Development of mullite/zirconia composites from a mixture of aluminum dross and zircon

Castro, Marcela Nohemi Ibarra; Almanza-Robles, J.M.; Cortés-Hernández, Dora A.; Escobedo‐Bocardo, José C.; Torres, J.

doi:10.1016/j.ceramint.2008.03.006

Cited by 49 publications

(18 citation statements)

References 6 publications

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“…There are several methods for the treatment of this byproduct and most of them focus on the recovering of metallic aluminum; its composition varies depending on the purification procedure, in general, it may contain Al 2 O 3 , AlN, Al 4 C 3 , SiO 2 , MgO, Al and minor quantities of Si, Fe and Mg. Many small aluminum recycling companies do not treat the generated aluminum dross and it is usually confined in landscapes in incandescent state allowing the metallic aluminum to oxidize, therefore this kind of byproduct has a high alumina content (1) . Aluminum dross has been used in several applications, such as reinforcing material in aluminum-dross composites (2) synthesis of spinel (3) by solid-state reaction with MgO, synthesis of SiAlON (4) and carbothermal reduction and nitridation process, as raw material for the preparation of refractory (5), manufacture of calcium aluminate cement (6) synthesis of Mg-Al, Ca-Al and Zn-Al type LDH S (7) using HCl and NaOH solutions.…”

Section: Introductionmentioning

confidence: 99%

Synthesis and mechanical properties of a calcium sulphoaluminate cement made of industrial wastes

et al. 2014

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Environmentally-friendly calcium sulphoaluminate clinkers were obtained from a mixture of aluminium dross, fluorgypsum, fly ash and CaCO 3 at temperatures within the range of 1100 to 1400 °C. After the heat treatments Ca 4 Al 6 O 12 SO 4 was the main phase. Three different cements were prepared using the clinkers synthesized at 1250, 1350 and 1400 °C; the clinker powders were mixed with 20 wt% of hemihydrate. Cement pastes were prepared using a water/cement ratio (w/c), 0.4 followed by curing at 20 or 40 °C for periods of time ranging from 1 to 28 days. Most of the samples showed high compression strengths 40-47 MPa after 28 days, which were comparable to the strength of Portland cement. Ettringite was the main hydration product and its morphology consisted of acicular and hexagonal plates, which is typical of this phase.

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Section: Introductionmentioning

confidence: 99%

Synthesis and mechanical properties of a calcium sulphoaluminate cement made of industrial wastes

et al. 2014

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“…For the T1500 material the microstructure is a well-defined mullite (dark gray) ceramic matrix with a homogeneous distribution of imbibed zirconia and zirconium titanate grains (light gray, the second slightly darker), this microstructure is comparable to the typical dispersoidal mullite zirconia composites [7][8][9][10][11][12][13][14][15][16][17][18][19] but with the addition ZrTiO 4 phase. This interlocked microstructure with the imbibed zirconia grains has been fully described and several toughening mechanisms have been proposed to be possible to occur in this kind of materials [58,[60][61][62].…”

Section: Microstructure (Sem)mentioning

confidence: 99%

“…Zircon and alumina are largely employed as raw materials in their manufacture [13][14][15]. The reaction sintering processes is a suitable strategy for obtaining zirconia composites at comparatively lower costs than introducing zirconia as starting powder [16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Dense mullite–zirconia–zirconium titanate ceramic composites by reaction sintering

Rendtorff

Gómez

Gauna

et al. 2016

Ceramics International

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Materials from the Al 2 O 3 -SiO 2 -ZrO 2 and the Al 2 O 3 -SiO 2 -ZrO 2 -TiO 2 systems have several high temperature applications because they present the good refractoriness, chemical inertness, adequate mechanical and thermo-mechanical behaviors with a relatively good cost: performance ratio. In this work stoichiometric (3:2:1) molar incompatible mixtures of alumina (Al 2 O 3 ), zircon (ZrSiO 4 ) and titania (TiO 2 ) were slip casted and sintered in a 1300-1500 1C temperature range in order to obtain mullite (3Al 2 O 3 Á 2SiO 2 ), zirconia (ZrO 2 ) and zirconium titanate (ZrTiO 4 ) dense triple ceramic composite.Both sