Western Siberia. Human activity was recorded there from cal AD 1958 (±6). Anthropogenic spheroidal aluminosilicates clearly identify the beginning of industrial development and are proposed as a new indicator of the Anthropocene. In cal AD 1963 (±5), greatly elevated dust deposition and an increase in REE serve to show that the geochemistry of elements in the peat can be evidence of nuclear weapon testing; such constituted an enormous force blowing soil dust into the atmosphere. Among the natural dust sources, minor signals of dryness and of the Tunguska cosmic body (TCB) impact were noted. The TCB impact was indirectly confirmed by an unusual occurrence of mullite in the peat.

  15. Ceramic technology for solar thermal receivers

    NASA Technical Reports Server (NTRS)

    Kudirka, A. A.; Smoak, R. H.

    1981-01-01

    The high-temperature capability, resistance to corrosive environments and non-strategic nature of ceramics have prompted applications in the solar thermal field whose advantages over metallic devices of comparable performance may begin to be assessed. It is shown by a survey of point-focusing receiver designs employing a variety of ceramic compositions and fabrication methods that the state-of-the-art in structural ceramics is not sufficiently advanced to fully realize the promised benefits of higher temperature capabilities at lower cost than metallic alternatives. The ceramics considered include alumina, berylia, magnesia, stabilized zirconia, fused silica, silicon nitride, silicon carbide, mullite and cordierite, processed by such methods as isostatic pressing, dry pressing, slip casting, extrusion, calendaring and injection molding.

  16. Comparison of the properties of glass, glass-ceramic and ceramic materials produced from coal fly ash.

    PubMed

    Erol, M; Küçükbayrak, S; Ersoy-Meriçboyu, A

    2008-05-01

    Glass, glass-ceramic and ceramic materials were produced from thermal power plant fly ash without any additives. X-ray diffraction (XRD) analysis revealed the amorphous phase of the glass sample. Augite phase was detected in the glass-ceramic sample, while the enstatite and mullite phases occurred in the ceramic samples. Scanning electron microscopy (SEM) investigations showed that tiny crystallites homogeneously dispersed in the microstructure of the glass-ceramic sample and elongated crystals formed in the ceramic samples. Density values of the obtained samples are comparable to those of the commercially produced glass, glass-ceramic and ceramic samples. Toxicity characteristic leaching procedure (TCLP) results indicated that the produced samples could be taken as non-hazardous materials. Produced samples showed high resistance to alkali solutions in contrast to acidic solutions. Microstructural, physical, chemical and mechanical properties of the produced glass-ceramic samples are better than those of the produced glass and ceramic samples.

  17. Zr doped anatase supported reticulated ceramic foams for photocatalytic water purification

    SciTech Connect

    Plesch, G.; Vargová, M.; Vogt, U.F.; Gorbár, M.; Jesenák, K.

    2012-07-15

    Highlights: ► Thick photocatalytic anatase films on macroporous reticulated ceramic foams. ► Alumina and alumina–mullite macroporous reticulated foams as photocatalyst support. ► Zr doping significantly improves the TiO{sub 2} film activity in phenol photomineralization. ► Comparison of photocatalytic activity of thick films and powder suspensions. -- Abstract: Titanium dioxide films were deposited on macroporous reticulated Al{sub 2}O{sub 3} and alumina–mullite foams with pore sizes of 15 ppi (pores per inch). Coatings were prepared from suspensions of precursor powders of Aeroxide{sup ®} P25 nanopowder and precipitated TiO{sub 2} by using a dip coating process. The TiO{sub 2} forms films with a thickness of ∼2–20 μm. The photocatalytic activity was characterized as the mineralization rate of an aqueous phenol solution under UVA irradiation by the TOC technique. Precipitated TiO{sub 2} films have nearly the same photocatalytic activity as a titania suspension, in which powder aggregates have a size comparable with the thickness of the films. Samples made of Aeroxide{sup ®} P25 nanopowder, in which the size of aggregates is ∼0.1 μm show higher efficiency of photodecomposition in suspensions with films. The doping of precipitated anatase with Zr(IV) in the atomic ratio Zr/Ti = 0.008 significantly improves the photocatalytic activity of the foam supported titania. Zr doped anatase films show better performance as the films prepared only from Aeroxide{sup ®} P25 nanopowder.

  18. Plasma electrolytic oxidation coating of synthetic Al-Mg binary alloys

    SciTech Connect

    Tarakci, Mehmet

    2011-12-15

    The binary Al-Mg synthetic alloys were prepared in a vacuum/atmosphere controlled furnace with the addition of 0.5, 1, 2, 4, 7, and 15 wt.% pure Mg into pure aluminum as substrate material. The surfaces of the Al-Mg alloys and pure aluminum were coated for 120 min by plasma electrolytic oxidation in the same electrolyte of 12 g/L sodium silicate and 2 g/L KOH in distilled water. The coating was characterized by X-ray diffraction, scanning electron microscopy, profilometry and Vickers microhardness measurements. There regions of loose outer layer, dense inner layer with precipitate like particles of {alpha}-Al{sub 2}O{sub 3} and a thin transition layer were identified for the coated samples. The coating thickness increases from 85 to 150 {mu}m with Mg contents in the alloys. The surface morphology becomes more porous and consequently surface roughness tends to increase with plasma electrolytic oxidation treatment and further with Mg content. The increase in magnesium content reduces the formation of {alpha}-Al{sub 2}O{sub 3} and crystalline mullite phases in the coating and decreases microhardness of coating. The Mg concentration is constant throughout the other loose and dense regions of coating though it gradually decreases in the thin inner region. - Research Highlights: Black-Right-Pointing-Pointer The average thickness of PEO coating of Al-Mg alloys increases with Mg content. Black-Right-Pointing-Pointer The addition of Mg reduces and prevents the formation of {alpha}-Al{sub 2}O{sub 3} and mullite. Black-Right-Pointing-Pointer The surface roughness increases with Mg content in the Al-Mg alloys. Black-Right-Pointing-Pointer The hardness values of the coating decreases with the Mg amount in the substrate. Black-Right-Pointing-Pointer The Mg concentration is constant throughout the main regions of coating.

  19. Water Adsorption Isotherms on Fly Ash from Several Sources.

    PubMed

    Navea, Juan G; Richmond, Emily; Stortini, Talia; Greenspan, Jillian

    2017-10-03

    In this study, horizontal attenuated total reflection (HATR) Fourier-transform infrared (FT-IR) spectroscopy was combined with quartz crystal microbalance (QCM) gravimetry to investigate the adsorption isotherms of water on fly ash, a byproduct of coal combustion in power plants. Because of composition variability with the source region, water uptake was studied at room temperature as a function of relative humidity (RH) on fly ash from several regions: United States, India, The Netherlands, and Germany. The FT-IR spectra show water features growth as a function of RH, with water absorbing on the particle surface in both an ordered (ice-like) and a disordered (liquid-like) structure. The QCM data was modeled using the Brunauer, Emmett, and Teller (BET) adsorption isotherm model. The BET model was found to describe the data well over the entire range of RH, showing that water uptake on fly ash takes place mostly on the surface of the particle, even for poorly combusted samples. In addition, the source region and power-plant efficiency play important roles in the water uptake and ice nucleation (IN) ability of fly ash. The difference in the observed water uptake and IN behavior between the four samples and mullite (3Al2O3·2SiO2), the aluminosilicate main component of fly ash, is attributed to differences in composition and the density of OH binding sites on the surface of each sample. A discussion is presented on the RH required to reach monolayer coverage on each sample as well as a comparison between surface sites of fly ash samples and enthalpies of adsorption of water between the samples and mullite.

  20. Processing and characterization of multi-cellular monolithic bioceramics for bone regenerative scaffolds

    SciTech Connect

    Ari-Wahjoedi, Bambang; Ginta, Turnad Lenggo; Parman, Setyamartana; Abustaman, Mohd Zikri Ahmad

    2014-10-24

    Multicellular monolithic ceramic body is a ceramic material which has many gas or liquid passages partitioned by thin walls throughout the bulk material. There are many currently known advanced industrial applications of multicellular ceramics structures i.e. as supports for various catalysts, electrode support structure for solid oxide fuel cells, refractories, electric/electronic materials, aerospace vehicle re-entry heat shields and biomaterials for dental as well as orthopaedic implants by naming only a few. Multicellular ceramic bodies are usually made of ceramic phases such as mullite, cordierite, aluminum titanate or pure oxides such as silica, zirconia and alumina. What make alumina ceramics is excellent for the above functions are the intrinsic properties of alumina which are hard, wear resistant, excellent dielectric properties, resists strong acid and alkali attacks at elevated temperatures, good thermal conductivities, high strength and stiffness as well as biocompatible. In this work the processing technology leading to truly multicellular monolithic alumina ceramic bodies and their characterization are reported. Ceramic slip with 66 wt.% solid loading was found to be optimum as impregnant to the polyurethane foam template. Mullitic ceramic composite of alumina-sodium alumino disilicate-Leucite-like phases with bulk and true densities of 0.852 and 1.241 g cm{sup −3} respectively, pore linear density of ±35 cm{sup −1}, linear and bulk volume shrinkages of 7-16% and 32 vol.% were obtained. The compressive strength and elastic modulus of the bioceramics are ≈0.5-1.0 and ≈20 MPa respectively.

  1. Anisotropic lattice thermal expansion of PbFeBO{sub 4}: A study by X-ray and neutron diffraction, Raman spectroscopy and DFT calculations

    SciTech Connect

    Murshed, M. Mangir; Mendive, Cecilia B.; Curti, Mariano; Nénert, Gwilherm; Kalita, Patricia E.; Lipinska, Kris; Cornelius, Andrew L.; Huq, Ashfia; Gesing, Thorsten M.

    2014-11-15

    Highlights: • Mullite-type PbFeBO{sub 4} shows uni-axial negative coefficient of thermal expansion. • Anisotropic thermal expansion of the metric parameters was modeled using modified Grüneisen approximation. • The model includes harmonic, quasi-harmonic and intrinsic anharmonic contributions to the internal energy. • DFT calculation, temperature- and pressure-dependent Raman spectra help understand the phonon decay and associated anharmonicity. - Abstract: The lattice thermal expansion of mullite-type PbFeBO{sub 4} is presented in this study. The thermal expansion coefficients of the metric parameters were obtained from composite data collected from temperature-dependent neutron and X-ray powder diffraction between 10 K and 700 K. The volume thermal expansion was modeled using extended Grüneisen first-order approximation to the zero-pressure equation of state. The additive frame of the model includes harmonic, quasi-harmonic and intrinsic anharmonic potentials to describe the change of the internal energy as a function of temperature. The unit-cell volume at zero-pressure and 0 K was optimized during the DFT simulations. Harmonic frequencies of the optical Raman modes at the Γ-point of the Brillouin zone at 0 K were also calculated by DFT, which help to assign and crosscheck the experimental frequencies. The low-temperature Raman spectra showed significant anomaly in the antiferromagnetic regions, leading to softening or hardening of some phonons. Selected modes were analyzed using a modified Klemens model. The shift of the frequencies and the broadening of the line-widths helped to understand the anharmonic vibrational behaviors of the PbO{sub 4}, FeO{sub 6} and BO{sub 3} polyhedra as a function of temperature.

  2. The high temperature creep behavior of oxides and oxide fibers

    NASA Technical Reports Server (NTRS)

    Jones, Linda E.; Tressler, Richard E.

    1991-01-01

    A thorough review of the literature was conducted on the high-temperature creep behavior of single and polycrystalline oxides which potentially could serve as fiber reinforcements in ceramics or metal matrix applications. Sapphire when oriented with the basal plane perpendicular to the fiber axis (c-axis oriented) is highly creep resistant at temperatures in excess of 1600 C and applied loads of 100 MPa and higher. Pyramidal slip is preferentially activated in sapphire under these conditions and steady-state creep rates in the range of 10(exp -7) to 10 (exp -8)/s were reported. Data on the creep resistance of polycrystalline beryllia suggest that C-axiz oriented single crystal beryllia may be a viable candidate as a fiber reinforcement material; however, the issure of fabricability and moisture sensitivity must be addressed for this material. Yttrium aluminum garnet (YAG) also appears to be a fiber candidate material having a high resistance to creep which is due to it's complex crystal structure and high Peierl resistance. The high creep resistance of garnet suggests that there may be other complex ternary oxides such as single crystal mullite which may also be candidate materials for fiber reinforcements. Finally, CVD and single crystal SiC, although not oxides, do possess a high resistance to creep in the temperature range between 1550 and 1850 C and under stresses of 110 to 220 MPa. From a review of the literature, it appears that for high creep resistant applications sapphire, silicon carbide, yttrium aluminum garnet, mullite, and beryllia are desirable candidate materials which require further investigation.

  3. Statistical Approach to the Transformation of Fly Ash into Zeolites

    NASA Astrophysics Data System (ADS)

    Derkowski, Arkadiusz; Michalik, Marek

    2007-01-01

    The experimental conversion of F-class fly ash into zeolites is described. The ash, composed mainly of aluminosilicate glass, mullite and quartz, was collected in the Cracow power plant (southern Poland). The experiments involved the heating of fly ash samples in PTFE vessels. Time, temperature and solution composition were the reaction parameters considered in the experiments and in the subsequent modeling. A series of reactions with 0.5, 3 and 5M NaOH solutions (and some with additional 3M NaCl) were carried out at 70°, 100° and 150°C for 12-48 hours under autogenic pressure (not measured) and at a constant ash-to-solution ratio of 33.3 g/l. The following zeolite phases were synthesized: sodalite (SOD structure), hydroxysodalite (SOD), CAN type phases, Na-X (FAU), and NaP1 (GIS). Statistically calculated relationships based on the mineral- and chemical compositions of the reaction products support the conclusion that the type of zeolite phase that crystallizes depends on the concentration of OH- and Cl- in solution and on the temperature of the reaction. The duration of reaction, if on the order of tens of hours, is of less significance. The nature of the zeolite phase that crystalises is controlled by the intensity and selectivity of the substrate dissolution. That dissolution can favour, in sequence, one or other of the components in the substrate, resulting in Si/Al variation in the reaction solutions. Mullite dissolution (decreasing solution Si/Al) characterizes the most advanced reaction stages. The sequence of crystallization of the zeolite phases mirrors the sequential dissolution of substrate components, and the composition of the crystallizing zeolite crystals reflects the changes in the solution Si/Al.

  4. Interfacial coatings for ceramic-matrix composites -- Volume 2. Final report

    SciTech Connect

    Sambasivan, S.

    1998-06-09

    This report summarizes the task conducted to examine various activities on interface development for ceramic-matrix composites (CMCs) intended for high-temperature applications. While several articles have been published on the subject of CMC interfaces, the purpose of this report is to describe the various ongoing efforts on interface concepts, material selection, and issues related to processing methods employed for developing interface coatings. The most exciting and new development in the field is the discovery of monazite as a potential interface material for mullite- and alumina-based composites. Monazite offers two critical properties to the CMC system; a weakly bonded layer due to its non-wetting behavior and chemical compatibility with both alumina and mullite up to very high temperatures (> 1,600 C). Other interesting concepts with intensive material development efforts are also being pursued and a brief discussion of these are given in the main text. While demonstration of new interface concepts seems to be the primary objective in most studies, difficulties in processing of interface coatings and designing reliable test methods for determining interface properties have actually retarded the progress. Some of the concepts appear to be simple in nature but require sophisticated processing schemes to develop the coatings. Multilayered coatings with each layer serving specific function are also being proposed. Recent studies also show that significant degradation in fiber strength (30--50%) can result from merely applying the interface coating. These factors have compounds the complexity of interface tailoring in CMCs leading to a need for specific solution for a specific CMC system.

  5. Processing and Characterizing Alumina/Aluminum Composites with Tailored Microstructures Formed by Reactive Metal Penetration

    SciTech Connect

    Corral, E.; Ellerby, D.; Ewsuk, K.; Fahrenholtz, B.; Loehman, R.

    1999-01-28

    In industry, the need to maximize energy efficiency depends on the availability of suitable advanced materials. Ceramic composites are exemplary materials for many advanced engineering applications because they exhibit good thermal stability, oxidation resistance and enhanced toughness. Presently, ceramic composite fabrication processes are costly, often requiring high temperatures and pressures to achieve reasonable densities. Our research is focused on developing a processing technique, that will allow production of alumina/aluminum composites using relatively low temperatures and without the application of an external force, thus reducing the processing costs. Our composites were formed using Reactive Metal Penetration (RMP), which is a process involving the reaction of molten Al with a dense ceramic preform. The result is a near net shape ceramic/metal composite with interpenetrating phases. The volume fraction of metal in the composites was varied by doping an aluminosilicate ceramic preform with silica. For this study we fabricated composites using pure mullite and mullite doped with 23 and 42 weight percent silica, yielding 18, 25, and 30 volume percent metal in the composites, respectively. Optical and Scanning Electron Microscopy were used to characterize the homogeneity and scale of the microstructure. The scale of the microstructure varied with preform composition, the reaction temperature and with secondary heat treatments. Four-point bend testing was used to evaluate the influence of microstructure on strength and reliability. During these studies a gradient in the microstructure was observed, which we further characterized using microhardness testing. Alumina/aluminum composites formed by RMP show higher toughness then monolithic alumina and have the potential for improved reliability when compared to monolithic ceramics.

  6. Metal stabilization mechanism of incorporating lead-bearing sludge in kaolinite-based ceramics.

    PubMed

    Lu, Xingwen; Shih, Kaimin

    2012-02-01

    The feasibility and mechanism of incorporating simulated lead-laden sludge into low-cost ceramic products was investigated by observing the reaction of lead with two kaolinite-based precursors under sintering conditions. To investigate the phase transformation process of lead, lead oxide (PbO) mixed with a kaolinite or mullite precursor were fired at 500-950°C for 3h. Detailed X-ray diffraction analysis of sintered products revealed that both precursors had crystallochemically incorporated lead into the lead feldspar (PbAl(2)Si(2)O(8)) crystalline structure. By mixing lead oxide with kaolinite, lead feldspar begins to crystallize at 700°C; maximum incorporation of lead into this structure occurred at 950°C. However, two intermediate phases, Pb(4)Al(4)Si(3)O(16) and a polymorph of lead feldspar, were detected at temperatures between 700 and 900°C. By sintering lead oxide with the mullite precursor, lead feldspar was detected at temperatures above 750°C, and an intermediate phase of Pb(4)Al(4)Si(3)O(16) was observed in the temperature range of 750-900°C. This study compared the lead leachabilities of PbO and lead feldspar using a prolonged leaching test (at pH 2.9 for 23d) modified from the toxicity characteristic leaching procedure. The results indicate the superiority of lead feldspar in stabilizing lead and suggest a promising and reliable strategy to stabilize lead in ceramic products.

  7. High-temperature oxidation studies of several silicon-based systems

    NASA Astrophysics Data System (ADS)

    Ramberg, Charles Eric

    1997-10-01

    alumina. The oxidation kinetics as a function of temperature were determined for hot pressed Mo(Alsb{0.1}Sisb{0.9})sb2 and Mo(Alsb{0.01}Sisb{0.99})sb2. The hot-pressed Mo(Alsb{0.1}Sisb{0.9})sb2 materials formed alumina scales at low temperatures (1200 C), and oxide scales composed of alumina (Alsb2Osb3) and mullite (3Alsb2Osb3sp\\*2SiOsb2) at higher temperatures (>1300 C). Hot pressed Mo(Alsb{0.01}Sisb{0.99})sb2 materials formed scales consisting of cristobalite (SiOsb2) and mullite. At 1500 C, the oxidation kinetics were extremely nonlinear, presumably due to the formation of a continuous mullite layer at the scale/substrate interface after ˜20 hours.

  8. Stabilization of nickel by aluminum- and iron-rich ceramic materials: Reaction pathways and product leaching behavior

    NASA Astrophysics Data System (ADS)

    Shih, Kaimin

    The feasibility of stabilizing nickel-laden sludge with commonly available ceramic precursors was investigated. Nickel aluminate spinel (NiAl2O 4) was the immobilization phase produced when NiO was sintered with aluminum-rich precursors, including gamma-Al2O3, corundum, kaolinite and mullite. Analogously, nickel ferrite spinel (NiFe2O 4) was the stable phase produced by firing NiO with hematite, as an iron-rich precursor. By using gamma-Al2O3 as the precursor, the NiAl2O4 formation mechanism was a reaction between NiO and gamma-Al2O3 at lower temperatures (990°C), while the reaction was between NiO and corundum at higher temperatures. When sintering NiO with kaolinite, nickel can be efficiently incorporated in NiAl2O4 by two mechanisms: (i) a low temperature reaction with a defect spinel, and (ii) a high temperature reaction with mullite. Nickel-incorporation efficiency was quantitatively estimated by powder X-ray Diffraction (XRD) analysis. With 3-hours sintering, NiFe2O 4 (trevorite) formation took place above 600°C with more than 95% nickel incorporation efficiency achieved above 1000°C; while NiAl 2O4 crystallized above 1000°C with an efficiency >90% above 1250°C. In using kaolinite and mullite as precursors, nickel is not incorporated in any silicon-containing phase. The kinetic factors responsible for nickel incorporation efficiency from different precursors were revealed through investigation of product microstructures. Moreover, four raw material mixing procedures were compared, with the ball-milled slurries demonstrating the highest nickel incorporation efficiency. Prolonged leach tests of NiO, NiAl2O4, NiFe 2O4 and sintered kaolinite + NiO samples were carried out using the TCLP extraction fluids #1 and #2 to evaluate the durability of sintered products. Over longer leaching periods, spinel proved superior to NiO for immobilization of nickel, although NiFe2O4 appears slightly more leachable than NiAl2O4. With TCLP extraction fluid #1 (pH 4.9), the

  9. Feasible voltage-tap based quench detection in a Ag/Bi-2212 coil enabled by fast 3D normal zone propagation

    DOE PAGES

    Shen, Tengming; Ye, Liyang; Li, Pei

    2016-07-01

    For this study, small insert solenoids have been built using a commercial Ag/Bi-2212 multifilamentary round wire, insulated with a new thin TiO2– polymer coating insulation (thickness in ~20 μm versus ~100 μm for a commonly used mullite braided sleeve insulation), and characterized in background magnetic field up to 14 T at 4.2 K to explore the high-field performance and quench detection of Bi-2212 magnets. The coil has no visible leakage and no electrical shorts after reaction, and it carries 280 A/mm-2 in a background field 14 T and generates an additional 1.7 T. A notable result is that, despite normalmore » zones propagate slowly along the conductor, the hot spot temperature upon detection increases only from 40 K to 60 K when the resistive quench detection voltage threshold increases from 0.1 V to 1 V for all operating current density investigated, showing that quench detection using voltage taps is feasible for this coil. This is in a strong contrast to a coil we previously built to the same specifications but from wires insulated with the mullite braided sleeve insulation, for which the hot spot temperature upon detection increases from ~80 K to ~140 K while increasing from the detection voltage threshold from 0.1 V to 1 V, and thus for which quench detection using voltage taps presents significant risks, consistent with the common belief that the effectiveness of quench detection using voltage taps for superconducting magnets built using high temperature superconductors is seriously compromised by their slow normal zone propagation. This striking difference is ascribed to the fast transverse quench propagation enabled by thin insulation and improved thermal coupling between conductor turns. Finally, this work demonstrates that quench detection for high-temperature superconducting magnets highly depends on the design and construction of the coils such as insulation materials used and this dependence should be factored into the overall magnet design.« less

  10. Feasible voltage-tap based quench detection in a Ag/Bi-2212 coil enabled by fast 3D normal zone propagation

    SciTech Connect

    Shen, Tengming; Ye, Liyang; Li, Pei

    2016-07-01

    For this study, small insert solenoids have been built using a commercial Ag/Bi-2212 multifilamentary round wire, insulated with a new thin TiO2– polymer coating insulation (thickness in ~20 μm versus ~100 μm for a commonly used mullite braided sleeve insulation), and characterized in background magnetic field up to 14 T at 4.2 K to explore the high-field performance and quench detection of Bi-2212 magnets. The coil has no visible leakage and no electrical shorts after reaction, and it carries 280 A/mm-2 in a background field 14 T and generates an additional 1.7 T. A notable result is that, despite normal zones propagate slowly along the conductor, the hot spot temperature upon detection increases only from 40 K to 60 K when the resistive quench detection voltage threshold increases from 0.1 V to 1 V for all operating current density investigated, showing that quench detection using voltage taps is feasible for this coil. This is in a strong contrast to a coil we previously built to the same specifications but from wires insulated with the mullite braided sleeve insulation, for which the hot spot temperature upon detection increases from ~80 K to ~140 K while increasing from the detection voltage threshold from 0.1 V to 1 V, and thus for which quench detection using voltage taps presents significant risks, consistent with the common belief that the effectiveness of quench detection using voltage taps for superconducting magnets built using high temperature superconductors is seriously compromised by their slow normal zone propagation. This striking difference is ascribed to the fast transverse quench propagation enabled by thin insulation and improved thermal coupling between conductor turns. Finally, this work demonstrates that quench detection for high-temperature superconducting magnets highly depends on the design and construction of the coils such as insulation materials used and this dependence should be factored into the overall

  11. Paragenesis of unusual Fe-cordierite (sekaninaite)-bearing paralava and clinker from the Kuznetsk coal basin, Siberia, Russia

    NASA Astrophysics Data System (ADS)

    Grapes, Rodney; Korzhova, Sophia; Sokol, Ella; Seryotkin, Yurii

    2011-08-01

    Sekaninaite (XFe > 0.5)-bearing paralava and clinker are the products of ancient combustion metamorphism in the western part of the Kuznetsk coal basin, Siberia. The combustion metamorphic rocks typically occur as clinker beds and breccias consisting of vitrified sandstone-siltstone clinker fragments cemented by paralava, resulting from hanging-wall collapse above burning coal seams and quenching. Sekaninaite-Fe-cordierite (XFe = 95-45) is associated with tridymite, fayalite, magnetite, ± clinoferrosilite and ±mullite in paralava and with tridymite and mullite in clinker. Unmelted grains of detrital quartz occur in both rocks (<3 vol% in paralavas and up to 30 vol% in some clinkers). Compositionally variable siliceous, K-rich peraluminous glass is <30% in paralavas and up to 85% in clinkers. The paralavas resulted from extensive fusion of sandstone-siltstone (clinker), and sideritic/Fe-hydroxide material contained within them, with the proportion of clastic sediments ≫ ferruginous component. Calculated dry liquidus temperatures of the paralavas are 1,120-1,050°C and 920-1,050°C for clinkers, with calculated viscosities at liquidus temperatures of 101.6-7.0 and 107.0-9.8 Pa s, respectively. Dry liquidus temperatures of glass compositions range between 920 and 1,120°C (paralava) and 920-960°C (clinker), and viscosities at these temperatures are 109.7-5.5 and 108.8-9.7 Pa s, respectively. Compared with worldwide occurrences of cordierite-sekaninaite in pyrometamorphic rocks, sekaninaite occurs in rocks with XFe (mol% FeO/(FeO + MgO)) > 0.8; sekaninaite and Fe-cordierite occur in rocks with XFe 0.6-0.8, and cordierite (XFe < 0.5) is restricted to rocks with XFe < 0.6. The crystal-chemical formula of an anhydrous sekaninaite based on the refined structure is | {{{K}}_{0.02} } |({{Fe}}_{1.54}^{2 + } {{Mg}}_{0.40} {{Mn}}_{0.06} )_{Upsigma 2.00}M [({{Al}}_{1.98} {{Fe}}_{0.02}^{2 + } {{Si}}_{1.00} )_{Upsigma 3.00}^{T1} ({{Si}}_{3.94} {{Al}}_{2.04} {{Fe}}_{0

  12. Feasible voltage-tap based quench detection in a Ag/Bi-2212 coil enabled by fast 3D normal zone propagation

    NASA Astrophysics Data System (ADS)

    Shen, Tengming; Ye, Liyang; Li, Pei

    2016-08-01

    Small insert solenoids have been built using a commercial Ag/Bi-2212 multifilamentary round wire, insulated with a new thin TiO2-polymer coating insulation (thickness of ˜20 μm versus ˜100 μm for a commonly used mullite braided sleeve insulation), and characterized in a background magnetic field up to 14 T at 4.2 K to explore the high-field performance and quench detection of Bi-2212 magnets. The coil has no visible leakage and no electrical shorts after reaction, and it carries 280 A mm-2 in a background field of 14 T and generates an additional 1.7 T. A notable result is that, despite normal zones propagating slowly along the conductor, the hot spot temperature upon detection increases only from 40 K to 60 K when the resistive quench detection voltage threshold increases from 0.1 V to 1 V for all operating current density investigated, showing that quench detection using voltage taps is feasible for this coil. This is in strong contrast to a coil we have previously built to the same specifications but from wires insulated with mullite braided sleeve insulation, for which the hot spot temperature upon detection increases from ˜80 K to ˜140 K while increasing the detection voltage threshold from 0.1 V to 1 V, and thus for which quench detection using voltage taps presents significant risks, consistent with the common belief that the effectiveness of quench detection using voltage taps for superconducting magnets built using high-temperature superconductors is seriously compromised by their slow normal zone propagation. This striking difference is ascribed to the fast transverse quench propagation enabled by thin insulation and the improved thermal coupling between conductor turns. This work demonstrates that quench detection for high-temperature superconducting magnets highly depends on the design and construction of the coils such as the insulation materials used and this dependence should be factored into the overall magnet design.

  13. Environmental Barrier Coatings for Ceramic Matrix Composites - An Overview

    NASA Technical Reports Server (NTRS)

    Lee, Kang; Zhu, Dongming; Wiesner, Valerie Lynn; van Roode, Mark; Kashyap, Tania; Zhu, Dongming; Wiesner, Valerie

    2016-01-01

    Ceramic Matrix Composites (CMCs) are increasingly being considered as structural materials for advanced power generation equipment. Broadly speaking the two classes of materials are oxide-based CMCs and non-oxide based CMCs. The non-oxide CMCs are primarily silicon-based. Under conditions prevalent in the gas turbine hot section the water vapor formed in the combustion of gaseous or liquid hydrocarbons reacts with the surface-SiO2 to form volatile products. Progressive surface recession of the SiC-SiC CMC component, strength loss as a result of wall thinning and chemical changes in the component occur, which leads to the loss of structural integrity and mechanical strength and becomes life limiting to the equipment in service. The solutions pursued to improve the life of SiC-SiC CMCs include the incorporation of an external barrier coating to provide surface protection to the CMC substrate. The coating system has become known as an Environmental Barrier Coating (EBC). The relevant early coatings work was focused on coatings for corrosion protection of silicon-based monolithic ceramics operating under severely corrosive conditions. The development of EBCs for gas turbine hot section components was built on the early work for silicon-based monolithics. The first generation EBC is a three-layer coating, which in its simplest configuration consists of a silicon (Si) base coat applied on top of the CMC, a barium-strontium-aluminosilicate (BSAS) surface coat resistant to water vapor attack, and a mullite-based intermediate coating layer between the Si base coat and BSAS top coat. This system can be represented as Si-Mullite-BSAS. While this baseline EBC presented a significant improvement over the uncoated SiC-SiC CMC, for the very long durations of 3-4 years or more expected for industrial operation further improvements in coating durability are desirable. Also, for very demanding applications with higher component temperatures but shorter service lives more rugged EBCs

  14. Feasible voltage-tap based quench detection in a Ag/Bi-2212 coil enabled by fast 3D normal zone propagation

    SciTech Connect

    Shen, Tengming; Ye, Liyang; Li, Pei

    2016-07-01

    For this study, small insert solenoids have been built using a commercial Ag/Bi-2212 multifilamentary round wire, insulated with a new thin TiO2– polymer coating insulation (thickness in ~20 μm versus ~100 μm for a commonly used mullite braided sleeve insulation), and characterized in background magnetic field up to 14 T at 4.2 K to explore the high-field performance and quench detection of Bi-2212 magnets. The coil has no visible leakage and no electrical shorts after reaction, and it carries 280 A/mm-2 in a background field 14 T and generates an additional 1.7 T. A notable result is that, despite normal zones propagate slowly along the conductor, the hot spot temperature upon detection increases only from 40 K to 60 K when the resistive quench detection voltage threshold increases from 0.1 V to 1 V for all operating current density investigated, showing that quench detection using voltage taps is feasible for this coil. This is in a strong contrast to a coil we previously built to the same specifications but from wires insulated with the mullite braided sleeve insulation, for which the hot spot temperature upon detection increases from ~80 K to ~140 K while increasing from the detection voltage threshold from 0.1 V to 1 V, and thus for which quench detection using voltage taps presents significant risks, consistent with the common belief that the effectiveness of quench detection using voltage taps for superconducting magnets built using high temperature superconductors is seriously compromised by their slow normal zone propagation. This striking difference is ascribed to the fast transverse quench propagation enabled by thin insulation and improved thermal coupling between conductor turns. Finally, this work demonstrates that quench detection for high-temperature superconducting magnets highly depends on the design and construction of the coils such as insulation materials used and this dependence should be factored into the overall

  15. Inspection of functionally graded coating materials using frequency domain photoacoustic microscopy

    NASA Astrophysics Data System (ADS)

    Steen, Thomas Lowell

    A frequency domain photoacoustic microscopy system has been developed for the inspection of functionally graded mullite coatings deposited on SiC substrates. Narrow-bandwidth surface acoustic waves (SAWs) are generated with an amplitude modulated laser source. A photorefractive crystal based interferometer coupled to a lock-in amplifier is used for the detection of the resulting surface displacements. The complex displacement field is mapped over a source-to-receiver distance of approximately 500mum in order to extract the wavelengths of SAWs at a given excitation frequency, from which the phase velocities are determined. SAW dispersion characteristics are sensitive to the elastic properties of the near surface region. The measured SAW dispersion is compared to a theoretical model in order to extract the elastic properties and thickness of the coatings. Frequency domain photoacoustic microscopy allows for the rapid, non-contact characterization of graded coatings and is potentially suitable for in-situ process control. The velocities of SAWs propagating in graded materials are found using the reflectance function technique combined with a transfer matrix approach. Theoretical results demonstrate that SAW dispersion in micron-scale functionally graded coatings over the 100-200 MHz frequency range is most sensitive to the mean elastic modulus of the coating and the coating thickness. In addition, the dispersion behavior is also influenced by the form of the elastic property variation through the coating thickness and can, in some cases, be used to determine the elastic property distribution. The photoacoustic microscopy technique was used to measure SAW dispersion on as-grown mullite coatings, and a simplex optimization algorithm was used to determine the mean elastic modulus and thickness through minimization of the error between measured and calculated SAW velocities. The results show agreement with independent measurements of the mean elastic modulus and thickness

  16. Simultaneous leaching and carbon sequestration in constrained aqueous solutions

    SciTech Connect

    Phelps, Tommy Joe; Moon, Ji Won; Roh, Yul; Cho, Kyu Seong

    2011-01-01

    The behavior of metal ions leaching and precipitated mineral phases of metal-rich fly ash (FA) was examined in order to evaluate microbial impacts on carbon sequestration and metal immobilization. The leaching solutions consisted of aerobic deionized water (DW) and artificial eutrophic water (AEW) that was anaerobic, organic- and mineral-rich, and higher salinity as is typical of bottom water in eutrophic algae ponds. The Fe- and Ca-rich FAs were predominantly composed of quartz, mullite, portlandite, calcite, hannebachite, maghemite, and hematite. After 86 days, only Fe and Ca contents exhibited a decrease in leaching solutions while other major and trace elements showed increasing or steady trends in preference to the type of FA and leaching solution. Ca-rich FA showed strong carbon sequestration efficiency ranging up to 32.3 g CO(2)/kg FA after 86 days, corresponding to almost 65% of biotic carbon sequestration potential under some conditions. Variations in the properties of FAs such as chemical compositions, mineral constituents as well as the type of leaching solution impacted CO(2) capture. Even though the relative amount of calcite increased sixfold in the AEW and the relative amount of mineral phase reached 37.3 wt% using Ca-rich FA for 86 days, chemical sequestration did not accomplish simultaneous precipitation and sequestration of several heavy metals.

  17. Simultaneous leaching and carbon sequestration in constrained aqueous solutions.

    PubMed

    Moon, Ji-Won; Cho, Kyu-Seong; Moberly, James G; Roh, Yul; Phelps, Tommy J

    2011-12-01

    The behavior of metal ions' leaching and precipitated mineral phases of metal-rich fly ash (FA) was examined in order to evaluate microbial impacts on carbon sequestration and metal immobilization. The leaching solutions consisted of aerobic deionized water (DW) and artificial eutrophic water (AEW) that was anaerobic, organic- and mineral-rich, and higher salinity as is typical of bottom water in eutrophic algae ponds. The Fe- and Ca-rich FAs were predominantly composed of quartz, mullite, portlandite, calcite, hannebachite, maghemite, and hematite. After 86 days, only Fe and Ca contents exhibited a decrease in leaching solutions while other major and trace elements showed increasing or steady trends in preference to the type of FA and leaching solution. Ca-rich FA showed strong carbon sequestration efficiency ranging up to 32.3 g CO(2)/kg FA after 86 days, corresponding to almost 65% of biotic carbon sequestration potential under some conditions. Variations in the properties of FAs such as chemical compositions, mineral constituents as well as the type of leaching solution impacted CO(2) capture. Even though the relative amount of calcite increased sixfold in the AEW and the relative amount of mineral phase reached 37.3 wt% using Ca-rich FA for 86 days, chemical sequestration did not accomplish simultaneous precipitation and sequestration of several heavy metals.

  18. Investigation of Sintering Temperature on Attrition Resistance of Highly Porous Diatomite Based Material

    SciTech Connect

    Garderen, Noemie van; Clemens, Frank J.; Scharf, Dagobert; Graule, Thomas

    2010-05-30

    Highly porous diatomite based granulates with a diameter of 500 mum have been produced by an extrusion method. In order to investigate the relation between microstructure, phase composition and attrition resistance of the final product, the granulates were sintered between 800 and 1300 deg. C. Mean pore size of the granulates was evaluated by Hg-porosimetry. An increase of the pore size is observed in the range of 3.6 nm to 40 mum with increasing sintering temperature. Higher mean pore radii of 1.6 mum and 5.7 mum obtained by sintering at 800 and 1300 deg. C respectively. X-ray diffraction shows that mullite phase appears at 1100 deg. C due to the presence of clay. At 1100 deg. C diatomite (amorphous silicate) started to transform into alpha-cristobalite. Attrition resistance was determined by evaluating the amount of ground material passed through a sieve with a predefined mesh size. It was observed that a material sintered at high temperature leads to an increase of attrition resistance due to the decrease of total porosities and phase transformation. Due to the reason that attrition resistance significantly increased by sintering the granulates at higher temperature, a so called attrition resistance index was determined in order to compare all the different attrition resistance values. This attrition resistance index was determined by using the exponential component of the equation obtained from attrition resistance curves. It permits comparison of the attrition behaviour without a time influence.

  19. Tension-Compression Fatigue of a Nextel™720/alumina Composite at 1200 °C in Air and in Steam

    NASA Astrophysics Data System (ADS)

    Lanser, R. L.; Ruggles-Wrenn, M. B.

    2016-08-01

    Tension-compression fatigue behavior of an oxide-oxide ceramic-matrix composite was investigated at 1200 °C in air and in steam. The composite is comprised of an alumina matrix reinforced with Nextel™720 alumina-mullite fibers woven in an eight harness satin weave (8HSW). The composite has no interface between the fiber and matrix, and relies on the porous matrix for flaw tolerance. Tension-compression fatigue behavior was studied for cyclical stresses ranging from 60 to 120 MPa at a frequency of 1.0 Hz. The R ratio (minimum stress to maximum stress) was -1.0. Fatigue run-out was defined as 105 cycles and was achieved at 80 MPa in air and at 70 MPa in steam. Steam reduced cyclic lives by an order of magnitude. Specimens that achieved fatigue run-out were subjected to tensile tests to failure to characterize the retained tensile properties. Specimens subjected to prior cyclic loading in air retained 100 % of their tensile strength. The steam environment severely degraded tensile properties. Tension-compression cyclic loading was considerably more damaging than tension-tension cyclic loading. Composite microstructure, as well as damage and failure mechanisms were investigated.

  20. Improving heat transfer with pool boiling by covering of heating surface with metallic spheres

    SciTech Connect

    Matijevic, M.; Djuric, M.; Zavargo, Z.; Novakovic, M. )

    1992-01-01

    In this paper, boiling heat transfer (BHT) is investigated experimentally. Smooth copper walls were covered with single sphere layer and corresponding temperature difference and heat flux were measured. The results were compared with published data for several types of heating surfaces. Comparative analysis shows that surfaces covered with spheres have characteristics as good as the other systems, if not better. There are many ways to enhance boiling heat transfer. One of them is to cover the heating surface with a layer of solid particles, which either remain on the surface during the process or circulate through the boiling liquid, generating a porous two-component, three-phase system. Particles are made of various materials (glass, alumosilicate, corundum, sand, mullite some metals, etc.), which are shaped as spheres mostly, but sometimes are irregular bodies. Many different parameters were proposed to characterize the porous layer. The influence of particles can be expressed by introducing the effective thermal-physical properties of a complex medium. Also, if the working regime can be described as any kind of fluidization, then all quantities developed to be applied to this matter can be used in the case of heat fluidization.

  1. Environmental Barrier Coatings for Ceramics and Ceramic Composites

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Fox, Dennis; Eldridge, Jeffrey; Robinson, R. Craig; Bansal, Narottam

    2004-01-01

    One key factor that limits the performance of current gas turbine engines is the temperature capability of hot section structural components. Silicon-based ceramics, such as SiC/SiC composites and monolithic Si3N4, are leading candidates to replace superalloy hot section components in the next generation gas turbine engines due to their excellent high temperature properties. A major stumbling block to realizing Si-based ceramic hot section components is the recession of Si-based ceramics in combustion environments due to the volatilization of silica scale by water vapor. An external environmental barrier coating (EBC) is the most promising approach to preventing the recession. Current EBCs are based on silicon, mullite (3A12O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit the durability and temperature capability of current EBCs. Research is underway to develop EBCs with longer life and enhanced temperature capability. Understanding key issues affecting the performance of current EBCs is necessary for successful development of advanced EBCs. These issues include stress, chemical compatibility, adherence, and water vapor stability. Factors that affect stress are thermal expansion mismatch, phase stability, chemical stability, elastic modulus, etc. The current understanding on these issues will be discussed.

  2. Interfacial studies of chemical vapor infiltrated (CVI) ceramic-matrix composites. Annual report, 1 August 1987-31 July 1988

    SciTech Connect

    Brennan, J.J.

    1988-10-01

    The objective of this program is to investigate the fiber/matrix interfacial chemistry in Chemical Vapor Infiltrated Silicon Carbide matrix composites utilizing Nicalon SiC and Nextel 440 mullite fibers and how this interface influences composite properties such as strength, toughness, and environmental stability. The SiC matrix was deposited using three different reactants; methyldichlorosilane (MDS), methyltrichlorosilane (MTS), and dimethyldichlorosilane (DMDS). It was found that by varying the reactant gas flow rates, the ratio of carrier gas to reactant gas, the type of carrier gas (hydrogen or argon), the flushing gas used in the reactor prior to deposition (hydrogen or argon), or the type of silane reactant gas used, the composition of the deposited SiC could be varied from very silicon rich (75 at %) to carbon rich (60%) to almost pure carbon. Stoichiometric SiC was found to bond very strongly to both Nicalon and Nextel fibers, resulting in a weak and brittle composite. A thin carbon interfacial layer deposited either deliberately by the decomposition of methane or inadvertently by the introduction of argon into the reactor prior to silane flow, resulted in a weakly bonded fiber/matrix interface and strong and tough composites. However, composites with this type of interface were not oxidatively stable. Preliminary results point to the use of a carbon-rich SiC interfacial zone to achieve a relatively weak, crack-deflecting fiber/matrix bond but also exhibiting oxidative stability.

  3. Interfacial studies of chemical-vapor-infiltrated (CVI) ceramic matrix composites. Final report

    SciTech Connect

    Brennan, J.J.

    1990-03-31

    The objective of this program was to investigate the fiber/matrix interfacial chemistry in CVI SiC matrix composites utilizing Nicalon SiC and Nextel 440 mullite fibers and to determine how this interface influences composite properties such as strength, toughness, and environmental stability. The SiC matrix was deposited using three different reactants; methyldichlorosilane (MDS), methyltrichlorosilane (MTS), and dimethyldichlorosilane (DMDS). The fiber/matrix interface was tailored by means of introducing a carbon, BN, or carbon rich SiC interfacial layer. It was found that applying a carbon interfacial layer to either NICALON or Nextel 440 fibers prior to deposition of SiC resulted in a weakly bonded interface that imparted toughness to CVI matrix composite through its ability to deflect matrix cracks. This carbon layer can be applied either deliberately by the decomposition of methane or by utilizing an argon flushing gas in the reactor that apparently interrupted the normal deposition of SiC from silane precursors and instead allowed carbon to deposit. It was found that this carbon interfacial layer, no matter how it was deposited, was not oxidatively stable at elevated temperatures, leading to severe degradation of composite properties.

  4. Continuous coating of silicon-on-ceramic

    NASA Technical Reports Server (NTRS)

    Heaps, J. D.; Schuldt, S. B.; Grung, B. L.; Zook, J. D.; Butter, C. D.

    1980-01-01

    Growth of sheet silicon on low-cost substrates has been demonstrated by the silicon coating with inverted meniscus (SCIM) technique. A mullite-based ceramic substrate is coated with carbon and then passed over a trough of molten silicon with a raised meniscus. Solidification occurs at the trailing edge of the downstream meniscus, producing a silicon-on-ceramic (SOC) layer. Meniscus shape and stability are controlled by varying the level of molten silicon in a reservoir connected to the trough. The thermal conditions for growth and the crystallographic texture of the SOC layers are similar to those produced by dip-coating, the original technique of meniscus-controlled growth. The thermal conditions for growth have been analyzed in some detail. The analysis correctly predicts the velocity-thickness relationship and the liquid-solid interface shape for dip-coating, and appears to be equally applicable to SCIM-coating. Solar cells made from dip-coated SOC material have demonstrated efficiencies of 10% on 4-sq cm cells and 9.9% on 10-sq cm cells.

  5. Cyclic Failure Mechanisms of Thermal and Environmental Barrier Coating Systems Under Thermal Gradient Test Conditions

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

    2002-01-01

    Plasma-sprayed ZrO2-8wt%Y2O3 and mullite+BSAS/Si multilayer thermal and environmental barrier coating (TBC-EBC) systems on SiC/SiC ceramic matrix composite (CMC) substrates were thermally cyclic tested under high thermal gradients using a laser high-heat-flux rig in conjunction with furnace exposure in water-vapor environments. Coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after exposure. Sintering kinetics of the coating systems were also independently characterized using a dilatometer. It was found that the coating failure involved both the time-temperature dependent sintering and the cycle frequency dependent cyclic fatigue processes. The water vapor environments not only facilitated the initial coating conductivity increases due to enhanced sintering and interface reaction, but also promoted later conductivity reductions due to the accelerated coating cracking and delamination. The failure mechanisms of the coating systems are also discussed based on the cyclic test results and are correlated to the sintering and thermal stress behavior under the thermal gradient test conditions.

  6. Characterization of solid airborne particles deposited in snow in the vicinity of urban fossil fuel thermal power plant (Western Siberia).

    PubMed

    Talovskaya, A V; Yazikov, E G; Filimonenko, E A; Lata, J-C; Kim, J; Shakhova, T S

    2017-07-20

    Recognition and detailed characterization of solid particles emitted from thermal power plants into the environment is highly important due to their potential detrimental effects on human health. Snow cover is used for the identification of anthropogenic emissions in the environment. However, little is known about types, physical and chemical properties of solid airborne particles (SAP) deposited in snow around thermal power plants. The purpose of this study is to quantify and characterize in detail the traceable SAP deposited in snow near fossil fuel thermal power plant in order to identify its emissions into the environment. Applying the scanning electron microscopy-energy dispersive spectroscopy, and X-ray diffraction, mineral and anthropogenic phase groups in SAP deposited in snow near the plant and in fly ash were observed. We identified quartz, albite and mullite as most abundant mineral phases and carbonaceous matter, slag and spherical particles as dominate anthropogenic phases. This is the first study reporting that zircon and anthropogenic sulphide-bearing, metal oxide-bearing, intermetallic compound-bearing and rare-earth element-bearing particles were detected in snow deposits near thermal power plant. The identified mineral and anthropogenic phases can be used as tracers for fossil fuel combustion emissions, especially with regard to their possible effect on human health.

  7. Crack-resistant Al2O3–SiO2 glasses

    PubMed Central

    Rosales-Sosa, Gustavo A.; Masuno, Atsunobu; Higo, Yuji; Inoue, Hiroyuki

    2016-01-01

    Obtaining “hard” and “crack-resistant” glasses have always been of great important in glass science and glass technology. However, in most commercial glasses both properties are not compatible. In this work, colorless and transparent xAl2O3–(100–x)SiO2 glasses (30 ≤ x ≤ 60) were fabricated by the aerodynamic levitation technique. The elastic moduli and Vickers hardness monotonically increased with an increase in the atomic packing density as the Al2O3 content increased. Although a higher atomic packing density generally enhances crack formation in conventional oxide glasses, the indentation cracking resistance increased by approximately seven times with an increase in atomic packing density in binary Al2O3–SiO2 glasses. In particular, the composition of 60Al2O3•40SiO2 glass, which is identical to that of mullite, has extraordinary high cracking resistance with high elastic moduli and Vickers hardness. The results indicate that there exist aluminosilicate compositions that can produce hard and damage-tolerant glasses. PMID:27053006

  8. Crack Driving Forces in a Multilayered Coating System for Ceramic Matrix Composite Substrates

    NASA Technical Reports Server (NTRS)

    Ghosn, Louis J.; Zhu, Dongming; Miller, Robert A.

    2005-01-01

    The effects of the top coating thickness, modulus and shrinkage strains on the crack driving forces for a baseline multilayer Yttria-Stabilized-Zirconia/Mullite/Si thermal and environment barrier coating (TEBC) system for SiC/SiC ceramic matrix composite substrates are determined for gas turbine applications. The crack driving forces increase with increasing modulus, and a low modulus thermal barrier coating material (below 10 GPa) will have no cracking issues under the thermal gradient condition analyzed. Since top coating sintering increases the crack driving forces with time, highly sintering resistant coatings are desirable to maintain a low tensile modulus and maintain a low crack driving force with time. Finite element results demonstrated that an advanced TEBC system, such as ZrO2/HfO2, which possesses improved sintering resistance and high temperature stability, exhibited excellent durability. A multi-vertical cracked structure with fine columnar spacing is an ideal strain tolerant coating capable of reducing the crack driving forces to an acceptable level even with a high modulus of 50 GPa.

  9. Thermodynamic effects of calcium and iron oxides on crystal phase formation in synthetic gasifier slags containing from 0 to 27wt.% V2O3

    DOE PAGES

    Nakano, Jinichiro; Duchesne, Marc; Bennett, James; ...

    2014-11-15

    Thermodynamic phase equilibria in synthetic slags (Al2O3–CaO–FeO–SiO2–V2O3) were investigated with 0–27 wt.% vanadium oxide corresponding to industrial coal–petroleum coke (petcoke) feedstock blends in a simulated gasifier environment. Samples encompassing coal–petcoke mixed slag compositions were equilibrated at 1500 °C in a 64 vol.% CO/36 vol.% CO2 atmosphere (Po2 ≈ 10–8 atm at 1500 °C) for 72 h, followed by rapid water quench, then analyzed by inductively coupled plasma optical emission spectrometry, X-ray diffractometry, and scanning electron microscopy with wavelength dispersive spectroscopy. With increasing CaO content, FeO content, or both; the slag homogeneity region expanded and a composition range exhibiting crystals wasmore » reduced. The mullite (Al6Si2O13) crystalline phase was not present in the slags above 9 wt.% FeO while the karelianite (V2O3) crystalline phase was always present in compositions studied if a sufficient amount of vanadium existed in the slag. Furthermore, based on the present experimental equilibrium evaluation, a set of isothermal phase diagrams showing effects of CaO and FeO on thermodynamic phase stabilities in the vanadium-bearing slags is proposed. Some uses of the diagrams for potential industrial practice are discussed.« less

  10. Sliding durability of candidate seal fiber materials in hydrogen from 25 to 900 C

    NASA Technical Reports Server (NTRS)

    Dellacorte, Christopher; Steinetz, Bruce M.

    1992-01-01

    Sliding durability studies of candidate ceramic fibers were conducted in hydrogen to support the high temperature seal development program at NASA LeRC. Pin-on-disk tests were used to measure the friction and durability of a tow or bundle of ceramic fibers in sliding against a superalloy disk. This procedure was used previously to test candidate fibers in an air environment. The fibers based upon mullite (Al2O3-SiO2) chemistry (Nextel 550, 440, and 312) exhibited better durability in hydrogen than in air. HPZ, a complex silicon carboxynitride fiber which showed good durabilty in air, however, showed a significant loss of durability in hot hydrogen. These results are consistent with recent thermodynamic and experimental studies of ceramic compatibility with hydrogen at elevated temperatures. These research results indicate that only oxide fibers display good durability in both air and hydrogen environments. Also, simple, low cost testing in air can provide an adequate data base for initial seal material screening and selection, especially for oxide fiber candidates. The findings of this research provide critical input to the seal design team.

  11. Tribological Study on Plasma Electrolytic Oxidation Treatment in Al-Si Alloys for Engine Application

    NASA Astrophysics Data System (ADS)

    Eiliat, Hoda

    Automotive industry strives to reach an optimum level of fuel economy. This can be achieved by overcoming two impacting factors on fuel consumption: weight and friction force. This research contributes to reduce both. The proposed surface treatment can replace cylinder liners of hypoeutectic aluminum silicon alloy engine blocks with a thin layer of ceramic oxide composed of alpha and gamma phases of Al2O3 and mullite. The coatings are achieved in an aqueous electrolytic bath with current densities of 0.1 to 0.2 A/cm2. Coatings produced in silicate based solutions have shown good adaptability to the counter surface with an average 0.12 coefficient of friction. Coatings produced in phosphate and aluminate solution have shown signs of delamination, and excessive porosity and roughness respectively. Coatings produced under Bipolar Pulsed Direct Current mode has up to 12% higher hardness values compared to unipolar coatings. For each increment of 0.2 A/cm2 current density, there is a 30% of increase in coating growth rate. Higher pH values of the solution creates faster growth rate up to 1.5 mu/min. These coatings are 20% more susceptible to wear. Samples treated in MoS2 solution showed 22% lower average roughness values and 37% of reduction in coefficient of friction. Mild wear scars on the piston rings were detected for the optimized coatings.

  12. Hot corrosion of ceramic engine materials

    NASA Technical Reports Server (NTRS)

    Fox, Dennis S.; Jacobson, Nathan S.; Smialek, James L.

    1988-01-01

    A number of commercially available SiC and Si3N4 materials were exposed to 1000 C in a high velocity, pressurized burner rig as a simulation of a turbine engine environment. Sodium impurities added to the burner flame resulted in molten Na2SO4 deposition, attack of the SiC and Si4N4 and formation of substantial Na2O-x(SiO2) corrosion product. Room temperature strength of the materials decreased. This was a result of the formation of corrosion pits in SiC, and grain boundary dissolution and pitting in Si3N4. Corrosion regimes for such Si-based ceramics have been predicted using thermodynamics and verified in rig tests of SiO2 coupons. Protective mullite coatings are being investigated as a solution to the corrosion problem for SiC and Si3N4. Limited corrosion occurred to cordierite (Mg2Al4Si5O18) but some cracking of the substrate occurred.

  13. Development of thin film thermocouples on ceramic materials for advanced propulsion system applications

    NASA Technical Reports Server (NTRS)

    Holanda, Raymond

    1993-01-01

    Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

  14. Joining NZP ceramics. Final report

    SciTech Connect

    Nicklas, K.D.; Richey, M.W.; Holcombe, C.E. Jr.; Santella, M.L.

    1995-09-26

    Objective was to assess techniques for joining NZP ceramics, a new family of ceramic materials that have low coefficient of thermal expansion, low thermal conductivity, and excellent thermal-shock resistance. Initially, the authors evaluated laser-beam welding over volatile fluxing agents (ferric oxide, copper oxide, boric acid, and boron nitride). They also examined other laser, arc-welding, brazing, and cold joining techniques. The NZP materials were capable of sustaining the thermal stresses associated with these joining processes without substantial cracking. Of the volatile fluxes, only the copper oxide promoted weld fusion. Efforts to accomplish fusion by laser-beam welding over copper, titanium, stainless steel, yttrium barium copper oxide, fused silica glass, and mullite/alumina were unsuccessful. Gas-tungsten arc welding accompanied by porosity, irregularities, and cracking was achieved on copper sheet sandwiched between NZP tiles. Attempts at conventional oxy-acetylene welding and torch brazing were unproductive. Silica-based oxide mixtures and copper oxide-based materials show potential for development into filler materials for furnace brazing, and phosphate-based cements show promise as a means of cold joining.

  15. Recycling and utilisation of industrial solid waste: an explorative study on gold deposit tailings of ductile shear zone type in China.

    PubMed

    Liu, Rui; Huang, Fei; Du, Runxiang; Zhao, Chunming; Li, Yongli; Yu, Haoran

    2015-06-01

    Tailings are solid waste arising from mineral processing. This type of waste can cause severe damage to the environment during stockpiling as a result of the leaching of something harmful into the ecosystem. Gold deposit of ductile shear zone type is an important type of gold deposit, and the recycling of its tailings has been challenging researchers for a long time. In this article, the characteristics of this type of tailings were systematically studied by using modern technical means. Considering the characteristics of the tailings, clay was selected to make up for the shortcomings of the tailings and improve their performance. Water and raw materials were mixed to produce green bodies, which are subsequently sintered into ceramic bodies at 980 °C~1020 °C (sintering temperature). The results showed that some new kinds of mineral phases, such as mullite, anorthite and orthoclase, appear in ceramic bodies. Furthermore, the ceramic bodies have a surface hardness of 5 to 6 (Mohs scale), and their water absorption and modulus of rupture can meet some technical requirements of ceramic materials described in ISO 13006-2012 and GB 5001-1985. These gold mine tailings can be made into ceramic tiles, domestic ceramic bodies, and other kinds of ceramic bodies for commercial and industrial purposes after further improvements. © The Author(s) 2015.

  16. Development of low-cost amine-enriched solid sorbent for CO2 capture.

    PubMed

    Bachelor, Thuy Thi Nguyen; Toochinda, Pisanu

    2012-12-01

    CO2 capture amine-enriched solid sorbent using agricultural wastes, such as bagasse, or industrial wastes, such as mullite, as support materials could provide efficient alternative CO2 reduction due to their low cost and ability to shape into many forms. These amine-enriched solid sorbents were prepared by treatment with monoethanolamine (MEA), diethanolamine, piperazine (PZ), 2-(2-aminoethyl-amino) ethanol (AEEA) and mixtures of these amines. The performance of amine-enriched solid sorbents with various amine compositions was studied in a tubular column at 1 atm and an adsorption temperature of 303 K. The CO2 capture capacities of the amine-enriched solid sorbents were determined by gas chromatography at a desorption temperature of 393 K. Amine-enriched solid sorbents in this study exhibited high performance CO2 capture. The MEA-PZ-enriched solid sorbent does have the highest CO2 capture performance of the amine-enriched bagasse support-based sorbents, and the results indicate that PZ is the most effective promoter in this study. The CO2 capture performances of solid sorbents in this study were compared with commercial solid sorbents. This study could lead to the development of low-cost solid sorbents for CO2 capture that can be used in many industrial applications.

  17. Fly ash from a Mexican mineral coal. II. Source of W zeolite and its effectiveness in arsenic (V) adsorption.

    PubMed

    Medina, Adriana; Gamero, Prócoro; Almanza, José Manuel; Vargas, Alfredo; Montoya, Ascención; Vargas, Gregorio; Izquierdo, María

    2010-09-15

    Coal-fired plants in Coahuila (Mexico) produce highly reactive fly ash (MFA), which is used in a one-step process as a raw material in producing zeolite. We explored two routes in the synthesis of zeolite: (a) direct MFA zeolitization, which resulted in the formation of W zeolite with KOH and analcime with NaOH and (b) a MFA fusion route, which resulted in the formation of zeolite W or chabazite with KOH and zeolite X or P with NaOH. No residual crystalline phases were present. When LiOH was employed, ABW zeolite with quartz and mullite were obtained. For both zeolitization routes, the nature of the alkali (KOH, NaOH, LiOH), the alkali/MFA ratio (0.23-1.46), and the crystallization temperature and time (90-175 degrees C; 8-24 h) were evaluated. Additionally, the effect of temperature and time on MFA fusion was studied. W zeolite was obtained by both zeolitization methods. The direct route is preferred because it is a straightforward method using soft reaction conditions that results in a high yield of low cost zeolites with large crystal agglomerates. It was demonstrated that aluminum modified W zeolite has the ability to remove 99% of the arsenic (V) from an aqueous solution of Na(2)HAsO(4).7H(2)O originally containing 740 ppb. Copyright 2010 Elsevier B.V. All rights reserved.

  18. The Effect of Thermal and Mechanical Treatments on Kaolinite: Characterization by XPS and IEP Measurements.

    PubMed

    Torres Sánchez RM; Basaldella; Marco

    1999-07-15

    The surface transformations induced on kaolinite by different thermal and mechanical treatments have been investigated by means of X-ray photoelectron spectroscopy (XPS), Bremsstrahlung induced Auger spectroscopy, and isoelectric point (IEP) measurements. Heating the kaolinite at temperatures between 500 and 750 degrees C results in the change of a substantial fraction of surface Al from octahedral to tetrahedral coordination, which we associate with the dehydroxylation of kaolinite. Heating at 900 and 980 degrees C brings about the development of an octahedral Al fraction which is associated with the formation of gamma-Al(2)O(3). The development of an Al tetrahedral component in the Al KLL spectra of the mechanically treated (ground) samples has been also observed. The Si/Al atomic ratio obtained by XPS in the thermally treated samples is the same as that shown by the original kaolinite. However, the XPS data show a clear reduction of the Si/Al atomic ratio in the mechanically treated samples, which suggests that the mechanical treatment has induced an Al enrichment of the kaolinite surface. The IEP values indicated a thermal transformation to metakaolinite and mullite with the increase of temperature (750 to 980 degrees C). The IEP change for the milled samples can be only explained by assuming a 30% kaolinite coating by the Al oxide neoformed by grinding. Copyright 1999 Academic Press.

  19. Plasma synthesis of high temperature ceramic films

    SciTech Connect

    Brown, I.G.; Monteiro, O.R.

    1998-11-01

    Thin films of alumina, chromia, mullite, yttria and zirconia have been synthesized using a plasma-based method called metal plasma immersion ion implantation and deposition (Mepiiid)--a highly versatile plasma deposition technique with ion energy control. Monolithic films (a single ceramic component) and multilayer films (individual layers of different ceramic materials) were formed. The films were characterized for their composition and structure in a number of different ways, and the high temperature performance of the films was explored, particularly for their ability to maintain their integrity and adhesion when subjected to repetitive high temperature thermal cycling up 1100 C. We found that the films retain their adhesion and quality without any apparent degradation with time, even after a large number of cycles; (the tests were extended out to a total of 40 cycles each of 24 hours duration). After repetitive high temperature thermal cycling, the film-substrate adhesion was greater than {approx}70 Mpa, the instrumental limit of measurement, and the interface toughness was approximately 0.8 MPa m{sup 1/2}.

  20. Incorporation of zinc for fabrication of low-cost spinel-based composite ceramic membrane support to achieve its stabilization.

    PubMed

    Li, Lingling; Dong, Xinfa; Dong, Yingchao; Zhu, Li; You, Sheng-Jie; Wang, Ya-Fen

    2015-04-28

    In order to reduce environment risk of zinc, a spinel-based porous membrane support was prepared by the high-temperature reaction of zinc and bauxite mineral. The phase evolution process, shrinkage, porosity, mechanical property, pore size distribution, gas permeation flux and microstructure were systematically studied. The XRD results, based on a Zn/Al stoichiometric composition of 1/2, show a formation of ZnAl2O4 structure starting from 1000°C and then accomplished at 1300°C. For spinel-based composite membrane, shrinkage and porosity are mainly influenced by a combination of an expansion induced by ZnAl2O4 formation and a general densification due to amorphous liquid SiO2. The highest porosity, as high as 44%, is observed in ZnAl4 membrane support among all the investigated compositions. Compared with pure bauxite (Al), ZnAl4 composite membrane support is reinforced by ZnAl2O4 phase and inter-locked mullite crystals, which is proved by the empirical strength-porosity relationships. Also, an increase in average pore diameter and gas flux can be observed in ZnAl4. A prolonged leaching experiment reveals the zinc can be successfully incorporated into ceramic membrane support via formation of ZnAl2O4, which has substantially better resistance toward acidic attack.

  1. Filter Component Assessment

    SciTech Connect

    Alvin, M.A.; Lippert, T.E.; Diaz, E.S.; Smeltzer, E.E.

    1996-12-31

    Advanced particulate filtration systems are currently being developed at Westinghouse for use in both coal-fired Integrated Gasification Combined Cycle (IGCC) and Pressurized Fluidized Bed Combustion (PFBC) systems. To date, Westinghouse has demonstrated 5855 hours of successful operation of first generation monolithic filter elements in PFBC applications when ash bridging or process thermal transient excursions are avoided. Alternate advanced monolithic and second generation fiber reinforced, filament wound and vacuum infiltrated filters are also being developed which are considered to have enhanced high temperature creep resistance, improved fracture toughness, or enhanced thermal shock characteristics, respectively. Mechanical and component fabrication improvements, as well as degradation mechanisms for each filter element have been identified by Westinghouse during exposure to simulated PFBC operating conditions and alkali-containing steam/air environments. Additional effort is currently being focused on determining the stability of the advanced monolithic high temperature creep resistant clay bonded silicon carbide (SiC) materials, alumina/mullite, and chemically vapor infiltrated (CVI) SiC materials during operation in the Westinghouse Advanced Particulate Filtration (W-APF) system at Foster Wheeler`s pressurized circulating fluidized-bed combustion (PCFBC) test facility in Karhula, Finland. Select advanced filter materials are being defined for additional long-term exposure in integrated gasification combined cycle (IGCC) gas streams. The results of these efforts are summarized in this paper. 6 refs., 7 figs., 11 tabs.

  2. Stability of polycrystalline Nextel 720 fiber

    SciTech Connect

    Das, G.

    1996-12-31

    The microstructure and tensile properties of polycrystalline Nextel 720 fiber (85 wt.% Al{sub 2}O{sub 3} - 15 wt-% SiO{sub 2}), both crystallized and precrystallized, were evaluated following prolonged thermal exposure at 982{degrees}C in air. The room temperature tensile strengths of Nextel 720 fibers did not appear to suffer degradation for exposures up to 3000 h and the microstructure remained unaffected by thermal exposures. The tensile strength of precrystallized Nextel 720 fiber was also determined at room temperature following heat treatments at 1093-1427{degrees}C in air. The precrystallized Nextel 720 fiber started to show a slight loss of strength after heat treatment at 1093{degrees}C/4 h and the strength deterioration was exacerbated for heat treatments at 1204{degrees}C/4 h and above. Microstructural characterization by x-ray and transmission electron microscopy (TEM) revealed the formation of mullite in heat treated precrystallized Nextel 720 fiber at 1204{degrees}C and a coarsening of microstructure above 1204{degrees}C. The degradation of strength in precrystallized Nextel 720 fiber heat treated at 1204{degrees}C/4 h and above may be attributed to phase instability and grain coarsening. Fractographs showed that fracture originated predominantly at the fiber surface.

  3. Preparation of Functionally Graded Materials (FGMs) Using Coal Fly Ash and NiCr-Based Alloy Powder by Spark Plasma Sintering (SPS)

    SciTech Connect

    Kaneko, Gen-yo; Kitagawa, Hiroyuki; Hasezaki, Kazuhiro; Ito, Yuji; Kakuda, Hideaki

    2008-02-15

    Functionally Graded Materials (FGMs) were prepared by spark plasma sintering (SPS) using coal fly ash and NiCr alloy powder. The coal fly ash was produced by the Misumi Coal Thermal Power Station (Chugoku Electric Power Co., Inc.), with 80 wt% nickel and 20 wt% chromium (Fukuda Metal Foil and Powder Co., Ltd.) used as source materials. The sintering temperature in the graphite die was 1000 deg. C. X-ray diffraction patterns of the sintered coal fly ash materials indicated that mullite (3Al{sub 2}O{sub 3}{center_dot}2SiO{sub 2}) and silica (SiO{sub 2}) phases were predominant. Direct joining of coal fly ash and NiCr causes fracture at the interface. This is due to the mismatch in the thermal expansion coefficients (CTE). A crack in the FGM was observed between the two layers with a CTE difference of over 4.86x10{sup -6} K{sup -1}, while a crack in the FGM was difficult to detect when the CTE difference was less than 2.77x10{sup -6} K{sup -1}.

  4. Heated blends of phosphate waste: Microstructure characterization, effects of processing factors and use as a phosphorus source for alfalfa growth.

    PubMed

    Loutou, M; Hajjaji, M; Mansori, M; Favotto, C; Hakkou, R

    2016-07-15

    Microstructure of expandable lightweight aggregates (LWAs), which was composed of phosphate waste (PW), cement kiln dust (CKD) and raw clay (RC) was investigated, and the effects of processing factors (temperature, waste content, soaking time) on their physical properties were quantified by using response surface methodology (RSM). The potential use of LWAs as a phosphorus source was assessed through the use of seeds of alfalfa. It was found that the main minerals of the waste, namely carbonates and fluorapatite, were involved in the formation of labradorite/anorthite and melt respectively. Stability of mullite- the main constituent of CKD- was sensitive to the melt content. The assemblage of the identified phases was discussed based on the CaO-SiO2-Al2O3 phase diagram. The results of RSM showed that the change of compressive strength, firing shrinkage and water absorption of LWAs versus processing factors was well described with a polynomial model and the weights of the effects of the factors increased in the following order: sintering temperature > waste content (in the case of PW-RC) > soaking time. On the other hand, it was found that due to the release of phosphorus by soil-embedded pellets, the growth of alfalfa plants improved, and the rate enhanced in this order: PW-RC > PW-CKD > PW-CKD-RC. The absorbed quantity of phosphorus (0.12%) was still lower than the common uptake amount.

  5. Elevated-temperature fracture resistances of monolithic and composite ceramics using chevron-notched bend tests

    NASA Technical Reports Server (NTRS)

    Ghosh, Asish; Jenkins, Michael G.; Ferber, Mattison K.; Peussa, Jouko; Salem, Jonathan A.

    1992-01-01

    The quasi-static fracture behaviors of monolithic ceramics (SiC, Si3N4, MgAl2O4), self-reinforced monoliths (acicular grained Si3N4, acicular grained mullite), and ceramic matrix composites (SiC whisker/Al2O3 matrix, TiB2 particulate/SiC matrix, SiC fiber/CVI SiC matrix, Al2O3 fiber/CVI SiC matrix) were measured over the temperature range of 20 to 1400 C. The chevron notched, bend bar test geometry was essential for characterizing the elevated temperature fracture resistances of this wide range of quasi-brittle materials during stable crack growth. Fractography revealed the differences in the fracture behavior of the different materials at the various temperatures. The fracture resistances of the self-reinforced monoliths were comparable to those of the composites and the fracture mechanisms were found to be similar at room temperature. However at elevated temperatures the differences of the fracture behavior became apparent where the superior fracture resistance of the self-reinforced monoliths were attributed to the minor amounts of glassy, intergranular phases which were often more abundant in the composites and affected the fracture behavior when softened by elevated temperatures.

  6. Current Issues with Environmental Barrier Coatings for Ceramics and Ceramic Composites

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.

    2004-01-01

    The environmental barrier coating (EBC) for SiC/SiC ceramic matrix composites and Si3N4 ceramics is an emerging field as the application of silicon-based ceramics in the gas turbine engine hot section is on the horizon, both for aero and industrial gas turbines. EBC is an enabling technology for silicon-based ceramics because these materials without an EBC cannot be used in combustion environments due to rapid surface recession. Significant progress in EBC development has been made during the last decade through various government-sponsored programs. Current EBCs are based on silicon, mullite (3Al2O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit temperature capability of current EBCs to about 1350 C for long-term applications. There is a need for higher temperature EBCs as the temperature capability of silicon-based ceramics continue to increase. Therefore, research is underway to develop EBCs with improved temperature capability compared to current EBCs. The current status and issues with the advanced EBC development efforts will be discussed.

  7. Durability and Design Issues of Thermal/environmental Barrier Coatings on Sic/sic Ceramic Matrix Composites Under 1650 C Test Conditions

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Choi, Sung R.; Ghosn, Louis J.; Miller, Robert A.

    2004-01-01

    Ceramic thermal/environmental barrier coatings for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability remains a major concern with the ever-increasing temperature requirements. Currently, advanced T/EBC systems, which typically include a high temperature capable zirconia- (or hahia-) based oxide top coat (thermal barrier) on a less temperature capable mullite/barium-strontium-aluminosilicate (BSAS)/Si inner coat (environmental barrier), are being developed and tested for higher temperature capability Sic combustor applications. In this paper, durability of several thermal/environmental barrier coating systems on SiC/SiC ceramic matrix composites was investigated under laser simulated engine thermal gradient cyclic, and 1650 C (3000 F) test conditions. The coating cracking and delamination processes were monitored and evaluated. The effects of temperature gradients and coating configurations on the ceramic coating crack initiation and propagation were analyzed using finite element analysis (FEA) models based on the observed failure mechanisms, in conjunction with mechanical testing results. The environmental effects on the coating durability will be discussed. The coating design approach will also be presented.

  8. Environmental Barrier Coatings for Ceramics and Ceramic Composites

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Fox, Dennis; Eldridge, Jeffrey; Robinson, R. Craig; Bansal, Narottam

    2004-01-01

    One key factor that limits the performance of current gas turbine engines is the temperature capability of hot section structural components. Silicon-based ceramics, such as SiC/SiC composites and monolithic Si3N4, are leading candidates to replace superalloy hot section components in the next generation gas turbine engines due to their excellent high temperature properties. A major stumbling block to realizing Si-based ceramic hot section components is the recession of Si-based ceramics in combustion environments due to the volatilization of silica scale by water vapor. An external environmental barrier coating (EBC) is the most promising approach to preventing the recession. Current EBCs are based on silicon, mullite (3A12O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit the durability and temperature capability of current EBCs. Research is underway to develop EBCs with longer life and enhanced temperature capability. Understanding key issues affecting the performance of current EBCs is necessary for successful development of advanced EBCs. These issues include stress, chemical compatibility, adherence, and water vapor stability. Factors that affect stress are thermal expansion mismatch, phase stability, chemical stability, elastic modulus, etc. The current understanding on these issues will be discussed.

  9. Mesoporous nanocomposite coatings for photonic devices: sol-gel approach

    NASA Astrophysics Data System (ADS)

    Islam, Shumaila; Bidin, Noriah; Riaz, Saira; Suan, Lau Pik; Naseem, Shahzad; Sanagi, Mohd. Marsin

    2016-10-01

    Thermally stable, optically active inorganic nanocomposites, i.e., aluminum-silicate (AS) and silica-titania (ST), are synthesized via acid-catalyzed low-temperature sol-gel method in order to get stable, crack-free coating material for photonic devices. The samples are characterized by atomic force microscope, field emission scanning electron microscope (FE-SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), Brunauer-Emmett--Teller (BET) surface area, Barrett-Joyner-Halenda (BJH) pore size distribution surface analysis and UV-Vis spectroscopy. Microscopic results show good incorporation of ST and AS particles as composites with grain size within range of 12-17 and 62-109 nm, respectively. EDX analysis substantiated the stoichiometric formation of homogeneous nanocomposites. XRD of the films reveals primary polycrystalline anatase titania phase and mullite phase of ST and AS nanocomposites. FTIR confirms the heterogeneous bond linkage between titania, silica and alumina species. Furthermore, the fabricated samples have mesoporous nature with high surface area, large pore volume and diameter. The tunable refractive index of 1.33-1.35 with high transparency is obtained for synthesized nanocomposites. The experimental findings show that these physically modified and thermally stable alumina- and titania-doped silica-based composite coatings are promising for photonic devices modification.

  10. Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

    2002-01-01

    Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

  11. Effect of size of man-made and natural mineral fibers on chemiluminescent response in human monocyte-derived macrophages.

    PubMed

    Ohyama, M; Otake, T; Morinaga, K

    2001-10-01

    Fiber size is an important factor in the tumorigenicity of various mineral fibers and asbestos fibers in animal experiments. We examined the time course of the ability to induce lucigenin-dependent chemiluminescence (CL) from human monocyte-derived macrophages exposed to Japan Fibrous Material standard reference samples (glass wool, rock wool, micro glass fiber, two types of refractory ceramic fiber, refractory mullite fiber, potassium titanium whisker, silicon carbide whisker, titanium oxide whisker, and wollastonite). We determined how fiber length or width might modify the response of cells. We found that the patterns of time-dependent increase of CL (sigmoid type) were similar for each sample except wollastonite. We observed a strong correlation between geometric-mean length and ability to induce CL in seven samples > 6 microm in length over the time course (largest r(2) = 0.9760). Although we also observed a close positive correlation between geometric-mean width and the ability to induce CL in eight samples < 1.8 microm in width at 15 min (r(2) = 0.8760), a sample of 2.4 microm in width had a low ability to induce CL. Moreover, the relationship between width and the rate of increase in ability to induce CL had a negative correlation at 30-60 min (largest r(2) = 0.7473). Our findings suggest that the release of superoxide from macrophages occurs nonspecifically for various types of mineral fibers depending on fiber length.

  12. The Influence of Interfacial Roughness on Fiber Sliding in Oxide Composites with La-Monazite Interphases

    NASA Technical Reports Server (NTRS)

    Davis, J. B.; Hay, R. S.; Marshall, D. B.; Morgan, P. E. D.; Sayir, A.; Gray, Hugh R. (Technical Monitor); Farmer, Serene C. (Technical Monitor)

    2002-01-01

    Room temperature debonding and sliding of La-Monazite coated fibers is assessed using a composite with a polycrystalline alumina matrix and fibers of several different single crystal (mullite, sapphire) and directionally solidified eutectic (Al2O3/Y3Al5O12 and Al2O3/Y-ZrO2) compositions. These fibers provide a range of residual stresses and interfacial roughnesses. Sliding occurred over a debond crack at the fiber-coating interface when the sliding displacement and surface roughness were relatively small. At large sliding displacements with relatively rough interfaces, the monazite coatings were deformed extensively by fracture, dislocations and occasional twinning, whereas the fibers were undamaged. Dense, fine-grained (10 nm) microstructures suggestive of dynamic recrystallization were also observed in the coatings. Frictional heating during sliding is assessed. The possibility of low temperature recrystallization is discussed in the light of the known resistance of monazite to radiation damage. The ability of La-Monazite to undergo plastic deformation relatively easily at low temperatures may be enabling for its use as a composite interface.

  13. Transformation toughened ceramics for the heavy duty diesel engine technology program

    NASA Technical Reports Server (NTRS)

    Musikant, S.; Feingold, E.; Rauch, H.; Samanta, S.

    1984-01-01

    The objective of this program is to develop an advanced high temperature oxide structural ceramic for application to the heavy duty diesel engine. The approach is to employ transformation toughening by additions of ZrO.5HfO.5O2 solid solution to the oxide ceramics, mullite (2Al2O3S2SiO2) and alumina (Al2O3). The study is planned for three phases, each 12 months in duration. This report covers Phase 1. During this period, processing techniques were developed to incorporate the ZrO.5HfO.5O2 solid solution in the matrices while retaining the necessary metastable tetragonal phase. Modulus of rupture and of elasticity, coefficient of thermal expansion, fracture toughness by indent technique and thermal diffusivity of representative specimens were measured. In Phase 2, the process will be improved to provide higher mechanical strength and to define the techniques for scale up to component size. In Phase 3, full scale component prototypes will be fabri-]cated.

  14. Optical and Mechanical Properties of Glass Blown In Vacuo

    NASA Technical Reports Server (NTRS)

    Manning, andrew; Tucker, Dennis; Mooney, Theodore; Herren, Kenneth; Gregory, Don A.

    2006-01-01

    Theoretically, the strength of glass processed in vacuum should be higher due to outgassing of contaminants normally present in the glass, such as bulk water in the form of OH bonds that tends to weaken the glass structure. In this research, small discs of a few types of glass have been subjected to various temperatures for extended periods of time in vacuum. Their strength was then tested using a standard flexure technique, facilitated by a custom-designed test fixture, and the results were compared to glass tested in air using the same fixture. The purpose of the glass blowing investigation was to prove the basic feasibility of a high-level concept for in-space manufacture of optical elements. The central requirement was that the glass bubble had to be blown into a support structure such that the bubble could be handled by manipulation of the structure. The blown bubble attached itself to a mullite ring geometrically and mechanically, as a demonstration in the initial experiments described here, by expanding through and around it. The vacuum system used was custom made, as were most of the components of the system, such as the heating element, the glass and ring support structure, and the gas inlet system that provided the pressure needed to blow the glass.

  15. Chemical and mechanical consequences of environmental barrier coating exposure to calcium-magnesium-aluminosilicate.

    SciTech Connect

    Harder, B.; Ramirez-Rico, J.; Almer, J. D.; Kang, L.; Faber, K.

    2011-06-01

    The success of Si-based ceramics as high-temperature structural materials for gas turbine applications relies on the use of environmental barrier coatings (EBCs) with low silica activity, such as Ba{sub 1-x}Sr{sub x}Al{sub 2}Si{sub 2}O{sub 8} (BSAS), which protect the underlying components from oxidation and corrosion in combustion environments containing water vapor. One of the current challenges concerning EBC lifetime is the effect of sandy deposits of calcium-magnesium-aluminosilicate (CMAS) glass that melt during engine operation and react with the EBC, changing both its composition and stress state. In this work, we study the effect of CMAS exposure at 1300 C on the residual stress state and composition in BSAS-mullite-Si-SiC multilayers. Residual stresses were measured in BSAS multilayers exposed to CMAS for different times using high-energy X-ray diffraction. Their microstructure was studied using a combination of scanning electron microscopy and transmission electron microscopy techniques. Our results show that CMAS dissolves the BSAS topcoat preferentially through the grain boundaries, dislodging the grains and changing the residual stress state in the topcoat to a nonuniform and increasingly compressive stress state with increasing exposure time. The presence of CMAS accelerates the hexacelsian-to-celsian phase transformation kinetics in BSAS, which reacts with the glass by a solution-reprecipitation mechanism. Precipitates have crystallographic structures consistent with Ca-doped celsian and Ba-doped anorthite.

  16. Current Issues with Environmental Barrier Coatings for Ceramics and Ceramic Composites

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.

    2004-01-01

    The environmental barrier coating (EBC) for SiC/SiC ceramic matrix composites and Si3N4 ceramics is an emerging field as the application of silicon-based ceramics in the gas turbine engine hot section is on the horizon, both for aero and industrial gas turbines. EBC is an enabling technology for silicon-based ceramics because these materials without an EBC cannot be used in combustion environments due to rapid surface recession. Significant progress in EBC development has been made during the last decade through various government-sponsored programs. Current EBCs are based on silicon, mullite (3Al2O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit temperature capability of current EBCs to about 1350 C for long-term applications. There is a need for higher temperature EBCs as the temperature capability of silicon-based ceramics continue to increase. Therefore, research is underway to develop EBCs with improved temperature capability compared to current EBCs. The current status and issues with the advanced EBC development efforts will be discussed.

  17. Overburden characterization and post-burn study at the Hanna, Wyoming underground coal gasification site: stratigraphy, depositional environments and mineralogy, Hanna Formation

    SciTech Connect

    Craig, G.N. II; Burns, L.K.; Ethridge, F.G.; Laughter, T.; Youngberg, A.D.

    1982-03-01

    Several underground coal gasification (UCG) experiments have been conducted in the Hanna No. 1 coal seam. During the fall of 1980 the Laramie Energy Technology Center performed a post-burn field study of the Hanna II, Phases 2 and 3 experiment at the Hanna UCG site. The field work consisted of high resolution seismic, drilling, coring, and geophysical logging. The Department of Earth Resources, Colorado State University, contributed to the post-burn study by doing laboratory work on the cores and geophysical logs. The purpose of the laboratory work was to provide an estimate of the temperatures and chemical conditions reached during the conversion experiment by studying the mineralogical and textural characteristics of thermally altered and ulaltered overburden. In the vicinity of the burn cavity, overburden rocks have been subjected to high temperature pyrometamorphism during the Hanna II Phases 2 and 3 UCG experiments. Paralava rocks, buchites and paralava breccias containing glass and various high temperature minerals such as oligoclase, clinopyroxene, ferrocordierite, mullite, cristobalite, magnetite, and tridymite formed. Textures of some of these minerals suggest crystallization directly from a melt. Mineralogy and melting relations of the paralavas, ash fusion temperatures, and thermocouple measurements made during the experiment suggest that tempratures in excess of 1200/sup 0/C were attained. Rock color and the presence of reduced iron bearing minerals and blebs of native iron indicate that the experimental burn and the product gases in the area of paralava formation were reducing.

  18. [Exposure to ceramic fibers in the occupational environment. I. Production, kinds of ceramic fibers, changes in structure of these fibers, preliminary studies in the working environment].

    PubMed

    Wojtczak, J

    1994-01-01

    The production of fireproof SiO2/Al2O3 ceramic fibres started in the late forties. Primarily, the production was designed entirely for the aircraft industry. In the sixties the application of ceramic fibres became more wider. The first ceramic fibrous materials were characterised by thermal resistance reaching 1200 degrees C. Certain kinds of materials produced currently can be used in the temperature accounting for 1600 degrees C. Aluminosiliceous ceramic fibres recrystallise at high temperature (above 1000 degrees C) and produce mullite and crostobalite. Ceramic fibrous material may become hazardous to workers as a source of respirable fibres. Studies, carried out in plants which manufacture products from aluminosiliceous ceramic fibres, indicated that mean concentrations of respirable fibres ranged from 0.14 to 1.13 f/cm3 while the levels of mean concentrations of total dust accounted for 0.4-13.6 mg/m3. At working posts of plants producing china, where heat-insulating materials were changed mean level of respirable fibre concentration was 0.28-1.65 f/cm3 and concentration of total dust ranged from 7.0 to 17.7 mg/m3.

  19. TEM study of PM2.5 emitted from coal and tire combustion in a thermal power station.

    PubMed

    Gieré, Reto; Blackford, Mark; Smith, Katherine

    2006-10-15

    The research presented here was conducted within the scope of an experiment investigating technical feasibility and environmental impacts of tire combustion in a coal-fired power station. Previous work has shown that combustion of a coal+tire blend rather than pure coal increased bulk emissions of various elements (e.g., Zn, As, Sb, Pb). The aim of this study is to characterize the chemical and structural properties of emitted single particles with dimensions <2.5 microm (PM2.5). This transmission electron microscope (TEM)-based study revealed that, in addition to phases typical of coal fly ash (e.g., aluminum-silicate glass, mullite), the emitted PM2.5 contains amorphous selenium particles and three types of crystalline metal sulfates never reported before from stack emissions. Anglesite, PbSO4, is ubiquitous in the PM2.5 derived from both fuels and contains nearly all Pb present in the PM. Gunningite, ZnSO4-H2O, is the main host for Zn and only occurs in the PM derived from the coal+tire blend, whereas yavapaiite, KFe3+(SO4)2, is present only when pure coal was combusted. We conclude that these metal sulfates precipitated from the flue gas, may be globally abundant aerosols, and have, through hydration or dissolution, a major environmental and health impact.

  20. Study of Glazes and Their Effects on Properties of Triaxial Electrical Porcelains from Ugandan Minerals

    NASA Astrophysics Data System (ADS)

    Olupot, Peter W.; Jonsson, Stefan; Byaruhanga, Joseph K.

    2010-11-01

    Kaolin, ball clay, feldspar, and sand were collected from deposits in Uganda, milled and sieved to particle sizes of 45, 45, 53, and 25 μm, respectively. Three porcelain bodies and five glazes were formulated from them. The glazes were applied on porcelain specimens and subsequently evaluated for their effects on properties of porcelain samples. The formulated specimens were investigated using dilatometry, Steger test, FEG-SEM, XRD, 4-point bending, dielectric strength, and fracture toughness tests. A porcelain specimen consisting of 68% SiO2, 19% Al2O3, 4.7% K2O, and a glaze RO:0.57Al2O3:4.86SiO2 exhibited MOR of 105 MPa with Weibull modulus of 5.6 and a dielectric strength of 18 kV/mm upon firing at a heating rate of 6 °C/min to 1250 °C and holding for 2 h. The microstructure of the high-strength specimen exhibited round mullite needles, quartz, and glass. Holding samples for 2 h at peak temperature resulted in a 22% increase in MOR compared to 1 h holding. Glazing further improved strength by 67% for the best sample. Compressive stresses in glaze contributed to the strengthening effect. The dielectric and mechanical strength values obtained qualify the formulated sample for application in electrical insulation.

  1. Hollow proppants and a process for their manufacture

    DOEpatents

    Jones, Arfon H.; Cutler, Raymond A.

    1985-01-01

    Hollow, fine-grained ceramic proppants are less expensive and improve fracture control when compared to conventional proppants (dense alumina, mullite, bauxite, zirconia, etc.). Hollow proppants of the present invention have been fabricated by spray drying, followed by sintering in order to obtain a dense case and a hollow core. These proppants generally have high sphericity and roundness (Krumbein sphericity and roundness greater than 0.8), have diameters on average between 2250 and 125 .mu.m, depending on proppant size required, and have strength equal to or greater than that of sand. The hollow core, the size of which can be controlled, permits better fracture control in hydraulic fracturing treatments since the proppant can be transported in lower viscosity fluids. Hollow proppants produced at the same cost/weight as conventional proppants also provide for lower costs, since less weight is required to fill the same volume. The fine-grained (preferably less than 5 .mu.m in diameter) ceramic case provides the strength necessary to withstand closure stresses and prevent crushing.

  2. Hollow proppants and a process for their manufacture

    DOEpatents

    Jones, A.H.; Cutler, R.A.

    1985-10-15

    Hollow, fine-grained ceramic proppants are less expensive and improve fracture control when compared to conventional proppants (dense alumina, mullite, bauxite, zirconia, etc.). Hollow proppants of the present invention have been fabricated by spray drying, followed by sintering in order to obtain a dense case and a hollow core. These proppants generally have high sphericity and roundness (Krumbein sphericity and roundness greater than 0.8), have diameters on average between 2,250 and 125 [mu]m, depending on proppant size required, and have strength equal to or greater than that of sand. The hollow core, the size of which can be controlled, permits better fracture control in hydraulic fracturing treatments since the proppant can be transported in lower viscosity fluids. Hollow proppants produced at the same cost/weight as conventional proppants also provide for lower costs, since less weight is required to fill the same volume. The fine-grained (preferably less than 5 [mu]m in diameter) ceramic case provides the strength necessary to withstand closure stresses and prevent crushing. 6 figs.

  3. Scaling up the Single Transducer Thickness-Independent Ultrasonic Imaging Method for Accurate Characterization of Microstructural Gradients in Monolithic and Composite Tubular Structures

    NASA Technical Reports Server (NTRS)

    Roth, Don J.; Carney, Dorothy V.; Baaklini, George Y.; Bodis, James R.; Rauser, Richard W.

    1998-01-01

    Ultrasonic velocity/time-of-flight imaging that uses back surface reflections to gauge volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse-echo ultrasonic velocity/time-of-flight imaging is that the image shows the effects of thickness as well as microstructural variations unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse-echo time-of-flight-based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples that eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material microstructure in plate-like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex-shaped structures-those having (hollow) tubular/curved geometry. The experimental inspection technique and results are described as applied to (1) monolithic mullite ceramic and polymer matrix composite 'proof-of-concept' tubular structures that contain machined patches of various depths and (2) as-manufactured monolithic silicon nitride ceramic and silicon carbide/silicon carbide composite tubular structures that might be used in 'real world' applications.

  4. Development of Thin Film Thermocouples on Ceramic Materials for Advanced Propulsion System Applications

    NASA Technical Reports Server (NTRS)

    Holanda, R.

    1992-01-01

    Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.

  5. Quantitative x ray microanalysis of pulmonary mineral particles in a patient with pneumoconiosis and two primary lung tumours.

    PubMed Central

    Anttila, S; Sutinen, S; Pääkkö, P; Alapieti, T; Peura, R; Sivonen, S J

    1984-01-01

    The right upper lung lobe of a 74 year old man was resected for a central tumour. Two primary cancers were found; a central small cell carcinoma and a peripheral squamous cell carcinoma. In addition, the peripheral lung tissue showed generalised peribronchiolar fibrosis extending from the non-respiratory bronchioles to the level of the alveolar ducts. Abundant asbestos bodies and large amounts of black dust were seen around the bronchioles. Pulmonary mineral particles were studied by quantitative energy dispersive x ray microanalysis (EDS) using scanning transmission electron microscopy (STEM). The x ray spectra for mineral particles were measured in thin sections, and the characteristic peak intensities of the elements were converted to weight fractions (in oxides). The results enabled the minerals present to be identified and their presence confirmed by calculating the mineral formula. These originated from nine natural minerals, anthophyllite and chrysotile asbestos, talc, and quartz, feldspars, and muscovite, which are components of sand, and also from two artificial mullites used in fire clay. The exposure history of the patient explained the most likely origins of the minerals detected. The patient had been a mason for 23 years, repairing and demolishing stoves and fireplaces and using asbestos for insulation work. Images PMID:6093848

  6. Heat flux measurements on ceramics with thin film thermocouples

    NASA Technical Reports Server (NTRS)

    Holanda, Raymond; Anderson, Robert C.; Liebert, Curt H.

    1993-01-01

    Two methods were devised to measure heat flux through a thick ceramic using thin film thermocouples. The thermocouples were deposited on the front and back face of a flat ceramic substrate. The heat flux was applied to the front surface of the ceramic using an arc lamp Heat Flux Calibration Facility. Silicon nitride and mullite ceramics were used; two thicknesses of each material was tested, with ceramic temperatures to 1500 C. Heat flux ranged from 0.05-2.5 MW/m2(sup 2). One method for heat flux determination used an approximation technique to calculate instantaneous values of heat flux vs time; the other method used an extrapolation technique to determine the steady state heat flux from a record of transient data. Neither method measures heat flux in real time but the techniques may easily be adapted for quasi-real time measurement. In cases where a significant portion of the transient heat flux data is available, the calculated transient heat flux is seen to approach the extrapolated steady state heat flux value as expected.

  7. Strength testing of hot gas filters: Volume 6. Final report

    SciTech Connect

    Faber, K.T.

    1998-06-09

    The strength of various ceramic hot gas filter materials has been evaluated by four laboratories: Argonne National Laboratory, DuPont Lanxide, Southern Research Institute and Babcock and Wilcox. The filter materials under study include (a) a Nextel{trademark}/SiC composite filter (from 3M), (b) PRD-66, an all oxide layered microstructure of alumina, mullite, cordierite and some amorphous material by DuPont Lanxide, (c) a Babcock and Wilcox material consisting of an oxide composite of chopped fibers (Saffil) and continuous Nextel fibers, (d-f) monolithic and recrystallized SiC materials and an alumino/aluminosilicate material by IFPM, and (g) a monolithic SiC by the Pall Corporation. Not all four organizations tested each of the materials. PRD-66 was tested by three of the four. Four tests were used to evaluate properties of the candle filter materials. They included (a) the C-ring test, (b) the O-ring test, (c) the burst test and (d) the axial compression test. Each organization identified above did not perform all four tests. The objective of the study described here was to (a) provide an evaluation of the test methods used for hot gas filters to determine which is best for hot gas filter evaluation and (b) evaluate the discrepancies in results from tests run at different laboratories. No material ranking was made here, nor requested.

  8. Soft tissue response to four dense ceramic materials and two clinically used biomaterials.

    PubMed

    Richardson, W C; Klawitter, J J; Sauer, B W; Pruitt, J R; Hulbert, S F

    1975-07-01

    Disk-shaped implants of spinel, alumina, mullite, zircon, a cast Co-Cr-Mo alloy, and ultra-high molecular weight polyethylene (UHMWPE), were implanted in the paraspinalis muscle of 12 adult, male, white New Zealand rabbits. Prior to implantation the implants were characterized with respect to size and shape, weight and surface roughness. After periods of 1 month, 2 months, and 4 months, the rabbits were sacrificed and the tissue specimens were retrieved with the implants still intact. Histological examination of the tissues surrounding the implants along with changes in the size and shape, weight, and surface roughness of the implants were used as criteria for evaluating these materials for implant purposes. No surfaces degradation of any of the materials was detected using scanning electron microscopy. Fibrous tissue seemed to adhere to the UHMWPE implants more than any other material used in this study. Large amounts of fibrous tissue were also found to adhere to the cast Co-Cr-Mo alloy implants. The histological results indicated that within the limits of this investigation, the biocompatibility of the ceramic materials used in this study compared favorably with the clinically used Co-Cr-Mo alloy implants and the UHMWPE implants.

  9. Filter component assessment

    SciTech Connect

    Alvin, M.A.; Lippert, T.E.; Diaz, E.S.; Smeltzer, E.W.

    1995-11-01

    The objectives of this program are to provide a more ruggedized filter system that utilizes porous ceramic filters which have improved resistance to damage resulting from crack propagation, thermal fatigue and/or thermal excursions during plant or process transient conditions, and/or mechanical ash bridging events within the candle filter array. As part of the current Phase 1, Task 1, effort of this program, Westinghouse is evaluating the filtration characteristics, mechanical integrity, and corrosion resistance of the following advanced or second generation candle filters for use in advanced coal-fired process applications: 3M CVI-SiC composite--chemical vapor infiltration of silicon carbide into an aluminosilicate Nextel{trademark} 312 fiber preform; DuPont PRD-66--filament wound candle filter structure containing corundum, cordierite, cristobalite, and mullite; DuPont SiC-SiC--chemical infiltration of silicon carbide into a silicon carbide Nicalon{trademark} fiber mat or felt preform; and IF and P Fibrosic{trademark}--vacuum infiltrated oxide-based chopped fibrous matrix. Results to date are presented.

  10. Thin film thermocouples for high temperature measurement on ceramic materials

    NASA Technical Reports Server (NTRS)

    Holanda, Raymond

    1992-01-01

    Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

  11. Spinel formation for stabilizing simulated nickel-laden sludge with aluminum-rich ceramic precursors.

    PubMed

    Shih, Kaimin; White, Tim; Leckie, James O

    2006-08-15

    The feasibility of stabilizing nickel-laden sludge from commonly available Al-rich ceramic precursors was investigated and accomplished with high nickel incorporation efficiency. To simulate the process, nickel oxide was mixed alternatively with gamma-alumina, corundum, kaolinite, and mullite and was sintered from 800 to 1480 degrees C. The nickel aluminate spinel (NiAl2O4) was confirmed as the stabilization phase for nickel and crystallized with efficiencies greater than 90% for all precursors above 1250 degrees C and 3-h sintering. The nickel-incorporation reaction pathways with these precursors were identified, and the microstructure and spinel yield were investigated as a function of sintering temperature with fixed sintering time. This study has demonstrated a promising process for forming nickel spinel to stabilize nickel-laden sludge from a wide range of inexpensive ceramic precursors, which may provide an avenue for economically blending waste metal sludges via the building industry processes to reduce the environmental hazards of toxic metals. The correlation of product textures and nickel incorporation efficiencies through selection of different precursors also provides the option of tailoring property-specific products.

  12. Characterization of ceramics materials mixed with Co3O4

    NASA Astrophysics Data System (ADS)

    Guzmán, A. F.; Landínez Téllez, D. A.; Roa-Rojas, J.; Fajardo, F.

    2014-04-01

    We have performed the preparation, structural, electrical and mechanical characterizations of ceramic materials composed of kaolinite Al2(Si2O5)(OH)4 and alumina (Al2O3) mixed with different concentrations of cobalt oxide (Co3O4). Ceramic samples were prepared from a base concentration of alumina 30% and kaolinite 70%, mixed with various concentrations of cobalt oxide in steps of 4% up to a value of 20%. The samples were sintered by the standard solid-state reaction method at a temperature of 1350 °C. In all samples with cobalt was found the presence of mullite. It was determined that alumina and cristobalite decreased when the cobalt concentration was increased due to the formation of the cobalt spinel. In order to determine the crystal structure of the samples, crystallographic analysis from X-ray diffraction experiments and also the semi-quantitative phase analysis were performed. Results were compared with theoretical parameters through the PowderCell 2.4 software. By increasing the concentration of cobalt oxide was found a significant increase in the resistance of materials to friction wear and a small decrease on the mean value of the dielectric constant. Through flexion measurements is observed the increases of the elasticity modulus by about 45% for the sample with 4% of cobalt oxide when compared with the samples without cobalt.

  13. Crystallization kinetics of BaO-Al2O3-SiO2 glasses

    NASA Technical Reports Server (NTRS)

    Bansal, Narottam P.; Hyatt, Mark J.

    1988-01-01

    Barium aluminosilicate glasses are being investigated as matrix materials in high-temperature ceramic composites for structural applications. Kinetics of crystallization of two refractory glass compositions in the barium aluminosilicate system were studied by differential thermal analysis (DTA), X-ray diffraction (XRD), and scanning electron microscopy (SEM). From variable heating rate DTA, the crystallization activation energies for glass compositions (wt percent) 10BaO-38Al2O3-51SiO2-1MoO3 (glass A) and 39BaO-25Al2O3-35SiO2-1MoO3 (glass B) were determined to be 553 and 558 kJ/mol, respectively. On thermal treatment, the crystalline phases in glasses A and B were identified as mullite (3Al2O3-2SiO2) and hexacelsian (BaO-Al2O3-2SiO2), respectively. Hexacelsian is a high-temperature polymorph which is metastable below 1590 C. It undergoes structural transformation into the orthorhombic form at approximately 300 C accompanied by a large volume change which is undesirable for structural applications. A process needs to be developed where stable monoclinic celsian, rather than hexacelsian, precipitates out as the crystal phase in glass B.

  14. Peraluminous rocks of Bou-Azzer region (Morocco): Geology and firing transformations

    NASA Astrophysics Data System (ADS)

    Hajjaji, M.; Belkabir, A.; Berrada, S. H.

    2008-10-01

    The general geology of the peraluminous rocks of the Bou-Azzer region (Central Anti-Atlas, Morocco) and their firing transformations were investigated by several techniques: optical microscopy, microprobe analysis, X-ray diffraction (XRD), X-ray fluorescence (XRF), thermal analysis, scanning electron microscope (SEM), energy dispersive spectrometry (EDS), and by measuring selected physical properties. The results of the geological study show that these rocks consist mainly of a quartz-pyrophyllite assemblage (70-74 wt.% SiO 2 and 14-17 wt.% Al 2O 3), associated with minor amounts of muscovite and nacrite. They formed from a progressive deformation and hydrothermal alteration of felsic volcanic rocks. The principal mineralogical transformations recorded from rhyodacite to peraluminuous rocks are: K-feldspar → muscovite → pyrophyllite. Regarding the firing transformations, it is found that up to about 1100 °C the rock samples are subjected to expansion associated with the destruction of the pyrophyllite hydroxyl framework. The estimated amount of energy associated with this process is 50.226 kJ/mol. Beyond 1100 °C, a marked shrinkage was observed, due to the formation of a glassy phase, and the precipitation of mullite, cristobalite and K-feldspar. The reaction pathways for these phases are proposed and the evolved heat is determined (-160.928 kJ/mol).

  15. Mineralogy at the magma-hydrothermal system interface in andesite volcanoes, New Zealand

    NASA Astrophysics Data System (ADS)

    Wood, C. Peter

    1994-01-01

    Ejecta from phreatomagmatic eruptions of Ruapehu and White Island andesite volcanoes in New Zealand provide insight into the mineralogical reactions that occur when magma invades a vent-hosted hydrothermal system. At the surface and in ejected blocks from shallow depths, hydrothermal alteration mineralogies are dominated by silica polymorphs, anhydrite, natroalunite, and pyrite. Blocks from greater depths are composed mainly of cristobalite, anhydrite, halite, and magnetite. Where altered material was heated to magmatic temperatures, thermal decomposition reactions produced mullite, wollastonite, and indialite. Some ejected breccias contain osumilite, cordierite, sanidine, and hypersthene, indicative of reactions occurring near the osumilite-cordierite phase boundary at >800 °C and water pressure <0.2 kbar. Hedenbergite, wollastonite, andradite, and magnetite are found in rare skarn fragments, possibly formed by metasomatism of silica-poor, sulfate-rich hydrothermal deposits. High- temperature parageneses of these types have not been reported before in shallow, acidic volcano-hydrothermal systems. However, they may be typical of the magma- hydrothermal contact zone at many andesite volcanoes.

  16. Crack-resistant Al2O3–SiO2 glasses

    NASA Astrophysics Data System (ADS)

    Rosales-Sosa, Gustavo A.; Masuno, Atsunobu; Higo, Yuji; Inoue, Hiroyuki

    2016-04-01

    Obtaining “hard” and “crack-resistant” glasses have always been of great important in glass science and glass technology. However, in most commercial glasses both properties are not compatible. In this work, colorless and transparent xAl2O3–(100–x)SiO2 glasses (30 ≤ x ≤ 60) were fabricated by the aerodynamic levitation technique. The elastic moduli and Vickers hardness monotonically increased with an increase in the atomic packing density as the Al2O3 content increased. Although a higher atomic packing density generally enhances crack formation in conventional oxide glasses, the indentation cracking resistance increased by approximately seven times with an increase in atomic packing density in binary Al2O3–SiO2 glasses. In particular, the composition of 60Al2O3•40SiO2 glass, which is identical to that of mullite, has extraordinary high cracking resistance with high elastic moduli and Vickers hardness. The results indicate that there exist aluminosilicate compositions that can produce hard and damage-tolerant glasses.

  17. Characterization of the fly ashes from the lignite burning power plants of northern Greece based on their quantitative mineralogical composition.

    PubMed

    Kostakis, G

    2009-07-30

    In the present work, mineralogical analysis of fly ashes produced from the brown coal burning power plants of Agios Dimitrios, Kardia, Ptolemais, LIPTOL, Amynteon, and Achlada-Meliti (Western Macedonia, Greece) was performed, with the aim of characterizing the ashes on the basis of their quantitative mineral phase composition and asses their variability at different time periods. The fly ashes from the Agios Dimitrios, Kardia, and Ptolemais power plants were found to have nearly the same mineralogical composition, consisting mainly of feldspars, lime, anhydrite, quartz, calcium silicates, and high amounts of amorphous phases. The fly ashes from Amynteon were slightly different, having lower content of lime and higher content of feldspars, whilst those from LIPTOL had a relative variable quantitative composition. The fly ashes from the Meliti-Achlada power plant consisted mainly of amorphous phases (very high amounts), mullite, feldspars, and quartz. The mineralogical composition of the ashes produced in all the power plants, except from these of LIPTOL, did not fluctuate significantly over time. An assessment of the hydraulic (cementitious) or pozzolanic character of the ashes is proposed, introducing the use of triangle diagrams A-B-C, which represent the total fraction of the phases with hydraulic or pozzolanic (A), inert (B) character, and the amorphous phases (C).

  18. Calcination kinetics of coal series kaolinite determined by TG/DTG/DTA method

    SciTech Connect

    Gao, F.; Zhang, J.Y.; Zhang, B.J.

    1997-12-31

    Coal series kaolinite (CSK) is a kind of mineral, which often coexists with coal and in which the majority composition is kaolinite (normally > 90 wt.%). It is well-known that kaolin and its calcined products (metakaolin and mullite) are aluminosilicates of considerable importance as industrial raw material. This special mineral now can be considered as a substitute for kaolin in the paper and polymer industries. However in these fields, the optical properties of this mineral are of some importance, high brightness and opacity being desirable for coating applications. However, it is well known that CSK exhibits a black or brown color. To improve the brightness and other properties of CSK, the optimum treatment approach is to directly fire it. Several coal series kaolinite (CSK) samples were calcined in air atmosphere by using Temperature-Programmed Thermo-gravimetry method, and the TG, DTG and DTA profiles were obtained, respectively. The kinetic parameters of the calcination were calculated from the Freemen-Carroll method. It was concluded that the DTA curves of these CSK samples exhibit their own distinguishing features and the calcination mechanism of the CSK becomes much more complex, which had been demonstrated by the kinetics parameters calculated in this work.

  19. Thermal Conductivity and Stability of HfO2-Y2O3 and La2Zr2O7 Evaluated for 1650 Deg C Thermal/Environmental Barrier Coating Applications

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Bansal, Narottam P.; Miller, Robert A.

    2003-01-01

    HfO2-Y2O3 and La2Zr2O7 are candidate thermal and environmental barrier coating (T/EBC) materials for gas turbine ceramic matrix composite (CMC) combustor applications because of their relatively low thermal conductivity and high temperature capability. In this paper, thermal conductivity and high temperature stability of hot-pressed and plasma sprayed specimens with representative partially-stabilized and fully-cubic HfO2-Y2O3 compositions and La2Zr2O7 were evaluated at temperatures up to 1700 C using a steady-state laser heat-flux technique. Sintering behavior of the plasmasprayed coatings was determined by monitoring the thermal conductivity increases during a 20-hour test period at various temperatures. Durability and failure mechanisms of the HfO2-Y2O3 and La2Zr2O7 coatings on mullite/SiC hexoloy or SiC/SiC CMC substrates were investigated at 1650 C under thermal gradient cyclic conditions. Coating design and testing issues for the 1650 C thermal/environmental barrier coating applications are also discussed.

  20. Thermal Conductivity and Water Vapor Stability of Ceramic HfO2-Based Coating Materials

    NASA Technical Reports Server (NTRS)

    Zhu, Dong-Ming; Fox, Dennis S.; Bansal, Narottam P.; Miller, Robert A.

    2004-01-01

    HfO2-Y2O3 and La2Zr2O7 are candidate thermal/environmental barrier coating materials for gas turbine ceramic matrix composite (CMC) combustor liner applications because of their relatively low thermal conductivity and high temperature capability. In this paper, thermal conductivity and high temperature phase stability of plasma-sprayed coatings and/or hot-pressed HfO2-5mol%Y2O3, HfO2-15mol%Y2O3 and La2Zr2O7 were evaluated at temperatures up to 1700 C using a steady-state laser heat-flux technique. Sintering behavior of the plasma-sprayed coatings was determined by monitoring the thermal conductivity increases during a 20-hour test period at various temperatures. Durability and failure mechanisms of the HfO2-Y2O3 and La2Zr2O7 coatings on mullite/SiC Hexoloy or CMC substrates were investigated at 1650 C under thermal gradient cyclic conditions. Coating design and testing issues for the 1650 C thermal/environmental barrier coating applications will also be discussed.

  1. PARTICULATE HOT GAS STREAM CLEANUP TECHNICAL ISSUES

    SciTech Connect

    1999-05-01

    This quarterly report describes technical activities performed under Contract No. DE-AC21-94MC31160. The analyses of hot gas stream cleanup (HGCU) ashes and descriptions of filter performance studied under Task 1 of this contract are designed to address problems with filter operation that are apparently linked to characteristics of the collected ash. This report includes summaries of analyses performed on particulate samples from Sierra Pacific Power Company's Pinon Pine Power Project. This report also reviews the status of the HGCU data bank of ash and char characteristics, and plans for enhancing the data bank with interactive querying of measured particulate properties. Task 1 plans for the remainder of the project include completion and delivery of the HGCU data bank. Task 2 of this project concerns the testing and failure analyses of new and used filter elements and filter materials. Task 2 work during the past quarter included preliminary testing of two materials. One material tested was the soft candle filter manufactured by CGC and supplied by ABB. The other material was N610/mullite manufactured by Albany International (AIT).

  2. PARTICULATE HOT GAS STREAM CLEANUP TECHNICAL ISSUES

    SciTech Connect

    D.H. Pontius

    1999-08-30

    This quarterly report describes technical activities performed under Contract No. DE-AC21-94MC31160. The analyses of hot gas stream cleanup (HGCU) ashes and descriptions of filter performance studied under Task 1 of this contract are designed to address problems with filter operation that are apparently linked to characteristics of the collected ash. This report reviews the status of the HGCU data bank of ash and char characteristics, including the interactive querying of measured particulate properties. Task 1 plans for the remainder of the project include completion and delivery of the HGCU data bank, and issuance of a comprehensive final report on activities conducted under Task 1. Task 2 of this project concerns the testing and failure analyses of new and used filter elements and filter materials. Task 2 work during the past quarter included preliminary testing of two materials. One material tested was the soft candle filter manufactured by CGC and supplied by ABB. The other material was N610/mullite manufactured by Albany International (AIT).

  3. Fly ash from a Mexican mineral coal I: Mineralogical and chemical characterization.

    PubMed

    Medina, Adriana; Gamero, Prócoro; Querol, Xavier; Moreno, Natalia; De León, Beatriz; Almanza, Manuel; Vargas, Gregorio; Izquierdo, María; Font, Oriol

    2010-09-15

    The properties of coal fly ash are strongly dependent on the geological origin and the combustion process of the coal. It is important to characterize regional fly ash in detail to ascertain its potential uses as raw material in the production of high value products. The physicochemical properties of fly ash coming from the "Jose Lopez Portillo" coal-fired power plant, Coahuila, Mexico (MFA), are presented in this work. A detailed study of trace elements, the chemical composition of the amorphous phase, thermal stability and the leaching of contaminant elements under different conditions are included. MFA is composed of mullite, quartz, calcite, magnetite and an amorphous phase. This material contains mainly silica (59.6%), alumina (22.8%) and magnetite (5.6%). Its amorphous phase (78.3%) has a high silica (49.4%) and alumina (14.4%) content. According to its mineralogical and chemical composition, MFA is potentially useful as a raw material for making cement, silica, and alumina, as well as low silica/alumina ratio zeolites. Deleterious elements could be removed during the zeolitization process or with an additional acid treatment. Because of its morphological properties and structural and thermal stability, MFA can be used in thermal isolation and refractory materials and as a support for heterogeneous catalysts.

  4. Surface modification of oil fly ash and its application in selective capturing of carbon dioxide

    NASA Astrophysics Data System (ADS)

    Yaumi, Ali L.; Hussien, Ibnelwaleed A.; Shawabkeh, Reyad A.

    2013-02-01

    Oil fly ash from power generation plants was activated with 30% NH4OH and used for selective adsorption of carbon dioxide from CO2/N2 mixture. The treated samples were characterized for their surface area, morphology, crystalline phase, chemical composition and surface functional groups. Energy dispersive X-ray analysis showed an increase in the carbon contents from 45 to 73 wt% as a result of leaching out metal oxides. XRD proved that chemical activation of ash resulted in diminishing of major crystalline phases of zeolite, and other alumino-silicates leaving only quartz and mullite. BET analysis showed an increase in surface area from 59 to 318 m2/g after chemical activation and the pore volume increased from 0.0368 to 0.679 cm3/g. This increase in pore volume is supported by the results of SEM, where more micropores were opened with well-defined particle sizes and porous structure. The TGA of the treated fly ash showed stability at higher temperature as the weight loss decreased with increasing temperature. For treated ash, the FTIR displayed new peaks of amine functional group. The treated ash was used for the removal of CO2 from CO2/N2 mixture and the maximum adsorption/capturing capacity was found to be 240 mg/g. This capacity increases with increase in initial gas concentration, inlet flow rate and temperature suggesting the endothermic nature of the interaction between the gas molecules and the surface of the ash.

  5. Formation and use of coal combustion residues from three types of power plants burning Illinois coals

    USGS Publications Warehouse

    Demir, I.; Hughes, R.E.; DeMaris, P.J.

    2001-01-01

    Coal, ash, and limestone samples from a fluidized bed combustion (FBC) plant, a pulverized coal combustion (PC) plant, and a cyclone (CYC) plant in Illinois were analyzed to determine the combustion behavior of mineral matter, and to propose beneficial uses for the power plant ashes. Pyrite and marcasite in coal were converted during combustion to glass, hematite and magnetite. Calcite was converted to lime and anhydrite. The clay minerals were altered to mullite and glass. Quartz was partially altered to glass. Trace elements in coal were partially mobilized during combustion and, as a result, emitted into the atmosphere or adsorbed on fly ash or on hardware on the cool side of the power plants. Overall, the mobilities of 15 trace elements investigated were lower at the FBC plant than at the other plants. Only F and Mn at the FBC plant, F, Hg, and Se at the PC plant and Be, F, Hg, and Se at the CYC plant had over 50% of their concentrations mobilized. Se and Ge could be commercially recovered from some of the combustion ashes. The FBC ashes could be used as acid neutralizing agents in agriculture and waste treatment, and to produce sulfate fertilizers, gypsum wall boards, concrete, and cement. The PC and CYC fly ashes can potentially be used in the production of cement, concrete, ceramics, and zeolites. The PC and CYC bottom ashes could be used in stabilized road bases, as frits in roof shingles, and perhaps in manufacturing amber glass. ?? 2001 Elsevier Science Ltd. All rights reserved.

  6. Effects of atmospheric CO/sub 2/ concentration and water stress on water relations of wheat

    SciTech Connect

    Sionit, N.; Strain, B.R.; Hellmers, H.; Kramer, P.J.

    1981-06-01

    Water status and growth responses of wheat (Triticum aestivuum L. (GWO-1809)) to increased CO/sub 2/ concentration and water stress were studied in controlled-environment chambers. Plants were grown in 350 ..mu..l/liter or 1000 ..mu..1/liter CO/sub 2/ at similar temperature, irradiance, and photoperiod conditions. Groups of plants were subjected to water stress by withholding irrigation for one or two cycles of treatment. In most treatments, decreasing leaf water potential was correlated with decreasing osmotic potential. In leaves grown in both low and high CO/sub 2/ concentrations, the osmotic potentials were lower during the second stress cycle than during the first cycle. The stomata of plants in the low CO/sub 2/ concentration closed at a higher leaf water potential than those in the high CO/sub 2/ concentration. Stem and head production was greater in plants grown in high CO/sub 2/ concentrations than those grown in low CO/sub 2/, perhaps the result of turgor-pressure maintenance as leaf water potential decreased. In controlled-environment chambers, wheat plants adapted to water stress, apparently because of high CO/sub 2/ concentration and repeated stress cycles.

  7. Simplified reference electrode for electrorefining of spent nuclear fuel in high temperature molten salt

    SciTech Connect

    Davies, Kim; Li, Shelly X.

    2007-07-01

    Pyrochemical processing plays an important role in development of proliferation-resistant nuclear fuel cycles. Electrorefining in a high temperature molten salt is considered a signature or central technology in pyro-processing fuel cycles. Reference electrodes provide information essential for monitoring the reactions occurring at the electrodes, investigating separation efficiency, controlling the process rate, and determining the process end-point. Vycor-glass design reference electrodes have provided good durability and signal stability, but are not easily fabricated. The design is a complex construction involving multiple small pieces, glass joints, ceramic to glass joints, and ceramic to metal joints all assembled in a high purity inert gas environment. A simpler design, based on an ion-permeable membrane of mullite has been completed. The new design maximizes the use of commercial components, reduces assembly piece count more than one-half, and can be fabricated with less specialized skills. This has resulted in a significant reduction of effort and cost to fabricate replacements. The new design has been tested in a lab scale electro-refiner and has also been successfully scaled up and installed in engineering scale electro-refiners. (authors)

  8. Simultaneous reduction of particulate matter and NO(x) emissions using 4-way catalyzed filtration systems.

    PubMed

    Swanson, Jacob J; Watts, Winthrop F; Newman, Robert A; Ziebarth, Robin R; Kittelson, David B

    2013-05-07

    The next generation of diesel emission control devices includes 4-way catalyzed filtration systems (4WCFS) consisting of both NOx and diesel particulate matter (DPM) control. A methodology was developed to simultaneously evaluate the NOx and DPM control performance of miniature 4WCFS made from acicular mullite, an advanced ceramic material (ACM), that were challenged with diesel exhaust. The impact of catalyst loading and substrate porosity on catalytic performance of the NOx trap was evaluated. Simultaneously with NOx measurements, the real-time solid particle filtration performance of catalyst-coated standard and high porosity filters was determined for steady-state and regenerative conditions. The use of high porosity ACM 4-way catalyzed filtration systems reduced NOx by 99% and solid and total particulate matter by 95% when averaged over 10 regeneration cycles. A "regeneration cycle" refers to an oxidizing ("lean") exhaust condition followed by a reducing ("rich") exhaust condition resulting in NOx storage and NOx reduction (i.e., trap "regeneration"), respectively. Standard porosity ACM 4-way catalyzed filtration systems reduced NOx by 60-75% and exhibited 99.9% filtration efficiency. The rich/lean cycling used to regenerate the filter had almost no impact on solid particle filtration efficiency but impacted NOx control. Cycling resulted in the formation of very low concentrations of semivolatile nucleation mode particles for some 4WCFS formulations. Overall, 4WCFS show promise for significantly reducing diesel emissions into the atmosphere in a single control device.

  9. Growth of alumina/metal composites into porous ceramics by the oxidation of aluminum

    SciTech Connect

    Watari, Takanori; Mori, Koichiro; Torikai, Toshio; Matsuda, Ohsaku . Dept. of Applied Chemistry)

    1994-10-01

    Ductile metal is incorporated into brittle ceramics to improve their fracture toughness. Of the many methods for fabricating ceramic/metal composites, the oxidation of a molten alloy (DIMOX process) is particularly interesting because it affords (1) ease of composite production, (2) low cost, and (3) near-net-shape capability. Alumina/metal composites were grown into the pores of porous alumina, porous aluminosilicate, and porous silicon carbide substrates through the oxidation of Al-Si (5 wt %) powder compacts coated with magnesia powder (11 mg/cm[sup 2]). The thickness of the resulting composite increased with oxidation time and temperature, and was proportional to (pore size)[sup 0.5] on using porous alumina. The composite thickness was more than 2 times larger in the silicon carbide and about 4 times larger in the aluminosilicate than in the alumina at 1,523 K for 1 h. The products using these three types of substrates consisted of alumina, aluminum, and silicon, except that a silicon carbide phase occurred when using the silicon carbide substrate. Silica and mullite in the aluminosilicate substrate changed to silicon and alumina, and silica in the silicon carbide substrate changed to silicon because of the reduction by aluminum.

  10. Aluminum-containing intergranular phases in hot-pressed silicon carbide

    SciTech Connect

    Zhang, Xiao Feng; De Jonghe, Lutgard C.

    2003-01-12

    Aluminum-containing intergranular phases, forming intergranular films and secondary phase particles at triple-junctions in SiC hot-pressed with aluminum, boron, and carbon additions, were studied by transmission electron microscopy. Statistical high-resolution electron microscopy study of intergranular films indicated that a large fraction of the vitreous intergranular films in the s-hot-pressed SiC crystallized during postannealing in argon above 1000 C. However, brief heating to 1900 C indeed re-melted 25 percent of the crystallized intergranular films. The structural transitions were reflected in the statistical width distributions of the amorphous grain boundary layers. At triple-junctions, Al2O3, Al2OC-SiC solid solution, and mullite phases were newly identified. These phases,together with others reported before are represented in a quaternary phase diagram for 1900 C. It is proposed that a SiC-Al2OC liquid domain is to be included in this phase diagram.

  11. Theoretical prediction of energy release rate for interface crack initiation by thermal stress in environmental barrier coatings for ceramics

    NASA Astrophysics Data System (ADS)

    Kawai, E.; Umeno, Y.

    2017-05-01

    As weight reduction of turbines for aircraft engines is demanded to improve fuel consumption and curb emission of carbon dioxide, silicon carbide (SiC) fiber reinforced SiC matrix composites (SiC/SiC) are drawing enormous attention as high-pressure turbine materials. For preventing degradation of SiC/SiC, environmental barrier coatings (EBC) for ceramics are deposited on the composites. The purpose of this study is to establish theoretical guidelines for structural design which ensures the mechanical reliability of EBC. We conducted finite element method (FEM) analysis to calculate energy release rates (ERRs) for interface crack initiation due to thermal stress in EBC consisting of Si-based bond coat, Mullite and Ytterbium (Yb)-silicate layers on a SiC/SiC substrate. In the FEM analysis, the thickness of one EBC layer was changed from 25 μm to 200 μm while the thicknesses of the other layers were fixed at 25 μm, 50 μm and 100 μm. We compared ERRs obtained by the FEM analysis and a simple theory for interface crack in a single-layered structure where ERR is estimated as nominal strain energy in the coating layers multiplied by a constant factor (independent of layer thicknesses). We found that, unlike the case of single-layered structures, the multiplication factor is no longer a constant but is determined by the combination of consisting coating layer thicknesses.

  12. Structure and mechanical properties of ceramic coatings fabricated by plasma electrolytic oxidation on aluminized steel

    NASA Astrophysics Data System (ADS)

    Wu, Zhenqiang; Xia, Yuan; Li, Guang; Xu, Fangtao

    2007-08-01

    Ceramic coatings were formed by plasma electrolytic oxidation (PEO) on aluminized steel. Characteristics of the average anodic voltages versus treatment time were observed during the PEO process. The micrographs, compositions and mechanical properties of ceramic coatings were investigated. The results show that the anodic voltage profile for processing of aluminized steel is similar to that for processing bulk Al alloy during early PEO stages and that the thickness of ceramic coating increases approximately linearly with the Al layer consumption. Once the Al layer is completely transformed, the FeAl intermetallic layer begins to participate in the PEO process. At this point, the anodic voltage of aluminized steel descends, and the thickness of ceramic coating grows more slowly. At the same time, some micro-cracks are observed at the Al 2O 3/FeAl interface. The final ceramic coating mainly consists of γ-Al 2O 3, mullite, and α-Al 2O 3 phases. PEO ceramic coatings have excellent elastic recovery and high load supporting performance. Nanohardness of ceramic coating reaches about 19.6 GPa.

  13. High Temperature Tolerant Ceramic Composites Having Porous Interphases

    DOEpatents

    Kriven, Waltraud M.; Lee, Sang-Jin

    2005-05-03

    In general, this invention relates to a ceramic composite exhibiting enhanced toughness and decreased brittleness, and to a process of preparing the ceramic composite. The ceramic composite comprises a first matrix that includes a first ceramic material, preferably selected from the group including alumina (Al2O3), mullite (3Al2O3.2SiO2), yttrium aluminate garnet (YAG), yttria stabilized zirconia (YSZ), celsian (BaAl2Si2O8) and nickel aluminate (NiAl2O4). The ceramic composite also includes a porous interphase region that includes a substantially non-sinterable material. The non-sinterable material can be selected to include, for example, alumina platelets. The platelets lie in random 3-D orientation and provide a debonding mechanism, which is independent of temperature in chemically compatible matrices. The non-sinterable material induces constrained sintering of a ceramic powder resulting in permanent porosity in the interphase region. For high temperature properties, addition of a sinterable ceramic powder to the non-sinterable material provides sufficiently weak debonding interphases. The ceramic composite can be provided in a variety of forms including a laminate, a fibrous monolith, and a fiber-reinforced ceramic matrix. In the laminated systems, intimate mixing of strong versus tough microstructures were tailored by alternating various matrix-to-interphase thickness ratios to provide the bimodal laminate.

  14. Competitive adsorption of Pb2+ and Zn2+ ions from aqueous solutions by modified coal fly ash

    NASA Astrophysics Data System (ADS)

    Astuti, Widi; Martiani, Wulan; Any Ismawati Khair, N.

    2017-03-01

    Coal fly ash (CFA), which is a solid waste generated in large amounts worldwide, is mainly composed of some oxides having high crystallinity, including quartz (SiO2) and mullite (3Al2O3 2SiO2), and unburned carbon as a mesopore material that enables it to act as a dual site adsorbent. To decrease the crystallinity, CFA was modified by sodium hydroxide treatment. The modified fly ash (MFA) contains lower amount of Si and Al and has a higher specific surface area than the untreated fly ash (CFA). The objective of this study is to investigate the competitive adsorption of Pb2+ and Zn2+ from aqueous solutions by CFA and MFA. The effect of pH, contact time and initial concentration was investigated. Effective pH for Pb2+ and Zn2+ removal was 4. A greater percentage of Pb2+ and Zn2+ was removed with a decrease in the initial concentration of Pb2+ and Zn2+. Quasi-equilibrium reached in 240 min.

  15. Effect of Silica on High-Temperature Interfacial Phenomena of Monolithic Refractories with Al Alloy

    NASA Astrophysics Data System (ADS)

    Koshy, Pramod; Gupta, Sushil; Sahajwalla, Veena; Edwards, Phil

    2008-04-01

    An experimental study was conducted to study the interfacial phenomena between monolithic refractories and Al alloy at 1250 °C. Dynamic contact angles of monolithic substrates with varying silica levels were measured using the sessile drop technique, while phases present in the preheated monolithic samples and interfacial reaction products were characterized using X-ray diffraction (XRD) and an electron probe microanalyzer (EPMA). The contact angles in the Al alloy/silica system were found to change much more rapidly as compared to that of the alloy/alumina system, clearly demonstrating the high wetting tendency of silica. Under the tested conditions, the corundum phase forms at the interface while Mg was found to vaporize from the alloy and accumulate at the bottom of the monolithic substrate. Both these phenomena are shown to influence the intensity of contact angle variations with time and, thereby, the wetting behavior of monolithic substrates. Based on dynamic contact angles and equilibrium calculations, monolithic refractories are further classified into three groups, such that the wetting characteristics of those with compositions in the ranges of 0 to 25 pct, 25 to 45 pct, and >45 pct silica were shown to be dictated by the presence of corundum, mullite, and free silica, respectively, as the predominant phase.

  16. Design and processing of all-oxide composites

    SciTech Connect

    Lundberg, R.; Eckerbom, L.

    1995-12-01

    All-oxide ceramic composites as a material with potential for long life-time applications at temperatures in the 1400-1600{degrees}C range in combustion environments were studied. The properties of available polycrystalline and single crystal oxide fibres were summarised. The literature on stable weak interfaces in all-oxide composites was reviewed. Composites with single crystal fibres, a polycrystalline matrix of the same material as the fibres, and a compatible high temperature stable weak oxide interphase was suggested to be the most promising approach. Processing of all-oxide composites was performed. ZrO{sub 2}-coated sapphire fibres in reaction bonded alumina and in hot pressed alumina showed crack deflection and fibre pull-out. In reaction bonded mullite crack deflection and pull-out was observed even for un-coated sapphire fibres. This was attributed to thermal expansion mismatch. A recently started European project aiming at development, scale-up and property evaluation of all-oxide composites is briefly outlined.

  17. Viscous Behavior of Alumina and Titania in Amphoteric Slags and Their Influence on Refractory Corrosion

    NASA Astrophysics Data System (ADS)

    Kaußen, Frank; Friedrich, Bernd

    Recovering iron from bauxite residue (red mud) by carbothermic reduction creates, depending on the composition of bauxite, slag phases with high amounts of alumina and titania which are commonly known as amphoteric slag components. In this case the prediction of slag properties and even the calculation of basicity are very difficult since the slag consists of about 50 wt.-% amphoteric components. As a consequence the correct choice of refractory materials has to be taken into consideration as well. In this study synthetic slags similar to the compositions which occur during the reductive smelting of bauxite residue are mixed and melted. By the addition of CaO and Na2O and SiO2 the basicity is constantly adjusted to 1 [(CaO+Na2O)/SiO2] to monitor the influence of the addition of amphoteric compounds regarding the viscosity and refractory corrosion. In advance thermodynamic calculations concerning the liquidus temperature and viscosity of the examined slag are done by the software FactSage (vers. 6.4). The molten slags are qualitatively examined regarding the viscosity and later on exposed to three different types of refractory materials (MgO, Al2O3, mullite) in order to observe the refractory corrosion and infiltration behavior.

  18. Geochemistry of ultra-fine and nano-compounds in coal gasification ashes: a synoptic view.

    PubMed

    Kronbauer, Marcio A; Izquierdo, Maria; Dai, Shifeng; Waanders, Frans B; Wagner, Nicola J; Mastalerz, Maria; Hower, James C; Oliveira, Marcos L S; Taffarel, Silvio R; Bizani, Delmar; Silva, Luis F O

    2013-07-01

    The nano-mineralogy, petrology, and chemistry of coal gasification products have not been studied as extensively as the products of the more widely used pulverized-coal combustion. The solid residues from the gasification of a low- to medium-sulfur, inertinite-rich, volatile A bituminous coal, and a high sulfur, vitrinite-rich, volatile C bituminous coal were investigated. Multifaceted chemical characterization by XRD, Raman spectroscopy, petrology, FE-SEM/EDS, and HR-TEM/SEAD/FFT/EDS provided an in-depth understanding of coal gasification ash-forming processes. The petrology of the residues generally reflected the rank and maceral composition of the feed coals, with the higher rank, high-inertinite coal having anisotropic carbons and inertinite in the residue, and the lower rank coal-derived residue containing isotropic carbons. The feed coal chemistry determines the mineralogy of the non-glass, non-carbon portions of the residues, with the proportions of CaCO₃ versus Al₂O₃ determining the tendency towards the neoformation of anorthite versus mullite, respectively. Electron beam studies showed the presence of a number of potentially hazardous elements in nanoparticles. Some of the neoformed ultra-fine/nano-minerals found in the coal ashes are the same as those commonly associated with oxidation/transformation of sulfides and sulfates.

  19. Experimental observations of thermal spikes in microwave processing of ceramic oxide fibers

    SciTech Connect

    Vogt, G.J.; Unruh, W.P.; Thomas, J.R. Jr.

    1994-04-01

    Microwave heating of alumina/silica fiber tows in a single-mode microwave cavity at 2.45 GHz have produced a surprising thermal spike behavior on the fiber bundles. During a thermal spike, a ``hot spot`` on the tow brightens rapidly, persists for a few seconds, and rapidly extinguishs. A hot spot can encompass the entire tow in the cavity or just a localized portion of the tow. Some local hot spots propagate along the fiber. Thermal spikes are triggered by relatively small (<15%) increases in power, thus having obvious implications for the development of practical microwave fiber processing systems. A tow can be heated through several successive thermal spikes, after which the tow is left substantially cooler than it was originally, although the applied microwave electric field is much larger. X-ray diffraction studies show that after each temperature spike there is a partial phase transformation of the tow material into mullite. After several excursions the tow has been largely transformed to the new, less lossy phase and is more difficult to heat. Heating experiments with Nextel 550 tows are examined for a pausible explanation of this microwave heating behavior.

  20. Preparation of Functionally Graded Materials (FGMs) Using Coal Fly Ash and NiCr-Based Alloy Powder by Spark Plasma Sintering (SPS)

    NASA Astrophysics Data System (ADS)

    Kaneko, Gen-yo; Kitagawa, Hiroyuki; Hasezaki, Kazuhiro; Ito, Yuji; Kakuda, Hideaki

    2008-02-01

    Functionally Graded Materials (FGMs) were prepared by spark plasma sintering (SPS) using coal fly ash and NiCr alloy powder. The coal fly ash was produced by the Misumi Coal Thermal Power Station (Chugoku Electric Power Co., Inc.), with 80 wt% nickel and 20 wt% chromium (Fukuda Metal Foil & Powder Co., Ltd.) used as source materials. The sintering temperature in the graphite die was 1000 °C. X-ray diffraction patterns of the sintered coal fly ash materials indicated that mullite (3Al2O3ṡ2SiO2) and silica (SiO2) phases were predominant. Direct joining of coal fly ash and NiCr causes fracture at the interface. This is due to the mismatch in the thermal expansion coefficients (CTE). A crack in the FGM was observed between the two layers with a CTE difference of over 4.86×10-6 K-1, while a crack in the FGM was difficult to detect when the CTE difference was less than 2.77×10-6 K-1.

  1. Design and Initial Development of Monolithic Cross-Flow Ceramic Hot-Gas Filters

    SciTech Connect

    Barra, C.; Limaye, S.; Stinton, D.P.; Vaubert, V.M.

    1999-06-06

    Advanced, coal-fueled, power generation systems utilizing pressurized fluidized bed combustion (PFBC) and integrated gasification combined cycle (IGCC) technologies are currently being developed for high-efficiency, low emissions, and low-cost power generation. In spite of the advantages of these promising technologies, the severe operating environment often leads to material degradation and loss of performance in the barrier filters used for particle entrapment. To address this problem, LoTEC Inc., and Oak Ridge National Laboratory are jointly designing and developing a monolithic cross-flow ceramic hot-gas filter. The filter concept involves a truly monolithic cross-flow design that is resistant to delamination, can be easily fabricated, and offers flexibility of geometry and material make-up. During Phase I of the program, a thermo-mechanical analysis was performed to determine how a cross-flow filter would respond both thermally and mechanically to a series of thermal and mechanical loads. The cross-flow filter mold was designed accordingly, and the materials selection was narrowed down to Ca{sub 0.5}Sr{sub 0.5}Zr{sub 4}P{sub 6}O{sub 24} (CS-50) and 2Al{sub 2}O{sub 3}-3SiO{sub 2} (mullite). A fabrication process was developed using gelcasting technology and monolithic cross-flow filters were fabricated. The program focuses on obtaining optimum filter permeability and testing the corrosion resistance of the candidate materials.

  2. Initial test results from the Department of Energy`s pressurized fluidized bed combustion Hot Gas Cleanup Program

    SciTech Connect

    Dennis, R.A.; Lippert, T.E.; Bruck, G.J.; Alvin, M.A.; Mudd, M.J. |

    1993-06-01

    In August 1989 a cooperative agreement was signed between Ohio Power Company, through its agent the American Electric Power Service Corporation, and the United States Department of Energy to assess the readiness and economic viability of high-temperature and high-pressure (HTHP) particulate filter systems for pressurized fluidized bed combustion (PFBC) applications. In this agreement, known as the PFBC Hot Gas Cleanup (HGCU) Program, two HTHP particulate filtration systems are to be tested with one seventh of the flow from the Tidd 70-MWe PFBC Clean Coal Demonstration Plant. This paper describes the initial results from the first PFBC HGCU test and an additional proof-of-concept, pilot-scale test used to validate a ceramic candle filter element, which may be used in the second test of the PFBC HGCU Program. The first test consisted of a three-cluster filter system, incorporating 384, 1.5-meter long silicon carbide candle filters. This system utilized a one-seventh flow slipstream, approximately 7360 actual cubic feet per minute, from the Tidd 70-MWe PFBC. The proof-of-concept test is being used to qualify mullite candle filters as a potential candidate for the second test at the Tidd 70-MWe PFBC. Both filter systems were designed and fabricated by the Westinghouse Science and Technology Center.

  3. [Dust and occupational diseases in brickyards].

    PubMed

    Wiecek, E; Gościcki, J; Indulski, J; Stroszejn-Mrowca, G

    1983-01-01

    Air dustiness and mineralogical composition of dust in 9 building ceramics plants producing red brick were tested. Also analysed were occupational diseases diagnosed in Poland during 1979-1980 in workers of this industry. Concentrations of total dust and respirable fraction at all workstations exceeded the present mandatory allowable values for dusts containing free crystalline silica. By X-ray diffraction, alpha-quartz and illite were found in raw materials (clays) and intermediate products (green brick). In burnt brick alpha-quartz and mullite were found. The content of free crystalline silica was: in clay--over 30%, in total dust--5.8-18.4%, in respirable fraction 3.7-6.1%. Analysis of occupational diseases diagnosed in Poland during 1979-1980 revealed not a single case of pneumoconiosis or any dust--induced respiratory tract disease in those producing red brick. Instead, two pneumoconiosis cases were found among workers of the plant producing thermallite firebrick of biologically aggressive siliceous earth from Piotrowice--as one of its component. Most frequently, workers of the building ceramics plant were afflicted with occupational dermatoses, mostly this relates to bricklayers exposed to cement mortar. Two cases of occupational dermatosis were those of workers exposed to ash.

  4. Effects of nitrogen dioxide on algae

    SciTech Connect

    Wodzinski, R.S.; Alexander, M.

    1980-01-01

    Photosynthetic activity of Anabaena flos-aquae in a soil suspension at an initial pH of 4.9 was almost totally eliminated after 3 days of exposure to 5.0 ppM (..mu..l/liter) NO/sub 2/, at which time the pH had fallen to 3.9. In contrast, A. flos-aquae in soil suspensions at an initial pH of 6.0 was not inhibited after 3 days by 5.0 ppM NO/sub 2/, but the activity was reduced by half in the presence of 15.0 ppM NO/sub 2/; the pH was 6.5 and 5.8, respectively, in the NO/sub 2/-treated samples on day 3. Photosynthesis by the green algae Chlamydomonas reinhardtii and Ankistrodesmus falcatus in soil suspensions at an initial pH of approx. 4.2 was not appreciably affected by 15.0 ppM of NO/sub 2/ after 3 days, at which time the pH had fallen below 4.0. The high levels of NO/sub 2/ and low pH values required for toxicity suggest that blue-green and green algae probably will not be affected directly by NO/sub 2/ in polluted air.

  5. Effects of nitrogen dioxide on algae

    SciTech Connect

    Wodzinski, R.S.; Alexander, M.

    1980-01-01

    Photosynthetic activity of Anabaena flos-aquae in a soil suspension at an initial pH of 4.9 was almost totally eliminated after 3 days of exposure to 5.0 ppm (..mu..l/liter) NO/sub 2/, at which time the pH had fallen to 3.9. In contrast, A. flos-aquae in soil suspensions at an initial pH of 6.0 was not inhibited after 3 days by 5.0 ppm NO/sub 2/, but the activity was reduced by half in the presence of 15.0 ppm NO/sub 2/; the pH was 6.5 and 5.8, respectively, in the NO/sub 2/-treated samples on day 3. Photosynthesis by the green algae Chlamydomonas reinhardtii and Ankistrodesmus falcatus in soil suspensions at an initial pH of approx 4.2 was not appreciably affected by 15.0 ppm of NO/sub 2/ after 3 days, at which time the pH had fallen below 4.0. The high levels of NO/sub 2/ and low pH values required for toxicity suggest that blue-green and green algae probably will not be affected directly by NO/sub 2/ in polluted air.

  6. Component effects on crystallization of RE-containing aluminoborosilicate glass

    NASA Astrophysics Data System (ADS)

    Mohd Fadzil, Syazwani; Hrma, Pavel; Schweiger, Michael J.; Riley, Brian J.

    2016-09-01

    Lanthanide-aluminoborosilicate (LABS) glass is one option for immobilizing rare earth (RE) oxide fission products generated during reprocessing of pyroprocessed fuel. This glass system can accommodate a high loading of RE oxides and has excellent chemical durability. The present study describes efforts to model equilibrium crystallinity as a function of glass composition and temperature as well as liquidus temperature (TL) as a function of glass composition. The experimental method for determining TL was ASTM C1720-11. Typically, three crystalline phases were formed in each glass: Ce-borosilicate (Ce3BSi2O10), mullite (Al10Si2O19), and corundum (Al2O3). Cerianite (CeO2) was a common minor crystalline phase and Nd-silicate (Nd2Si2O7) occurred in some of the glasses. In the composition region studied, TL decreased as SiO2 and B2O3 fractions increased and strongly increased with increasing fractions of RE oxides; Al2O3 had a moderate effect on the TL but, as expected, it strongly affected the precipitation of Al-containing crystals.

  7. Ceramic Coating Inspection Using Laser-Based Ultrasonics and Nanoindentation

    SciTech Connect

    Steen, T. L.; Murray, T. W.; Basu, S. N.; Sarin, V. K.

    2007-03-21

    A combination of laser-based ultrasonic (LBU) inspection and nanoindentation testing is used to evaluate the thickness uniformity and through-thickness mechanical property distributions in 5-20 {mu}m thick CVD environmental barrier coatings. Mullite (3Al2O3{center_dot}2SiO2) coatings grown on silicon carbide substrates are studied in order to provide feedback on the growth process under a range of operating conditions. Nanoindentation tests are performed on polished coating cross sections, and the depth dependence of the elastic modulus of each coating is found. In the LBU experiments, a modulated continuous wave (CW) source is used for surface wave generation. The source is held at a fixed temporal frequency as it is scanned over the surface of the coating. At each temporal frequency of interest, the spatial frequencies of the acoustic modes are found, allowing for phase velocities to be determined. The mean values of elastic moduli found using the LBU approach compare well with the nanoindentation results.

  8. Recent advances in the development of lightweight CO{sub 2}-resistant well cements

    SciTech Connect

    Kukacka, L.E.; Sugama, T.

    1995-12-31

    Regardless of the properties of the cured material, the practical use of advanced cementitious materials for geothermal well completions depends primarily upon the ability to predictably extend the thickening times for the precursor slurries at elevated temperatures to times sufficient to permit conventional placement. Ongoing work at Brookhaven National Laboratory being conducted with assistance from the geothermal industry, indicates that lightweight calcium phosphate cement slurries being developed as CO{sub 2{minus}} resistant well completion materials, can be conventional pumped at temperatures > 100{degrees}C without the addition of retarding admixtures. These slurries consist of mullite-shelled hollow microspheres, calcium aluminate cements and polybasic sodium phosphate. When cured in hydrothermal environments, the slurries yield high strength, low permeability cements which bond well to steel casing. Two compositional factors that affect the thickening times were identified. One is the calcium aluminate cement species that serve as the base reagent in the slurry formulation, and the other is the rate of hydrothermal reaction between the microspheres and the polybasic sodium phosphate solution.

  9. Elevated-temperature fracture resistances of monolithic and composite ceramics using chevron-notched bend tests

    NASA Technical Reports Server (NTRS)

    Ghosh, Asish; Jenkins, Michael G.; Ferber, Mattison K.; Peussa, Jouko; Salem, Jonathan A.

    1992-01-01

    The quasi-static fracture behaviors of monolithic ceramics (SiC, Si3N4, MgAl2O4), self-reinforced monoliths (acicular grained Si3N4, acicular grained mullite), and ceramic matrix composites (SiC whisker/Al2O3 matrix, TiB2 particulate/SiC matrix, SiC fiber/CVI SiC matrix, Al2O3 fiber/CVI SiC matrix) were measured over the temperature range of 20 to 1400 C. The chevron notched, bend bar test geometry was essential for characterizing the elevated temperature fracture resistances of this wide range of quasi-brittle materials during stable crack growth. Fractography revealed the differences in the fracture behavior of the different materials at the various temperatures. The fracture resistances of the self-reinforced monoliths were comparable to those of the composites and the fracture mechanisms were found to be similar at room temperature. However at elevated temperatures the differences of the fracture behavior became apparent where the superior fracture resistance of the self-reinforced monoliths were attributed to the minor amounts of glassy, intergranular phases which were often more abundant in the composites and affected the fracture behavior when softened by elevated temperatures.

  10. ADVANCED HOT GAS FILTER DEVELOPMENT

    SciTech Connect

    E.S. Connolly; G.D. Forsythe

    1998-12-22

    Advanced, coal-based power plants will require durable and reliable hot gas filtration systems to remove particulate contaminants from the gas streams to protect downstream components such as turbine blades from erosion damage. It is expected that the filter elements in these systems will have to be made of ceramic materials to withstand goal service temperatures of 1600 F or higher. Recent demonstration projects and pilot plant tests have indicated that the current generation of ceramic hot gas filters (cross-flow and candle configurations) are failing prematurely. Two of the most promising materials that have been extensively evaluated are clay-bonded silicon carbide and alumina-mullite porous monoliths. These candidates, however, have been found to suffer progressive thermal shock fatigue damage, as a result of rapid cooling/heating cycles. Such temperature changes occur when the hot filters are back-pulsed with cooler gas to clean them, or in process upset conditions, where even larger gas temperature changes may occur quickly and unpredictably. In addition, the clay-bonded silicon carbide materials are susceptible to chemical attack of the glassy binder phase that holds the SiC particles together, resulting in softening, strength loss, creep, and eventual failure.

  11. Comparative study of the microstructural and magnetic properties of fly ashes obtained from different thermal power plants in West Bengal, India.

    PubMed

    Bhattacharjee, Ashis; Mandal, Haradhan; Roy, Madhusudan; Kusz, Joachim; Hofmeister, Wolfgang

    2013-10-01

    This paper deals with the physical nature of the fly ashes obtained from two thermal power plants, situated in West Bengal, India. The fly ash samples are characterized by using comprehensive techniques with an emphasis on their ultrafine nature. The particle sizes of the samples are estimated using scanning electron microcopy (SEM) and found to lie within 0.18-5.90 μm. For morphology and compositional analysis, we also use SEM coupled with energy dispersive X-ray spectrometry. From X-ray study of the fly ashes the nature of conglomeration is seen to be crystalline, and the major components are mullite (Al6Si2O13) and quartz (SiO2). The magnetic measurement of the fly ash samples was carried out by SQUID magnetometer. (57)Fe Mössbauer spectra are obtained using a conventional constant-acceleration spectrometer with a (57)Co/Rh Mössbauer source. The hyperfine parameters obtained, in general, support the findings as made from XRD analysis and provide a quantitative measure of different iron ions present in the samples. The paper presents experimental data on the physical aspects of the fly ash samples of the thermal power plants which comprise coarse, fine, and ultrafine magnetic particulate materials and attempts to provide an exhaustive analysis.

  12. Material and structural characterization of alkali activated low-calcium brown coal fly ash.

    PubMed

    Skvára, Frantisek; Kopecký, Lubomír; Smilauer, Vít; Bittnar, Zdenek

    2009-09-15

    The waste low-calcium Czech brown coal fly ash represents a considerable environmental burden due to the quantities produced and the potentially high content of leachable heavy metals. The heterogeneous microstucture of the geopolymer M(n) [-(Si-O)(z)-Al-O](n).wH(2)O, that forms during the alkaline activation, was examined by means of microcalorimetry, XRD, TGA, DSC, MIP, FTIR, NMR MAS ((29)Si, (27)Al, (23)Na), ESEM, EDS, and EBSD. The leaching of heavy metals and the evolution of compressive strength were also monitored. The analysis of raw fly ash identified a number of different morphologies, unequal distribution of elements, Fe-rich rim, high internal porosity, and minor crystalline phases of mullite and quartz. Microcalorimetry revealed exothermic reactions with dependence on the activator alkalinity. The activation energy of the geopolymerization process was determined as 86.2kJ/mol. The X-ray diffraction analysis revealed no additional crystalline phases associated with geopolymer formation. Over several weeks, the (29)Si NMR spectrum testified a high degree of polymerization and Al penetration into the SiO(4) tetrahedra. The (23)Na NMR MAS spectrum hypothesized that sodium is bound in the form of Na(H(2)O)(n) rather than Na(+), thus causing efflorescence in a moisture-gradient environment. As and Cr(6+) are weakly bonded in the geopolymer matrix, while excellent immobilization of Zn(2+), Cu(2+), Cd(2+), and Cr(3+) are reported.

  13. Anisotropic lattice thermal expansion of PbFeBO4: A study by X-ray and neutron diffraction, Raman spectroscopy and DFT calculations

    DOE PAGES

    Murshed, M. Mangir; Mendive, Cecilia B.; Curti, Mariano; ...

    2014-11-01

    We present the lattice thermal expansion of mullite-type PbFeBO4 in this study. The thermal expansion coefficients of the metric parameters were obtained from composite data collected from temperature-dependent neutron and X-ray powder diffraction between 10 K and 700 K. The volume thermal expansion was modeled using extended Grüneisen first-order approximation to the zero-pressure equation of state. The additive frame of the model includes harmonic, quasi-harmonic and intrinsic anharmonic potentials to describe the change of the internal energy as a function of temperature. Moreover, the unit-cell volume at zero-pressure and 0 K was optimized during the DFT simulations. Harmonic frequencies ofmore » the optical Raman modes at the Γ-point of the Brillouin zone at 0 K were also calculated by DFT, which help to assign and crosscheck the experimental frequencies. The low-temperature Raman spectra showed significant anomaly in the antiferromagnetic regions, leading to softening or hardening of some phonons. Selected modes were analyzed using a modified Klemens model. The shift of the frequencies and the broadening of the line-widths helped to understand the anharmonic vibrational behaviors of the PbO4, FeO6 and BO3 polyhedra as a function of temperature.« less

  14. Anisotropic lattice thermal expansion of PbFeBO4: A study by X-ray and neutron diffraction, Raman spectroscopy and DFT calculations

    SciTech Connect

    Murshed, M. Mangir; Mendive, Cecilia B.; Curti, Mariano; Nénert, Gwilherm; Kalita, Patricia E.; Lipinska, Kris; Cornelius, Andrew L.; Huq, Ashfia; Gesing, Thorsten M.

    2014-11-01

    We present the lattice thermal expansion of mullite-type PbFeBO4 in this study. The thermal expansion coefficients of the metric parameters were obtained from composite data collected from temperature-dependent neutron and X-ray powder diffraction between 10 K and 700 K. The volume thermal expansion was modeled using extended Grüneisen first-order approximation to the zero-pressure equation of state. The additive frame of the model includes harmonic, quasi-harmonic and intrinsic anharmonic potentials to describe the change of the internal energy as a function of temperature. Moreover, the unit-cell volume at zero-pressure and 0 K was optimized during the DFT simulations. Harmonic frequencies of the optical Raman modes at the Γ-point of the Brillouin zone at 0 K were also calculated by DFT, which help to assign and crosscheck the experimental frequencies. The low-temperature Raman spectra showed significant anomaly in the antiferromagnetic regions, leading to softening or hardening of some phonons. Selected modes were analyzed using a modified Klemens model. The shift of the frequencies and the broadening of the line-widths helped to understand the anharmonic vibrational behaviors of the PbO4, FeO6 and BO3 polyhedra as a function of temperature.

  15. Nanomineralogy in the real world: A perspective on nanoparticles in the environmental impacts of coal fire.

    PubMed

    Sehn, Janaína L; de Leão, Felipe B; da Boit, Kátia; Oliveira, Marcos L S; Hidalgo, Gelsa E; Sampaio, Carlos H; Silva, Luis F O

    2016-03-01

    Detailed geochemistry similarities between the burning coal cleaning rejects (BCCRs) and non-anthropogenic geological environments are outlined here. While no visible flames were detected, this research revealed that auto-combustion existed in the studied area for many years. The occurrence of several amorphous phases, mullite, hematite and many other Al/Fe-minerals formed by high temperature was found. Bad disposal of coal-dump wastes represents significant environmental concerns due to their potential influence on atmosphere, river sediments, soils and as well as on the surface and groundwater in the surroundings of these areas. The present work using multi-analytical techniques were performed to provide an improved understanding of the complex processes related with sulphide-rich coal waste oxidation, spontaneous combustion and newmineral creation. It recording huge numbers of rare minerals with alunite, montmorillonite, szmolnockite, halotrichite, coquimbite and copiapite at the BCCRs. The information presented the presence of abundant amorphous Si-Al-Fe-Ti as (oxy-)hydroxides and Fe-hydro/oxides with goethite and hematite with various degrees of crystallinity, containing potential hazardous elements (PHEs), such as Cu, Cr, Hf, Hg, Mo, Ni, Se, Pb, Th, U, Zr, and others. Most of the nano-particles and ultra-fine particles found in the burned coal-dump wastes are the same as those commonly associated with coal cleaning rejects, in which oxidation of sulphides plays an important impact to environment and subsequently animal and human health.

  16. Optical and Mechanical Properties of Glass Blown In Vacuo

    NASA Technical Reports Server (NTRS)

    Manning, andrew; Tucker, Dennis; Mooney, Theodore; Herren, Kenneth; Gregory, Don A.

    2006-01-01

    Theoretically, the strength of glass processed in vacuum should be higher due to outgassing of contaminants normally present in the glass, such as bulk water in the form of OH bonds that tends to weaken the glass structure. In this research, small discs of a few types of glass have been subjected to various temperatures for extended periods of time in vacuum. Their strength was then tested using a standard flexure technique, facilitated by a custom-designed test fixture, and the results were compared to glass tested in air using the same fixture. The purpose of the glass blowing investigation was to prove the basic feasibility of a high-level concept for in-space manufacture of optical elements. The central requirement was that the glass bubble had to be blown into a support structure such that the bubble could be handled by manipulation of the structure. The blown bubble attached itself to a mullite ring geometrically and mechanically, as a demonstration in the initial experiments described here, by expanding through and around it. The vacuum system used was custom made, as were most of the components of the system, such as the heating element, the glass and ring support structure, and the gas inlet system that provided the pressure needed to blow the glass.

  17. A study of surface tension driven segregation in monotectic alloy systems

    NASA Technical Reports Server (NTRS)

    Andrews, J. Barry; Andrews, Rosalia N.; Gowens, Terrell F.

    1988-01-01

    The compatibilities of various monotectic alloy systems with several different crucible materials were evaluated. The study was carried out using small candidate alloy samples of compositions that produced fifty volume percent of each liquid phase at the monotectic temperature. Compatibility was based on the evaluation of the wetting tendency of the two immiscible phases with the crucible material in a one-g solidified sample. Three types of wetting phenomena were observed during the evaluation. Type 1 indicates an alloy-crucible combination where the L2 phase preferentially wets the crucible material. Since L2 is usually the minority phase in desirable alloys, this material combination would be difficult to process and is therefore considered incompatible. Type 2 behavior indicates an alloy-crucible combination where the L1 phase preferentially wets the crucible material. This type of combination is considered compatible since surface tension effects should aid in processing the alloy to a useful form. Type 3 indicates any combination that leads to major reactions between the alloy and crucible material, gas entrapment, or separation of the metal from the crucible wall. Additional compatibility evaluations would have to be carried out on combinations of this category. The five alloy systems studied included aluminum-bismuth, copper-lead, aluminum-indium, aluminum-lead and cadmium-gallium. The systems were combined with crucibles of alumina, boron nitride, mullite, quartz, silicon carbide and zirconia.

  18. Mechanical properties and microstructure of an A1{sub 2}O{sub 3}-SiC-TiC composite.

    SciTech Connect

    Smirnov, B. I.; Nikolaev, V. I.; Orlova, T. S.; Shpeizman, V. V.; de Arellano-Lopez, A. R.; Goretta, K. C.; Singh, D.; Routbort, J. L.; Energy Technology; Russian Academy of Sciences; Univ. of Seville

    1998-02-01

    The mechanical properties and microstructure of a hard, electrodischarge-machinable composite, Al{sub 2}O{sub 3}-SiC-TiC, were studied. The material was fabricated by hot pressing 46.1 vol.% Al{sub 2}O{sub 3} powder, 30.9 vol.% SiC whiskers and 23.0 vol.% TiC powder. Significant reaction occurred between the Al{sub 2}O{sub 3} and SiC during processing. The resultant composite consisted of nearly unreacted TiC particles, Al{sub 2}O{sub 3}, plus smaller concentrations of SiC, mullite and possibly a mixture of Al-Si-O-C. The composite exhibited at room temperature an elastic modulus of 409.6{+-}0.5 GPa, microhardness values of 19-32 GPa, indentation fracture toughness (KIC) of 9.6{+-}0.6 MPa(m)0.5, compressive strength as high as 2.8 GPa and fracture strength in bending of {approx}680-825 MPa.

  19. Feasibility and process scale-up low cost alumina fibers for advanced Re-usable Surface Insulation (RSI)

    NASA Technical Reports Server (NTRS)

    Pearson, A.

    1975-01-01

    The objective of this program was to establish feasibility of a process to produce low cost aluminum oxide fibers having sufficient strength, flexibility, and thermal stability for multiple re-use at temperatures to 1480 C in advanced RSI type heat shields for reentry vehicles. Using bench-scale processing apparatus, the Alcoa 'Saphiber' process was successfully modified to produce nominally 8 microns diameter polycrystalline alpha-alumina fiber. Thermal stability was demonstrated in vacuum reheating tests to 1371 C and in atmospheric reheating to 1483 C. Individual fiber properties of strength, modulus, and flexibility were not determined because of friability and short length of the fiber. Rigidized tile produced from fiber of nominally 8, 20 and 40 micron diameter had thermal conductivities significantly higher than those of RSI SiO2 or mullite at relatively low temperature but became comparable above about 1000 C. Tile densities were high due to short fiber length, especially in the coarser diameter fiber. No significant effect of fiber diameter on thermal properties could be determined form the data. Mechanical properties of tiles deteriorated as fiber diameter increased.

  20. Development and Testing of a Refractory Millimeter-Wave Absorbent Heat Exchanger

    NASA Technical Reports Server (NTRS)

    Lambot, Thomas; Myrabo, Leik; Murakami, David; Parkin, Kevin

    2014-01-01

    Central to the Millimeter-Wave Thermal Launch System (MTLS) is the millimeter-wave absorbent heat exchanger. We have developed metallic and ceramic variants, with the key challenge being the millimeter-wave absorbent coatings for each. The ceramic heat exchanger came to fruition first, demonstrating for the first time 1800 K peak surface temperatures under illumination by a 110 GHz Gaussian beam. Absorption efficiencies of up to 80 are calculated for mullite heat exchanger tubes and up to 50 are calculated for alumina tubes. These are compared with estimates based on stratified layer and finite element analyses. The problem of how to connect the 1800 K end of the ceramic tubes to a graphite outlet manifold and nozzle is solved by press fitting, or by threading the ends of the ceramic tubes and screwing them into place. The problem of how to connect the ceramic tubes to a metallic or nylon inlet pipe is solved by using soft compliant PTFE and PVC tubes that accommodate thermal deformations of the ceramic tubes during startup and operation. We show the resulting heat exchangers in static tests using argon and helium as propellants.

  1. Component effects on crystallization of RE-containing aluminoborosilicate glass

    SciTech Connect

    Mohd Fadzil, Syazwani; Hrma, Pavel; Schweiger, Michael J.; Riley, Brian J.

    2016-09-01

    Lanthanide-aluminoborosilicate (LABS) glass is one option for immobilizing rare earth (RE) oxide fission products generated during reprocessing of pyroprocessed fuel. This glass system can accommodate a high loading of RE oxides and has excellent chemical durability. The present study describes efforts to model equilibrium crystallinity as a function of glass composition and temperature as well as liquidus temperature (TL) as a function of glass composition. The experimental method for determining TL was ASTM C1720-11. Typically, three crystalline phases were formed in each glass: Ce-borosilicate (Ce3BSi2O10), mullite (Al10Si2O19), and corundum (Al2O3). Cerianite (CeO2) was a common minor crystalline phase and Nd-silicate (Nd2Si2O7) occurred in some of the glasses. In the composition region studied, TL decreased as SiO2 and B2O3 fractions increased and strongly increased with increasing fractions of RE oxides; Al2O3 had a moderate effect on the TL but, as expected, it strongly affected the precipitation of Alcontaining crystals.

  2. Improved ceramic heat exchange material

    NASA Technical Reports Server (NTRS)

    Mccollister, H. L.

    1977-01-01

    Improved corrosion resistant ceramic materials that are suitable for use as regenerative heat exchangers for vehicular gas turbines is reported. Two glass-ceramic materials, C-144 and C-145, have superior durability towards sulfuric acid and sodium sulfate compared to lithium aluminosilicate (LAS) Corning heat exchange material 9455. Material C-144 is a leached LAS material whose major crystalline phase is silica keatite plus mullite, and C-145 is a LAS keatite solid solution (S.S.) material. In comparison to material 9455, material C-144 is two orders of magnitude better in dimensional stability to sulfuric acid at 300 C, and one order of magnitude better in stability to sodium sulfate at 1000 C. Material C-145 is initially two times better in stability to sulfuric acid, and about one order of magnitude better in stability to sodium sulfate. Both C-144 and C-145 have less than 300 ppm delta L/L thermal expansion from ambient to 1000 C, and good dimensional stability of less than approximately 100 ppm delta L/L after exposure to 1000 C for 100 hours. The glass-ceramic fabrication process produced a hexagonal honeycomb matrix having an 85% open frontal area, 50 micrometer wall thickness, and less than 5% porosity.

  3. The effects of heating and devitrification on the structure and biological activity of aluminosilicate refractory ceramic fibres.

    PubMed

    Brown, R C; Sara, E A; Hoskins, J A; Evans, C E; Young, J; Laskowski, J J; Acheson, R; Forder, S D; Rood, A P

    1992-04-01

    Three grades of ceramic fibre have been examined for their composition, structures and biological effect in several in vitro assay systems. The fibres were examined in the 'as-manufactured' state and after heating at 1200 and 1400 degrees C. Devitrification of the fibres at 1200 degrees C probably gave mullite crystals on the surface and caused the formation of the high-temperature form of cristobalite and, in zirconia grade fibres, the high-temperature, tetragonal form of zirconia as well. Further heating changed surface structure and led to zircon production in the zirconia fibres. Heating reduced the affinity of the fibres for the surface of V79-4 cells and lowered fibre toxicity toward these cells and towards macrophage-like cells. These changes in toxicity were not due to a reduction in the fibrous nature of the materials although they did become more brittle and powders prepared from them contained more isometric particles than those from as-manufactured materials. This suggests that the devitrification occurring during the use of these materials in high-temperature environments will not necessarily enhance their adverse biological activities despite the production of one phase of crystalline silica.

  4. Numerical Modeling of Suspension HVOF Spray

    NASA Astrophysics Data System (ADS)

    Jadidi, M.; Moghtadernejad, S.; Dolatabadi, A.

    2016-02-01

    A three-dimensional two-way coupled Eulerian-Lagrangian scheme is used to simulate suspension high-velocity oxy-fuel spraying process. The mass, momentum, energy, and species equations are solved together with the realizable k-ɛ turbulence model to simulate the gas phase. Suspension is assumed to be a mixture of solid particles [mullite powder (3Al2O3·2SiO2)], ethanol, and ethylene glycol. The process involves premixed combustion of oxygen-propylene, and non-premixed combustion of oxygen-ethanol and oxygen-ethylene glycol. One-step global reaction is used for each mentioned reaction together with eddy dissipation model to compute the reaction rate. To simulate the droplet breakup, Taylor Analogy Breakup model is applied. After the completion of droplet breakup, and solvent evaporation/combustion, the solid suspended particles are tracked through the domain to determine the characteristics of the coating particles. Numerical simulations are validated against the experimental results in the literature for the same operating conditions. Seven or possibly eight shock diamonds are captured outside the nozzle. In addition, a good agreement between the predicted particle temperature, velocity, and diameter, and the experiment is obtained. It is shown that as the standoff distance increases, the particle temperature and velocity reduce. Furthermore, a correlation is proposed to determine the spray cross-sectional diameter and estimate the particle trajectories as a function of standoff distance.

  5. Fuel Efficient Diesel Particulate Filter (DPF) Modeling and Development

    SciTech Connect

    Stewart, Mark L.; Gallant, Thomas R.; Kim, Do Heui; Maupin, Gary D.; Zelenyuk, Alla

    2010-08-01

    The project described in this report seeks to promote effective diesel particulate filter technology with minimum fuel penalty by enhancing fundamental understanding of filtration mechanisms through targeted experiments and computer simulations. The overall backpressure of a filtration system depends upon complex interactions of particulate matter and ash with the microscopic pores in filter media. Better characterization of these phenomena is essential for exhaust system optimization. The acicular mullite (ACM) diesel particulate filter substrate is under continuing development by Dow Automotive. ACM is made up of long mullite crystals which intersect to form filter wall framework and protrude from the wall surface into the DPF channels. ACM filters have been demonstrated to effectively remove diesel exhaust particles while maintaining relatively low backpressure. Modeling approaches developed for more conventional ceramic filter materials, such as silicon carbide and cordierite, have been difficult to apply to ACM because of properties arising from its unique microstructure. Penetration of soot into the high-porosity region of projecting crystal structures leads to a somewhat extended depth filtration mode, but with less dramatic increases in pressure drop than are normally observed during depth filtration in cordierite or silicon carbide filters. Another consequence is greater contact between the soot and solid surfaces, which may enhance the action of some catalyst coatings in filter regeneration. The projecting crystals appear to provide a two-fold benefit for maintaining low backpressures during filter loading: they help prevent soot from being forced into the throats of pores in the lower porosity region of the filter wall, and they also tend to support the forming filter cake, resulting in lower average cake density and higher permeability. Other simulations suggest that soot deposits may also tend to form at the tips of projecting crystals due to the axial

  6. Alkoxy-Siloxide Metal Complexes: Precursors to Metal Silica, Metal Oxide Silica, and Metal Silicate Materials.

    NASA Astrophysics Data System (ADS)

    Terry, Karl William

    The alkoxy-siloxide complexes M (OSi(O ^{rm t}Bu)_3 ]_4 (M = Ti(1), Zr(2), Hf(3)), were prepared by reaction with their respective metal diethylamides. These compounds readily undergo low-temperature decomposition to their respective metal oxide silica materials rm(MO_2{cdot}4SiO_2). The volatile products of the thermolysis of 2 (ca. 200 ^circC) were isobutylene (11.7 equiv) and water (5.4 equiv). The rm ZrO _2{cdot}4SiO_2 material from the decomposition of 2 at 400^circ C was amorphous until ca. 1100^ circC where crystallization of t-ZrO _2 occurred. After thermolysis to 1500 ^circC, t-ZrO_2 and cristobalite were the major products with minor amounts of m-ZrO_2. The rm HfO_2{cdot}4SiO_2 material from the decomposition of 3 at 400^ circC was amorphous until ca. 1000 ^circC where crystallization of c/t -HfO_2 was observed. Thermolysis to 1460^circC yielded c/t -HfO_2, m-HfO_2, and minor amounts of cristobalite. The crystallization of anatase in the rm TiO_2{cdot }4SiO_2 material from decomposed 1 at 400^circC was apparent after thermolysis to 1000^circC. Thermolysis to 1400^circC gave a mixture of anatase, rutile, and cristobalite. Compound 2 was decomposed in xylenes and yielded a transparent gel which was isolated as a white powder upon drying in vacuuo. The compounds [ Me _2AlOSi(O^{t}Bu)_3] _2 (4) and [( ^{t}BuO)MeAlOSi(O^{t}Bu) _3]_2 (5) were structurally characterized and contain bent and planar rm Al_2O_2 four membered rings, respectively. Both 4 and 5 yield isobutylene upon thermolysis (ca. 200 ^circC) and the crystallization of mullite occurs at 1034^circC and 1017^circC, respectively (by DTA). The solution thermolysis of 4 in refluxing toluene yields an opaque white gel. The crystallization of mullite occurs at 1029^circC (by DTA). The compounds [ CuOSi(O ^{t}Bu)_3]_{n } (6) and [ CuOSi(O ^{t}Bu)_2Ph]_4 (7) were prepared by reaction with [ CuO^{t}Bu]_4. The thermolysis of 6 at 1000^circ C under argon gave Cu^circ and amorphous silica and thermolysis under

  7. Transition-metal substitution in PbAlBO{sub 4}: Synthesis, structural and spectroscopic studies of manganese containing phases

    SciTech Connect

    Murshed, M. Mangir; Rusen, Aydin; Fischer, Reinhard X.; Gesing, Thorsten M.

    2012-06-15

    Highlights: ► Synthesis of mullite-type PbAl{sub 1−x}Mn{sub x}BO{sub 4} by solid state and glycerin methods. ► Fundamental parameter approach describes the X-ray powder diffraction profiles. ► Cell parameters anisotropically change with increasing Mn in the structure. ► Bond valence sums of Pb{sup 2+} linearly correlates eccentricity parameter. ► FTIR spectra confirm the trigonal planar BO{sub 3}. -- Abstract: Mullite-type metal borates PbAlBO{sub 4} with planar BO{sub 3} groups are potential candidates for nonlinear optical properties. We successively substituted aluminum with manganese in the composition PbAl{sub 1−x}Mn{sub x}BO{sub 4}, which would help tuning the crystal chemistry and related physical properties. The end member PbAlBO{sub 4} was synthesized by conventional solid state reaction; the other members of the PbAl{sub 1−x}Mn{sub x}BO{sub 4} series were prepared by glycerin method. The fundamental parameter approach was applied in the Rietveld refinements to describe the X-ray powder diffraction profiles. The cell parameters and interatomic bond distances were studied with respect to the chemical composition x. The MO{sub 6} octahedral distortion linearly increased with the averaged M-O bond distance, which is correlated with the increasing amount of manganese atoms in the structure. The change of the average crystal size and microstrain were explained in terms of Al/Mn ratio in the solid solution. While the empirical bond-valence sums (BVS) of one oxygen atom, bridging the edge-sharing MO{sub 6} octahedron, were found to be under-bonded, the other one was over-bonded. The stereoactivity of the 6s{sup 2} lone electron pair of the Pb{sup 2+} cation was characterized in terms of the absolute value of eccentricity parameter (|Φ{sub i}|). Both bond valence parameter (r{sub 0i}) and BVS of Pb showed a linear correlation with |Φ{sub i}|. Deconvolution of the absorption feature of the infrared powder spectra between 1000 cm{sup −1} and 1400

  8. Influence of the duty cycle on structural and mechanical properties of oxide layers on Al-1050 by a plasma electrolytic oxidation process

    NASA Astrophysics Data System (ADS)

    Song, Jeong-Hwan; Nam, Kyung-Su; Moon, Jung-In; Choi, Young-Jun; Lim, Dae-Young

    2014-05-01

    Oxide layers were prepared on Al-1050 substrates by an environmentally friendly plasma electrolytic oxidation process using an alkaline solution of Na2SiO3 (8 g/L) and NaOH (3 g/L) as the electrolyte. The effects of three different duty cycles (20%, 40%, and 60%) on the structure and hardness of the oxides were investigated. XRD analysis revealed that the oxides were mainly composed of α-Al2O3, γ-Al2O3, and mullite. The proportion of each phase depended on various electrical parameters, such as the duty cycle and frequency. The morphology, thickness, and the elemental distribution of the oxides were examined by scanning electron microscopy and energy dispersive spectroscopy. The thicknesses of the oxides were found to vary from 20 μm to more than 60 μm for various duty cycles, when identical treatment durations were used. The oxidation treatment also resulted in good adhesion between the oxide layer and the substrate. SEM images indicated that the oxide layers formed at the 60% duty cycle exhibited relatively coarser surfaces with larger pore sizes and sintering particles, and slower growth rates than did those formed at the 20% duty cycle, under identical treatment durations. The oxides prepared at the 20% duty cycle showed smooth surfaces. The oxides layers were found to improve the micro-hardness of Al-1050. In particular, the oxide layers formed at the 40% duty cycle exhibited relatively better micro-hardness owing to their compact microstructures.

  9. -C Refractories

    NASA Astrophysics Data System (ADS)

    Xu, Yibiao; Sang, Shaobai; Li, Yawei; Ren, Bo; Zhao, Lei; Li, Yuanbing; Li, Shujing

    2014-06-01

    Al2O3-C refractories were first fabricated in a coke bed at 1673 K (1400 °C) using tabular corundum, reactive alumina, carbon black, silicon, and microsilica as the starting materials and phenol resin as the binder. Then the alkali attack resistance of those materials was conducted in the powder mixture of carbon black and potassium carbonate (1:1 wt pct) in a graphite crucible at 1273 K (1000 °C) for 10 hours. The correlation between pore size, permeability of Al2O3-C refractories, and their alkali (K2CO3) attack was investigated by means of mercury intrusion porosimetry, X-ray diffraction (XRD), and scanning electron microscopy (SEM). The results showed that the pore structure of Al2O3-C refractories was controlled by the addition of silicon, ultrafine reactive alumina, and microsilica to in-situ form SiC whiskers and mullite in the preparation process. The mean pore size of Al2O3-C refractories was strongly associated with permeability. With the decrease of the mean pore size, the permeability of the Al2O3-C refractories reduced constantly. The alkali attack test also verified that the Al2O3-C refractories with lower permeability had better alkali corrosion resistance, because the penetration of K vapor into the materials could be restricted effectively. The corrosion mechanism of Al2O3-C refractories supposes that (1) K2CO3 was reduced to K vapor and penetrated into the specimen through the open pores and (2) K vapor reacted with SiC, SiO2, and alumina to form KAlSi2O6 and KAlSiO4, which is in agreement with the thermodynamic prediction.

  10. Supported growth of polycrystalline silicon sheet on low-cost ceramic, carbon, or reusable substrate. Quarterly report No. 1, September 26-December 31, 1979

    SciTech Connect

    Chapman, P.W.; Heaps, J.D.; Schuldt, S.B.; Zook, J.D.

    1980-02-01

    The overall objective of this program is to identify and develop high-throughput, supported-growth methods for producing low-cost, large-area polycrystalline silicon sheet on ceramic, carbon, or reusable substrates. The first method being investigated is the SCIM coating technique. (SCIM is an acronym for Silicon Coating by Inverted Meniscus.) With this technique, a low-cost ceramic substrate is silicon-coated in a continuous manner by passing the substrate over a molten silicon meniscus which is contained in a narrow fused-silica trough. During this reporting period, several mullite substrates were silicon-coated with this method. The best coatings were approximately 100 ..mu..m thick with large columnar grains up to 0.5 cm wide and several cm long. Structural characterization of these coatings shows that these large grains are heavily twinned with boundaries perpendicular to the surface of the layer. Minority-carrier diffusion length measurements made on photodiodes fabricated from these coatings indicate diffusion lengths of about 25 ..mu..m. The short-circuit current densities of the diodes were about 23 mA/cm/sup 2/, with open-circuit voltages of approximately 0.49 V. With the substrates positioned horizontally as they pass over the meniscus trough, instability usually occurs, causing a buildup of molten silicon immediately downstream from the trough. This solicon eventually spills over onto key parts of the coater. By tilting the substrate at angles of 10, 15, and 20/sup 0/, stability can be achieved. A theoretical study of meniscus shapes conducted during this reporting period suggests that with an appropriate trough design and the right pressure and substrate height, a SCIM-coating with horizontal substrates should also be possible.

  11. Silicon-on ceramic process. Silicon sheet growth and device developmentt for the Large-Area Silicon Sheet Task of the Low-Cost Solar Array Project. Quarterly report No. 13, October 1-December 31, 1979

    SciTech Connect

    Chapman, P W; Zook, J D; Grung, B L; McHenry, K; Schuldt, S B

    1980-02-15

    Research on the technical and economic feasibility of producing solar-cell-quality sheet silicon by coating inexpensive ceramic substrates with a thin layer of polycrystalline silicon is reported. The coating methods to be developed are directed toward a minimum-cost process for producing solar cells with a terrestrial conversion efficiency of 11 percent or greater. By applying a graphite coating to one face of a ceramic substrate, molten silicon can be caused to wet only that graphite-coated face and produce uniform thin layers of large-grain polycrystalline silicon; thus, only a minimal quantity of silicon is consumed. A variety of ceramic materials have been dip coated with silicon. The investigation has shown that mullite substrates containing an excess of SiO/sub 2/ best match the thermal expansion coefficient of silicon and hence produce the best SOC layers. With such substrates, smooth and uniform silicon layers 25 cm/sup 2/ in area have been achieved with single-crystal grains as large as 4 mm in width and several cm in length. Crystal length is limited by the length of the substrate. The thickness of the coating and the size of the crystalline grains are controlled by the temperature of the melt and the rate at which the substrate is withdrawn from the melt. The solar-cell potential of this SOC sheet silicon is promising. To date, solar cells with areas from 1 to 10 cm/sup 2/ have been fabricated from material with an as-grown surface. Conversion efficiencies of about 10 percent with antireflection (AR) coating have been achieved. Such cells typically have open-circuit voltage and short-circuit current densities of 0.55V and 23 mA/cm/sup 2/, respectively.

  12. Study of Advanced Railgun Hydrogen Pellet Injectors for Fusion Reactor Refueling.

    NASA Astrophysics Data System (ADS)

    King, Tony Levone

    An advanced railgun system has been developed to assess its feasibility as a hypervelocity hydrogen pellet injector for magnetically confined plasmas. It consists of a pellet generator/gas gun assembly for freezing hydrogen pellets and injecting them into the railgun at velocities as high as 1.5 km/s. A plasma armature is formed by ionizing the low-Z propellant gas behind the pellet and firing the railgun. This fuseless operation prevents high-Z impurities from entering the reactor during pellet injection. The railgun system has several features that distinguish it from its predecessors, including: (1) a more compact, versatile pellet generator, (2) a new gas gun configuration that produces significantly higher pellet speeds, (3) a perforated coupling piece between the gas gun and railgun to prevent spurious arcing, and (4) ablation-resistant sidewalls, perforated sidewalls and transaugmentation to reduce inertial and viscous drag, the primary obstacles to achieving hypervelocity. A unique system of sophisticated controls and diagnostics has been assembled to operate the railgun system and assess its performance, including fully automated pellet freezing and gas gun operation, an automatic timing circuit that is immune to mistriggering caused by pellet fragmentation or electromagnetic interference, a streak camera, photostations, light gates, current trans formers, B-dot probes, laser interferometry and optical spectroscopy. Free-arc and hydrogen pellet experiments were conducted to evaluate various railgun designs. Transaugmented and simple railguns 1.2 and 2 m long were tested. The performances of railguns using Mullite, solid Lexan and perforated Lexan sidewalls were compared. The railgun theory of operation and anticipated losses are also examined. The theoretical predictions are found to be in good agreement with the experimental results. The advanced railgun system has set several world records for bare hydrogen pellet velocity, including a 3.3 km/s shot on

  13. Thermal Cyclic Behavior of Thermal and Environmental Barrier Coatings Investigated Under High-Heat-Flux Conditions

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

    2002-01-01

    Environmental barrier coatings (EBC's) have been developed to protect silicon-carbide- (SiC) based ceramic components in gas turbine engines from high-temperature environmental attack. With continuously increasing demands for significantly higher engine operating temperature, future EBC systems must be designed for both thermal and environmental protection of the engine components in combustion gases. In particular, the thermal barrier functions of EBC's become a necessity for reducing the engine-component thermal loads and chemical reaction rates, thus maintaining the required mechanical properties and durability of these components. Advances in the development of thermal and environmental barrier coatings (TBC's and EBC's, respectively) will directly impact the successful use of ceramic components in advanced engines. To develop high-performance coating systems, researchers must establish advanced test approaches. In this study, a laser high-heat-flux technique was employed to investigate the thermal cyclic behavior of TBC's and EBC's on SiC-reinforced SiC ceramic matrix composite substrates (SiC/SiC) under high thermal gradient and thermal cycling conditions. Because the laser heat flux test approach can monitor the coating's real-time thermal conductivity variations at high temperature, the coating thermal insulation performance, sintering, and delamination can all be obtained during thermal cycling tests. Plasma-sprayed yttria-stabilized zirconia (ZrO2-8 wt% Y2O3) thermal barrier and barium strontium aluminosilicate-based environmental barrier coatings (BSAS/BSAS+mullite/Si) on SiC/SiC ceramic matrix composites were investigated in this study. These coatings were laser tested in air under thermal gradients (the surface and interface temperatures were approximately 1482 and 1300 C, respectively). Some coating specimens were also subject to alternating furnace cycling (in a 90-percent water vapor environment at 1300 C) and laser thermal gradient cycling tests

  14. Very high-temperature impact melt products as evidence for cosmic airbursts and impacts 12,900 years ago

    USGS Publications Warehouse

    Bunch, Ted E.; Hermes, Robert E.; Moore, Andrew M.T.; Kennett, Douglas J.; Weaver, James C.; Wittke, James H.; DeCarli, Paul S.; Bischoff, James L.; Hillman, Gordon C.; Howard, George A.; Kimbel, David R.; Kletetschka, Gunther; Lipo, Carl P.; Sakai, Sachiko; Revay, Zsolt; West, Allen; Firestone, Richard B.; Kennett, James P.

    2012-01-01

    It has been proposed that fragments of an asteroid or comet impacted Earth, deposited silica-and iron-rich microspherules and other proxies across several continents, and triggered the Younger Dryas cooling episode 12,900 years ago. Although many independent groups have confirmed the impact evidence, the hypothesis remains controversial because some groups have failed to do so. We examined sediment sequences from 18 dated Younger Dryas boundary (YDB) sites across three continents (North America, Europe, and Asia), spanning 12,000 km around nearly one-third of the planet. All sites display abundant microspherules in the YDB with none or few above and below. In addition, three sites (Abu Hureyra, Syria; Melrose, Pennsylvania; and Blackville, South Carolina) display vesicular, high-temperature, siliceous scoria-like objects, or SLOs, that match the spherules geochemically. We compared YDB objects with melt products from a known cosmic impact (Meteor Crater, Arizona) and from the 1945 Trinity nuclear airburst in Socorro, New Mexico, and found that all of these high-energy events produced material that is geochemically and morphologically comparable, including: (i) high-temperature, rapidly quenched microspherules and SLOs; (ii) corundum, mullite, and suessite (Fe3,/sup>Si), a rare meteoritic mineral that forms under high temperatures; (iii) melted SiO2 glass, or lechatelierite, with flow textures (or schlieren) that form at > 2,200 °C; and (iv) particles with features indicative of high-energy interparticle collisions. These results are inconsistent with anthropogenic, volcanic, authigenic, and cosmic materials, yet consistent with cosmic ejecta, supporting the hypothesis of extraterrestrial airbursts/impacts 12,900 years ago. The wide geographic distribution of SLOs is consistent with multiple impactors.

  15. Copper stabilization via spinel formation during the sintering of simulated copper-laden sludge with aluminum-rich ceramic precursors.

    PubMed

    Tang, Yuanyuan; Chui, Stephen Sin-Yin; Shih, Kaimin; Zhang, Lingru

    2011-04-15

    The feasibility of incorporating copper-laden sludge into low-cost ceramic products, such as construction ceramics, was investigated by sintering simulated copper-laden sludge with four aluminum-rich ceramic precursors. The results indicated that all of these precursors (γ-Al(2)O(3), corundum, kaolinite, mullite) could crystallochemically stabilize the hazardous copper in the more durable copper aluminate spinel (CuAl(2)O(4)) structure. To simulate the process of copper transformation into a spinel structure, CuO was mixed with the four aluminum-rich precursors, and fired at 650-1150 °C for 3 h. The products were examined using powder X-ray diffraction (XRD) and scanning electron microscopic techniques. The efficiency of copper transformation among crystalline phases was quantitatively determined through Rietveld refinement analysis of the XRD data. The sintering experiment revealed that the optimal sintering temperature for CuAl(2)O(4) formation was around 1000 °C and that the efficiency of copper incorporation into the crystalline CuAl(2)O(4) structure after 3 h of sintering ranged from 40 to 95%, depending on the type of aluminum precursor used. Prolonged leaching tests were carried out by using acetic acid with an initial pH value of 2.9 to leach CuO and CuAl(2)O(4) samples for 22 d. The sample leachability analysis revealed that the CuAl(2)O(4) spinel structure was more superior to stabilize copper, and suggested a promising and reliable technique for incorporating copper-laden sludge or its incineration ash into usable ceramic products. Such results also demonstrated the potential of a waste-to-resource strategy by using waste materials as part of the raw materials with the attainable temperature range used in the production of ceramics.

  16. Active coatings for SiC particles to reduce the degradation by liquid aluminium during processing of aluminium matrix composites: study of interfacial reactions.

    PubMed

    Ureña, A.; Rodrigo, P.; Baldonedo, J. L.; Gil, L.

    2001-02-01

    The application of a surface coating on SiC particles is studied as an alternative means of solving problems of reactivity between SiC reinforcements and molten aluminium and problems of low wetting which limit the application of casting routes for fabrication of Al-SiCp composites. The selected active barrier was a ceramic composed of SiO2, which was generated by controlled oxidation of the SiC particles. The coating behaves as an active barrier, preventing a direct reaction between molten aluminium and SiC to form Al4C3 as the main degradation product. At the same time, the SiO2 provokes other interfacial reactions, which are responsible for an improvement in wetting behaviour. Composites were prepared by mixing and compacting SiC particles with Al powders followed by melting in a vacuum furnace, and varying the residence time. Transmission electron microscopy (TEM), high resolution electron microscopy (HREM) and field emission TEM were employed as the main characterization techniques to study the interfacial reactions occurring between the barrier and the molten aluminium. These studies showed that the SiO2 coating behaves as an active barrier which reacts with the molten Al to form a glassy phase Al-Si-O. This compound underwent partial crystallization during the composite manufacture to form mullite. The formation of an outer crystalline layer, composed mainly of Al2O3, was also detected. Participation of other secondary interface reactions inside the active barrier was also identified by HREM techniques.

  17. Xenopumice erupted on 15 October 2011 offshore of El Hierro (Canary Islands): a subvolcanic snapshot of magmatic, hydrothermal and pyrometamorphic processes

    NASA Astrophysics Data System (ADS)

    Del Moro, S.; Di Roberto, A.; Meletlidis, S.; Pompilio, M.; Bertagnini, A.; Agostini, S.; Ridolfi, F.; Renzulli, A.

    2015-06-01

    On 15 October 2011, a submarine eruption offshore of El Hierro Island gave rise to floating volcanic products, known as xenopumices, i.e., pumiceous xenoliths partly mingled and coated with the juvenile basanitic magma. Over the last few years, no consensus in the scientific community in explaining the origin of these products has been reached. In order to better understand the formation of xenopumice, we present a textural, mineralogical, and geochemical study of the possible magmatic, hydrothermal, and pyrometamorphic processes, which usually operate in the plumbing systems of active volcanoes. We carried out a comprehensive SEM investigation and Sr-Nd-Pb isotope analyses on some samples representative of three different xenopumice facies. All the data were compared with previous studies, new data for El Hierro extrusives and a literature dataset of Canary Islands igneous and sedimentary rocks. In the investigated xenopumices, we emphasize the presence of restitic magmatic phases as well as crystallization of minerals (mainly olivine + pyroxene + magnetite aggregates) as pseudomorphs after pre-existing mafic phenocrysts, providing evidence of pyrometamorphism induced by the high-T juvenile basanitic magma. In addition, we identify veins consisting of zircon + REE-oxides + mullite associated with Si-rich glass and hydrothermal quartz, which indicate the fundamental role played by hydrothermal fluid circulation in the xenopumice protolith. The petrological data agree with a pre-syneruptive formation of the xenopumice, when El Hierro basanite magma intruded hydrothermally altered trachyandesite to trachyte rocks and triggered local partial melting. Therefore, the El Hierro xenopumice represents a snapshot of the transient processes at the magma-wall rock interface, which normally occurs in the feeding system of active volcanoes.

  18. Population Balance Modeling of Polydispersed Bubbly Flow in Continuous-Casting Using Multiple-Size-Group Approach

    NASA Astrophysics Data System (ADS)

    Liu, Zhongqiu; Li, Linmin; Qi, Fengsheng; Li, Baokuan; Jiang, Maofa; Tsukihashi, Fumitaka

    2015-02-01

    A population balance model based on the multiple-size-group (MUSIG) approach has been developed to investigate the polydispersed bubbly flow inside the slab continuous-casting mold and bubble behavior including volume fraction, breakup, coalescence, and size distribution. The Eulerian-Eulerian approach is used to describe the equations of motion of the two-phase flow. All the non-drag forces (lift force, virtual mass force, wall lubrication force, and turbulent dispersion force) and drag force are incorporated in this model. Sato and Sekiguchi model is used to account for the bubble-induced turbulence. Luo and Svendsen model and Prince and Blanch model are used to describe the bubbles breakup and coalescence behavior, respectively. A 1/4th water model of the slab continuous-casting mold was applied to investigate the distribution and size of bubbles by injecting air through a circumferential inlet chamber which was made of the specially-coated samples of mullite porous brick, which is used for the actual upper nozzle. Against experimental data, numerical results showed good agreement for the gas volume fraction and local bubble Sauter mean diameter. The bubble Sauter mean diameter in the upper recirculation zone decreases with increasing water flow rate and increases with increasing gas flow rate. The distribution of bubble Sauter mean diameter along the width direction of the upper mold increases first, and then gradually decreases from the SEN to the narrow wall. Close agreements between the predictions and measurements demonstrate the capability of the MUSIG model in modeling bubbly flow inside the continuous-casting mold.

  19. Assessment and comparison of three high-aluminum fly ash utilization scenarios in Inner Mongolia, China using an eco-efficiency indicator.

    PubMed

    Yang, Shuo; Lin, Ling; Li, Shao Peng; Li, Qiang; Wang, Xiu Teng; Sun, Liang

    2017-05-01

    Utilization of fly ash is of great importance in China in the context of resource and environmental crises. Different fly ash utilization processes are proposed, and some have been practically applied. However, none of these fly ash utilization pathways has been evaluated comprehensively by integrating both environmental and economic perspectives. In this study, three high-aluminum fly ash utilization methods in Mongolia were assessed and compared based on the concept of eco-efficiency. The environmental assessment was conducted in accordance with life-cycle assessment principles, and a monetization-weighting approach was applied to obtain social willingness-to-pay as a reflection of environmental impact. The environmental assessment results revealed that the reuse of fly ash had significant advantage for saving primary resource, while solid waste, depletion of water, and global warming were the three highest environmental impacts from the life cycle perspective. The economic performance assessment showed positive net profits for fly ash utilization, but high value-added products were not necessarily indicative of better economic performance due to the relatively high operation cost. Comparison of the eco-efficiency indicators (EEIs) implied that the process of scenario 1#, which produced mullite ceramic and active calcium silicate, was the most recommended out of the three scenarios on the present scale. This judgment was consistent with the evaluation of the resource utilization rate. The present study showed that the EEI could be used to compare different fly ash utilization processes in a comprehensive and objective manner, thus providing definitive and insightful suggestions for decision-making and technical improvement.

  20. Mechanisms of zinc incorporation in aluminosilicate crystalline structures and the leaching behaviour of product phases.

    PubMed

    Tang, Yuanyuan; Shih, Kaimin

    2015-01-01

    This study quantitatively evaluates a waste-to-resource strategy of blending zinc-laden sludge and clay material for low-cost ceramic products. Using ZnO as the simulated zinc-laden sludge to sinter with kaolinite, both zinc aluminate spinel (ZnAl₂O₄) and willemite (Zn₂SiO₄) phases were formed during the sintering process. To analyse the details of zinc incorporation reactions, γ-Al₂O₃and quartz were further used as precursors to observe ZnAl₂O₄and Zn₂SiO₄formations. By firing the ZnO mixtures and their corresponding precursors at 750-1350°C for 3 h, the efficiency of zinc transformation was determined through Rietveld refinement analyses of X-ray diffraction data. The results also show different incorporation behaviour for kaolinite and mullite precursors during the formation of ZnAl2O₄and Zn2SiO₄in the system. In addition, with a competitive formation between ZnAl₂O₄and Zn₂SiO₄, the ZnAl₂O₄spinel phase is predominant at temperatures higher than 1050°C. This study used a prolonged leaching test modified from the US Environmental Protection Agency's toxicity characteristic leaching procedure to evaluate ZnO, ZnAl₂O₄, and Zn₂SiO₄product phases. The zinc concentrations in ZnO and Zn₂SiO₄leachates were about two orders of magnitude higher than that of ZnAl₂O₄ leachate at the end of the experiment, indicating that ZnAl₂O₄formation is the preferred stabilization mechanism for incorporating zinc in ceramic products.

  1. Development of oxidation/corrosion-resistant composite materials and interfaces

    SciTech Connect

    Stinton, D.P.; Besmann, T.M.; Shanmugham, S.

    1995-06-01

    Continuous fiber ceramic composites (CFCCs) are being developed for high temperature structural applications, many of which are in oxidative environments. Such composites are attractive since they are light-weight and possess the desired mechanical properties at elevated temperature and in aggressive environments. The most significant advantage is their toughness and their non-catastrophic failure behavior. The mechanical properties of CFCCs have been characteristically linked with the nature of the interfacial bond between the fibers and the matrix. Weakly bonded fiber-matrix intefaces allow an impinging matrix crack to be deflected such that the fracture process occurs through several stages: Crack deflection, debonding at the interface, fiber slip and pull-out, and ultimately fiber failure. Such a composite will fail in a graceful manner and exhibit substantial fracture toughness. Currently, carbon interface coatings are used to appropriately tailor interface properties, however their poor oxidation resistance has required a search of an appropriate replacement. Generally, metal oxides are inherently stable to oxidation and possess thermal expansion coefficients relatively close to those of Nicalon and SiC. However, the metal oxides must also be chemically compatible with the fiber and matrix. If the fiber/interface/matrix system is chemically compatible, then the interfacial bonding stress is influenced by the thermal residual stresses that are generated as the composite is cooled from processing to room temperature. In the current work, thermomechanical computational results were obtained from a finite element model (FEM) for calculating the thermal residual stresses. This was followed by experimental evaluation of Nicalon/SiC composites with carbon, alumina, and mullite interfacial coatings.

  2. Potentially toxic elements in lignite and its combustion residues from a power plant.

    PubMed

    Ram, L C; Masto, R E; Srivastava, N K; George, J; Selvi, V A; Das, T B; Pal, S K; Maity, S; Mohanty, D

    2015-01-01

    The presence of potentially toxic elements in lignite and coal is a matter of global concern during energy extraction from them. Accordingly, Barsingsar lignite from Rajasthan (India), a newly identified and currently exploited commercial source of energy, was evaluated for the presence of these elements and their fate during its combustion. Mobility of these elements in Barsingsar lignite and its ashes from a power plant (Bikaner-Nagaur region of Thar Desert, India) is presented in this paper. Kaolinite, quartz, and gypsum are the main minerals in lignite. Both the fly ash and bottom ash of lignite belong to class-F with SiO₂ > Al₂O₃ > CaO > MgO. Both the ashes contain quartz, mullite, anhydrite, and albite. As, In, and Sr have higher concentration in the feed than the ashes. Compared to the feed lignite, Ba, Co, U, Cu, Cd, and Ni are enriched (10-5 times) in fly ash and Co, Pb, Li, Ga, Cd, and U in bottom ash (9-5 times). Earth crust-normalization pattern showed enrichment of Ga, U, B, Ag, Cd, and Se in the lignite; Li, Ba, Ga, B, Cu, Ag, Cd, Hg, Pb, and Se, in fly ash; and Li, Sr, Ga, U, B, Cu, Ag, Cd, Pb, and Se in bottom ash. Hg, Ag, Zn, Ni, Ba, and Se are possibly associated with pyrite. Leaching test by toxicity characteristic leaching procedure (TCLP) showed that except B all the elements are within the safe limits prescribed by Indian Standards.

  3. Very high-temperature impact melt products as evidence for cosmic airbursts and impacts 12,900 years ago.

    PubMed

    Bunch, Ted E; Hermes, Robert E; Moore, Andrew M T; Kennett, Douglas J; Weaver, James C; Wittke, James H; DeCarli, Paul S; Bischoff, James L; Hillman, Gordon C; Howard, George A; Kimbel, David R; Kletetschka, Gunther; Lipo, Carl P; Sakai, Sachiko; Revay, Zsolt; West, Allen; Firestone, Richard B; Kennett, James P

    2012-07-10

    It has been proposed that fragments of an asteroid or comet impacted Earth, deposited silica- and iron-rich microspherules and other proxies across several continents, and triggered the Younger Dryas cooling episode 12,900 years ago. Although many independent groups have confirmed the impact evidence, the hypothesis remains controversial because some groups have failed to do so. We examined sediment sequences from 18 dated Younger Dryas boundary (YDB) sites across three continents (North America, Europe, and Asia), spanning 12,000 km around nearly one-third of the planet. All sites display abundant microspherules in the YDB with none or few above and below. In addition, three sites (Abu Hureyra, Syria; Melrose, Pennsylvania; and Blackville, South Carolina) display vesicular, high-temperature, siliceous scoria-like objects, or SLOs, that match the spherules geochemically. We compared YDB objects with melt products from a known cosmic impact (Meteor Crater, Arizona) and from the 1945 Trinity nuclear airburst in Socorro, New Mexico, and found that all of these high-energy events produced material that is geochemically and morphologically comparable, including: (i) high-temperature, rapidly quenched microspherules and SLOs; (ii) corundum, mullite, and suessite (Fe(3)Si), a rare meteoritic mineral that forms under high temperatures; (iii) melted SiO(2) glass, or lechatelierite, with flow textures (or schlieren) that form at > 2,200 °C; and (iv) particles with features indicative of high-energy interparticle collisions. These results are inconsistent with anthropogenic, volcanic, authigenic, and cosmic materials, yet consistent with cosmic ejecta, supporting the hypothesis of extraterrestrial airbursts/impacts 12,900 years ago. The wide geographic distribution of SLOs is consistent with multiple impactors.

  4. Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics

    NASA Technical Reports Server (NTRS)

    Tewari, Surendra

    1997-01-01

    Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.

  5. SODIUM POLYPHOSPHATE-MODIFIED CLASS C/CLASS F FLY ASH BLEND CEMENTS FOR GEOTHERMAL WELLS.

    SciTech Connect

    SUGAMA, T.; BROTHERS, L.E.; KASPEREIT, D.

    2006-02-01

    The authors investigated the usefulness of the coal combustion by-products, Class C fly ash (C) and Class F fly ash (F), in developing cost-effective acid-resistant phosphate-based cements for geothermal wells. In the temperature range of 20-100 C, sodium polyphosphate (NaP) as the acidic cement-forming solution preferentially reacted with calcium sulfate and lime in the C as the base solid reactant through the exothermic acid-base reaction route, rather than with the tricalcium aluminate in C. This reaction led to the formation of hydroxyapatite (HOAp). In contrast, there was no acid-base reaction between the F as the acidic solid reactant and NaP. After autoclaving the cements at 250 C, a well-crystallized HOAp phase was formed in the NaP-modified C cement that was responsible for densifying the cement's structure, thereby conferring low water permeability and good compressive strength on the cement. however, the HOAp was susceptible to hot CO{sub 2}-laden H{sub 2}SO{sub 4} solution (pH 1.1), allowing some acid erosion of the cement. On the other hand, the mullite in F hydrothermally reacted with the Na from NaP to form the analcime phase. Although this phase played a pivotal role in abating acid erosion, its generation created an undesirable porous structure in the cement. They demonstrated that blending fly ash with a C/F ratio of 70/30 resulted in the most suitable properties for acid-resistant phosphate-based cement systems.

  6. Fusion of arkosic sand by intrusive andesite

    USGS Publications Warehouse

    Bailey, Roy A.

    1954-01-01

    An andesite dike in the Valles Mountains of northern New Mexico has intruded and partly fused arkosic sediments for a distance of 50 feet from its contacts. The dike is semi-circular in form, has a maximum width of about 100 feet, and is about 500 feet long. Small associated arcuate dikes are arranged in spiral fashion around the main dike, suggesting that they were intruded along shear fractures similar to those described by Burbank (1941). The fused rocks surrounding the andesite dike are of three general types: 1) partly fused arkosic sand, 2) fused clay, and 3) hybrid rocks. The fused arkosic sand consists of relict detrital grains of quartz, orthoclose, and plagioclase, imbedded in colorless glass containing microlites of tridymite, cordierite, and magnetite. The relict quartz grains are corroded and embayed by glass; the orthoclase is sanidinized and partly fused; and the plagioclase is inverted to the high temperature form and is partly fused. The fused clay, which was originally a mixture of montmorillonite and hydromica, consists primarily of cordierite but also contains needle-like crystals of sillimanite (?) or mullite (?). The hybrid rocks originated in part by intermixing of fused arkosic sediments and andesitic liquid and in part by diffusion of mafic constituents through the fused sediments. They are rich in cordierite and magnetite and also contain hypersthene, augite, and plagioclase. The composition of pigeonite in the andesite indicates that the temperature of the andesite at the time of intrusion probably did not exceed 1200?C. Samples of arkosic sand were fused in the presence of water in a Morey bomb at 1050?C. Stability relations of certain minerals in the fused sand suggest that fusion may have taken place at a lower temperature, however, and the fluxing action of volatiles from the andesite are thought to have made this possible.

  7. Properties and characterization of an oxide/oxide composite filter

    SciTech Connect

    Lane, J.E.; Painter, C.J.; Su, W.F.A.; Radford, K.C.; LeCostaouec, J.F.

    1996-12-31

    Westinghouse, with Techniweave as a major subcontractor, is conducting a three-phase program aimed at providing advanced candle filters for a 1997 pilot scale demonstration in one of the two hot gas filter system at Southern Company Service`s Wilsonville PSD Facility. This program`s objective is to develop an oxide CFCC (continuous fiber ceramic composite) candle filter that is cost competitive with prototype next generation filters through the development of a low cost sol-gel fabrication process and a 3D fiber architecture optimized for high volume filter manufacturing. Phase 1, Filter Material Development and Evaluation, results will be presented. Phase 1 activities included laboratory-scale development, characterization, and testing of a mullite matrix 3D fiber-reinforced (Nextel 550) ceramic composite filter material. Eleven 3D architectures were designed, preforms and ceramic matrix composite (CMC) filter materials were made, tested and evaluated. The CMC fabrication process was optimized for reduced cost and acceptable filter performance. Permeability, 4-pt bend and microstructural evaluation results, previously presented, were used to downselect to one 3D architecture and CMC processing method. The downselected filter material was fabricated and tested via permeability and 4-pt bend; Weibull modulus was determined. High-temperature flow-through corrosion tests and thermal aging tests in static air up to 5,000 h were conducted. SEM and XRD have been used to characterize microstructural and phase changes, if any, from high temperature exposure testing. Weaving feasibility studies for the flange and the closed end of a candle filter have been conducted in order to develop a low cost weaving method to make a single piece candle filter fiber preform. Results and conclusions for the evaluation of the downselected filter material above will be presented and discussed.

  8. Identification of Gravity-Related Effects on Crystal Growth From Melts With an Immiscibility Gap

    NASA Technical Reports Server (NTRS)

    Kassemi, M.; Sayir, A.; Farmer, S.

    1999-01-01

    This work involves an experimental-numerical approach to study the effects of natural and Marangoni convections on solidification of single crystals from a silicate melt with a liquid-liquid immiscibility gap. Industrial use of crystals grown from silicate melts is becoming increasingly important in electronic, optical, and high temperature structural applications. Even the simplest silicate systems like Al203-SiO2 have had, and will continue to have, a significant role in the development of traditional and advanced ceramics. A unique feature of crystals grown from the silicate systems is their outstanding linear electro-optic properties. They also exhibit exceptionally high optical rotativity. As a result, these crystals are attractive materials for dielectric, optical, and microwave applications. Experimental work in our laboratory has indicated that directional solidification of a single crystal mullite appears to be preceded by liquid-liquid phase separation in the melt. Disruption of the immiscible state results in crystallization of a two phase structure. There is also evidence that mixing in the melt caused by density-driven convection can significantly affect the stability of the immiscible liquid layers and result in poly-crystalline growth. On earth, the immiscible state has only been observed for small diameter crystals grown in float zone systems where natural convection is almost negligible. Therefore, it is anticipated that growth of large single crystals from silicate melts would benefit from microgravity conditions because of the reduction of the natural convective mixing. The main objective of this research is to determine the effects of transport processes on the phase separation in the melt during growth of a single crystal while addressing the following issues: (1) When do the immiscible layers form and are they real?; (2) What are the main physical characteristics of the immiscible liquids?; and (3) How mixing by natural or Marangoni convection

  9. Comparison of CO2 capture by ex-situ accelerated carbonation and in in-situ naturally weathered coal fly ash.

    PubMed

    Muriithi, Grace N; Petrik, Leslie F; Fatoba, Olanrewaju; Gitari, Wilson M; Doucet, Frédéric J; Nel, Jaco; Nyale, Sammy M; Chuks, Paul E

    2013-09-30

    Natural weathering at coal power plants ash dams occurs via processes such as carbonation, dissolution, co-precipitation and fluid transport mechanisms which are responsible for the long-term chemical, physical and geochemical changes in the ash. Very little information is available on the natural carbon capture potential of wet or dry ash dams. This study investigated the extent of carbon capture in a wet-dumped ash dam and the mineralogical changes promoting CO2 capture, comparing this natural phenomenon with accelerated ex-situ mineral carbonation of fresh fly ash (FA). Significant levels of trace elements of Sr, Ba and Zr were present in both fresh and weathered ash. However Nb, Y, Sr, Th and Ba were found to be enriched in weathered ash compared to fresh ash. Mineralogically, fresh ash is made up of quartz, mullite, hematite, magnetite and lime while weathered and carbonated ashes contained additional phases such as calcite and aragonite. Up to 6.5 wt % CO2 was captured by the fresh FA with a 60% conversion of calcium to CaCO3 via accelerated carbonation (carried out at 2 h, 4Mpa, 90 °C, bulk ash and a S/L ratio of 1). On the other hand 6.8 wt % CO2 was found to have been captured by natural carbonation over a period of 20 years of wet disposed ash. Thus natural carbonation in the ash dumps is significant and may be effective in capturing CO2. Copyright © 2013 Elsevier Ltd. All rights reserved.

  10. Behavior of sulfur and chlorine in coal during combustion and boiler corrosion. Technical report, December 1, 1992--February 28, 1993

    SciTech Connect

    Chou, C.L.; Hackley, K.C.; Cao, J.; Frost, R.R.; Ruch, R.R.; Pan, W.P.; Upchurch, M.L.; Cao, H.B.; Shao, D.; Ho, H.H.

    1993-05-01

    The goals of this project is to investigate the behavior of sulfur and chlorine during pyrolysis and combustion of Illinois coals, the chemistry of boiler deposits and the process of ash formation, and remedial measures to reduce the sulfur and chlorine compounds in combustion gases. The chemistry of boiler deposits provides information about the behavior of sulfur, chlorine, and ash particles during coal combustion. We report results obtained during this quarter on mineralogical and chemical compositions of twelve samples of boiler deposits collected from superheater and reheater tubes of an Illinois power plant. Scanning electron microscopy shows microscopic calcium sulfate droplets on cenospheres. There is a considerable variation of chemical composition among the samples. While eight out of twelve samples consist predominantly of quartz, mullite, and glass; the remaining four contain an appreciable amount additional phases (calcium sulfate and alkali iron sulfate) . The chlorine content in the samples is determined by neutron activation analysis. one sample contains 37 ppM chlorine, and the chlorine concentration is below the detection limit in other eleven samples (<15--45 ppM), indicating that most of the chlorine in feed coal is lost during combustion. In a separate set of experiments, the effects of composite gases containing Hcl, SO{sub 2}, and HCl+SO{sub 2} on six metals are determined. Chromium-nickel steel and alloy show higher resistance to corrosion than carbon-manganese steels and chromium-molybdenum steels when metal coupons are exposed to hot gases at 600{degree}C for 24 hours.

  11. Sodium phosphate-derived calcium phosphate cements

    SciTech Connect

    Sugama, T.; Carciello, N.R. )

    1995-01-01

    Calcium phosphate cements (CPC) were synthesized by the acid-base reaction between sodium phosphate, NaH[sub 2]PO[sub 4] or -(-NaPO[sub 3]-)-[sub n], as the acid solution, and calcium aluminate cements (CAC) as the base reactant at 25 C. The extent of reactivity of -(-NaPO[sub 3]-)-[sub n] with CAC was much higher than that of NaH[sub 2]PO[sub 4], thereby resulting in a compressive strength of > 20 MPa. Sodium calcium orthophosphate (SCOP) salts as amorphous reaction products were responsible for the development of this strength. When this CPC specimen as exposed in an autoclave, in-situ amorphous [r arrow] crystal conversions, such as SCOP [r arrow] hydroxyapatite (HOAp), and Al[sub 2]O[sub 3] [center dot] xH[sub 2]O [r arrow] [gamma]-AlOOH, occurred at [approx] 100 C, while the rate of reaction of the residual CAC with the phosphate reactant was increasingly accelerated by hydrothermal catalysis. Based upon this information, the authors prepared lightweight CPC specimens by hydrothermally treating a low-density cement slurry (1.28 g/cc) consisting of CAC powder, -(-NaPO[sub 3]-)-[sub n] solution, and mullite-hollow microspheres. The characteristics of the autoclaved lightweight specimens were a compressive strength of > 9.0 MPa, water permeability of [approx] 5.0 [times] 10[sup [minus]3] milli darcy, and a low rate of alkali carbonation. The reasons for such a low carbonation rate reflected the presence of a minimum amount of residual CAC, in conjunction with the presence of HOAp and [gamma]-AlOOH phases that are unsusceptible to wet carbonation.

  12. Examination of several potential "transformation weakeners" for ceramic-composite interfaces

    NASA Astrophysics Data System (ADS)

    Shull, James Lee, Jr.

    In an effort to broaden the use of transformable interphases in ceramic composites, investigations were conducted towards identifying several displacive phase transformations which could potentially be used in composites with alumina, YAG, and/or mullite. Phase transformations were examined in four materials: the rare earth pyroaluminates, e.g. Ysb4Alsb2Osb9; leucite, KAlSisb2Osb6; KAlSiOsb4; and hexacelsian, BaAlsb2Sisb2Osb8. Two previously unreported phase transformations were observed, a presumably second order transformation at ˜1500sp°C in Gdsb4Alsb2Osb9 between orthorhombic and monoclinic phases and another first order transformation in hexacelsian at {˜}700sp°C. Unfortunately, none of the transformations studied appear capable of causing transformation weakening of composite interfaces due to phase compatibility problems, difficulties stabilizing the high temperature phase, or lack of distinctive character in the transformation. (A potentially useful transformation was noted in KAlSiOsb4 above 1500sp°C, but the transformation temperature was beyond the capability of available equipment.) Experiments with composites of BaAlsb2Sisb2Osb8 and alumina, however, revealed a new mechanism for achieving debonding in composites. This mechanism, called reconstructive transformation toughening, uses a volume reducing reconstructive phase transformation to generate tensile stresses at interfaces in composites. Excellent debonding behavior was observed in BaAlsb2Sisb2Osb8/Alsb2Osb3 composites tested at room temperature and at 850sp°C. The most significant advantage of this new mechanism is that it can be made insensitive to changes in temperature.

  13. Authigenic phyllosilicates in modern acid saline lake sediments and implications for Mars

    NASA Astrophysics Data System (ADS)

    Story, Stacy; Bowen, Brenda Beitler; Benison, Kathleen Counter; Schulze, Darrell G.

    2010-12-01

    Aluminum- and Fe/Mg-phyllosilicates are considered important geochemical indicators in terrestrial and Martian sedimentary systems. Traditionally, Al-phyllosilicates are characterized as forming and remaining stable under conditions of low to moderate pH, while Fe/Mg-phyllosilicates are considered representative of only dilute and moderate to high pH conditions. However, we have observed Al- and Fe/Mg-phyllosilicates in acid saline lake sediments in Western Australia. Phyllosilicate formation mechanisms in these lake systems include direct precipitation from lake waters, early diagenetic precipitation from shallow groundwaters, and deposition/alteration of detrital grains. X-ray diffraction analysis of silt- and clay-size sediments from two acid saline lakes in Western Australia indicates the presence of several complex mineral assemblages with extreme spatial heterogeneity that reflects the complex geochemistry of these lakes. These assemblages include unique combinations of authigenic and/or detrital phyllosilicates (e.g., kaolinite, smectite, and palygorskite-sepiolite), sulfates (e.g., alunite, jarosite, and gypsum), Fe-oxides (e.g., hematite and goethite), and other silicates (e.g., mullite and heulandite-clinoptilolite). Observations of Fe/Mg-phyllosilicates found in acid saline sediments in southern Western Australia suggest their degradation under conditions of low pH (2.5-5.4) is slowed by the high salinity (5-25%) of the lake and shallow groundwaters. The occurrence of both Al- and Fe/Mg-phyllosilicates in these acid saline lake sediments suggests that environmental interpretations based on the occurrence of phyllosilicates require additional consideration of their spatial distribution and association with other minerals. Moreover, the similarity between the diverse mineral assemblages in these terrestrial acid saline systems and those on Mars indicates similar conditions may have existed on Mars.

  14. Potential of fly ash for neutralisation of acid mine drainage.

    PubMed

    Qureshi, Asif; Jia, Yu; Maurice, Christian; Öhlander, Björn

    2016-09-01

    Lignite (PK), bituminous (FI) and biomass (SE) fly ashes (FAs) were mineralogically and geochemically characterised, and their element leachability was studied with batch leaching tests. The potential for acid neutralisation (ANP) was quantified by their buffering capacity, reflecting their potential for neutralisation of acid mine drainage. Quartz was the common mineral in FAs detected by XRD with iron oxide, anhydrite, and magnesioferrite in PK, mullite and lime in FI, and calcite and anorthite in SE. All the FAs had high contents of major elements such as Fe, Si, Al and Ca. The Ca content in SE was six and eight times higher compared to PK and FI, respectively. Sulphur content in PK and SE was one magnitude higher than FI. Iron concentrations were higher in PK. The trace element concentrations varied between the FAs. SE had the highest ANP (corresponding to 275 kg CaCO3 tonne(-1)) which was 15 and 10 times higher than PK and FI, respectively. The concentrations of Ca(2+), SO4 (2-), Na(+) and Cl(-) in the leachates were much higher compared to other elements from all FA samples. Iron, Cu and Hg were not detected in any of the FA leachates because of their mild to strong alkaline nature with pH ranging from 9 to 13. Potassium leached in much higher quantity from SE than from the other ashes. Arsenic, Mn and Ni leached from PK only, while Co and Pb from SE only. The concentrations of Zn were higher in the leachates from SE. The FAs used in this study have strong potential for the neutralisation of AMD due to their alkaline nature. However, on the other hand, FAs must be further investigated, with scaled-up experiments before full-scale application, because they might leach pronounced concentrations of elements of concern with decreasing pH while neutralising AMD.

  15. Steel penetration in sand molds. Final technical report, September 1994--September 1997

    SciTech Connect

    Hayes, K.D.; Owens, M.; Barlow, J.; Stefanescu, D.M.; Lane, A.M.; Piwonka, T.S.

    1997-12-01

    The research program was successful in identifying the major factoirs that influence penetration. This was done first through a case study of penetration samples. The study revealed that both chemical and mechanical penetration were present in carbon and high manganese steels. It also found that only mechanical penetration is found in stainless steel samples. It should be noted that when mechanical penetration does occur, there is a greater risk of chemical reactions with the mold. Therefore, it is common to confuse mechanical penetration with chemical. Sessile drop experiments were run to discover the effect of steel chemistry on the contact angle for different substrates. These experiments revealed the best substrates for each type of metal. Bauxite, magnesite, and mullite were discovered to be the best materials for resisting mechanical penetration. It was also shown that high manganese steels cannot be poured into silica molds and that stainless steel should not be poured in chromite molds. The sessile drop data was used to develop a mechanical penetration model which correctly predicted penetration in sixteen of twenty castings poured at the University of Alabama. Mold/metal atmosphere tests were run to understand the effects of the atmosphere on chemical penetration. It was found that the chemistry affecting penetration has its greatest effect as the casting is just poured. Chemical penetration for low carbon steels cannot be completely eliminated by adding carbon (seacoal) to green sand molds although a marked decrease is obtained in its severity. Extremely high carbon concentrations might be able to totally eliminate the penetration but are not used because of their possible diffusion into the steel causing carburization. A chemical penetration model was produced and its results agree well with the experimental results.

  16. Next generation internet architecture and cyber-assisted energy efficiency in smart grids of buildings

    NASA Astrophysics Data System (ADS)

    Peterson, Robb Alex

    Northern Minnesota's iron mines are the starting point for the majority of the steel that gets produced in the United States. Their taconite processing plants use heat in furnaces to oxidize and indurate iron in the final stage of making a taconite pellet. Facilities can increase efficiencies when refractory service life is maintained. Efficiencies gained include: less fuel used, better quality control, better furnace control, and less mechanical component maintenance. Furnace refractory linings fail when the cracks that develop in them are uncontrolled or too large. These failures allow heat and gases retained by the lining to reach structural or mechanical components. Furnace control and efficiencies are also compromised when heat and gases are allowed to short circuit or escape the system. These failures are primarily the result of thermal of shock and expansion. It is common place to add stainless steel needle reinforcement to a monolithic refractory in an effort to counteract these effects. This study used several standard ASTM testing procedures to test 65% alumina mullite based refractory samples with 304 and 406 grade stainless steel needles. Mechanical property data gathered was used to analyze performance. The study found that adding reinforcement does not increase initial Compression and Cold Modulus of Ruptures strengths, however, after prolonged heat and thermal shock exposure, needles help maintain integrity and mechanical properties of samples. The study also found that corrosion due to oxidation was a major contributing factor to the way needles performed; and concluded that a concentration of 3% 406 "Alfa 1" stainless steel reinforcing needles added to the working lining of a taconite furnace is recommended.

  17. Why can tiAicrsiYN-based adaptive coatings deliver exceptional performance under extreme frictional conditions?

    PubMed

    Beake, Ben D; Fox-Rabinovich, German S; Losset, Yannick; Yamamoto, Kenji; Agguire, Myriam H; Veldhuis, Stephen C; Endrino, Jose L; Kovalev, Anatoliy I

    2012-01-01

    Adaptive TiAlCrSiYN-based coatings show promise under the extreme tribological conditions of dry ultra-high-speed (500-700 m min-1) machining of hardened tool steels. During high speed machining, protective sapphire and mullite-like tribo-films form on the surface of TiAlCrSiYN-based coatings resulting in beneficial heat-redistribution in the cutting zone. XRD and HRTEM data show that the tribo-films act as a thermal barrier creating a strong thermal gradient. The data are consistent with the temperature decreasing from approximately 1100-1200 degrees C at the outer surface to approximately 600 degrees C at the tribo-film/coating interface. The mechanical properties of the multilayer TiAICrSiYN/TiA1CrN coating were measured by high temperature nanoindentation. It retains relatively high hardness (21 GPa) at 600 degrees C. The nanomechanical properties of the underlying coating layer provide a stable low wear environment for the tribo-films to form and regenerate so it can sustain high temperatures under operation (600 degrees C). This combination of characteristics explains the high wear resistance of the multilayer TiAlCrSiYN/TiAICrN coating under extreme operating conditions. TiAlCrSiYN and TiAlCrN monolayer coatings have a less effective combination of adaptability and mechanical characteristics and therefore lower tool life. The microstructural reasons for different optimum hardness and plasticity between monolayer and multilayer coatings are discussed.

  18. PNAS Plus: Very high-temperature impact melt products as evidence for cosmic airbursts and impacts 12,900 years ago

    NASA Astrophysics Data System (ADS)

    Bunch, Ted E.; Hermes, Robert E.; Moore, Andrew M. T.; Kennett, Douglas J.; Weaver, James C.; Wittke, James H.; DeCarli, Paul S.; Bischoff, James L.; Hillman, Gordon C.; Howard, George A.; Kimbel, David R.; Kletetschka, Gunther; Lipo, Carl P.; Sakai, Sachiko; Revay, Zsolt; West, Allen; Firestone, Richard B.; Kennett, James P.

    2012-07-01

    It has been proposed that fragments of an asteroid or comet impacted Earth, deposited silica-and iron-rich microspherules and other proxies across several continents, and triggered the Younger Dryas cooling episode 12,900 years ago. Although many independent groups have confirmed the impact evidence, the hypothesis remains controversial because some groups have failed to do so. We examined sediment sequences from 18 dated Younger Dryas boundary (YDB) sites across three continents (North America, Europe, and Asia), spanning 12,000 km around nearly one-third of the planet. All sites display abundant microspherules in the YDB with none or few above and below. In addition, three sites (Abu Hureyra, Syria; Melrose, Pennsylvania; and Blackville, South Carolina) display vesicular, high-temperature, siliceous scoria-like objects, or SLOs, that match the spherules geochemically. We compared YDB objects with melt products from a known cosmic impact (Meteor Crater, Arizona) and from the 1945 Trinity nuclear airburst in Socorro, New Mexico, and found that all of these high-energy events produced material that is geochemically and morphologically comparable, including: (i) high-temperature, rapidly quenched microspherules and SLOs; (ii) corundum, mullite, and suessite (Fe3Si), a rare meteoritic mineral that forms under high temperatures; (iii) melted SiO2 glass, or lechatelierite, with flow textures (or schlieren) that form at > 2,200 °C; and (iv) particles with features indicative of high-energy interparticle collisions. These results are inconsistent with anthropogenic, volcanic, authigenic, and cosmic materials, yet consistent with cosmic ejecta, supporting the hypothesis of extraterrestrial airbursts/impacts 12,900 years ago. The wide geographic distribution of SLOs is consistent with multiple impactors.

  19. Synthesis of Zeolites Na-P1 from South African Coal Fly Ash: Effect of Impeller Design and Agitation

    PubMed Central

    Mainganye, Dakalo; Ojumu, Tunde Victor; Petrik, Leslie

    2013-01-01

    South African fly ash has been shown to be a useful feedstock for the synthesis of some zeolites. The present study focuses on the effect of impeller design and agitation rates on the synthesis of zeolite Na-P1 which are critical to the commercialization of this product. The effects of three impeller designs (4-flat blade, Anchor and Archimedes screw impellers) and three agitation speeds (150, 200 and 300 rpm) were investigated using a modified previously reported synthesis conditions; 48 hours of ageing at 47 °C and static hydrothermal treatment at 140 °C for 48 hours. The experimental results demonstrated that the phase purity of zeolite Na-P1 was strongly affected by the agitation rate and the type of impeller used during the ageing step of the synthesis process. Although zeolite Na-P1 was synthesized with a space time yield (STY) of 15 ± 0.4 kg d−1m−3 and a product yield of 0.98±0.05 g zeolites/g fly ash for each impeller at different agitation speeds, zeolite formation was assessed to be fairly unsuccessful in some cases due the occurrence of undissolved mullite and/or the formation of impurities such as hydroxysodalite with the zeolitic product. This study also showed that a high crystalline zeolite Na-P1 can be synthesized from South African coal fly ash using a 4-flat blade impeller at an agitation rate of 200 rpm during the ageing step at 47 °C for 48 hours followed by static hydrothermal treatment at 140 °C for 48 hours. PMID:28809261

  20. Testing of Westinghouse hot gas candle filter at Foster Wheeler Karhula R and D Center

    SciTech Connect

    Eriksson, T.; Sellakumar, K.M.; Lippert, T.; Dennis, R.; Feldmann, H.; Brown, R.

    1996-12-31

    The main objectives of the project are to provide performance and environmental data to the design of a PCFB Demonstration project and evaluate Westinghouse advanced ceramic barrier filter system and candle materials. A total test duration of 1,000 to 1,500 hrs in three segments of 500 hrs each has been planned for evaluating the filter unit. A single cluster Westinghouse hot gas candle filter is being tested. The filter system, which houses 112 ceramic candles in three plenums, takes the full flue gas flow from the PCFB combustor. At full load operation (10 MW load, 10 Bar, 850 C), the nominal filtration velocity is 4.3 cm/s. FWEI and WEC have selected a set of advanced ceramic candle materials based on a state of the art evaluation of the material characteristics in the WEC facilities and earlier test experience at many coal-fired test sites including the 2000 hour testing at the Karhula PCFB pilot plant. The selection comprises the following four types of advanced ceramic candles: Schumacher FT-20; 3M SiCoNeX; Pall 326; and Coors mullite. The ICB has supplied coal and the sorbent. Tests have been in progress since November 1995 and are scheduled for completion by the middle of 1996. The filter unit performance so far has been very satisfactory at the nominal design conditions--10 to 12 bar (150 to 175 psis), 800 to 850 C (1,500 to 1,575 F), and nearly 100% dust removal. There was no visible evidence of any dust carry over into the clean side. This paper describes the performance of the filter including the pulse system and the mechanical package.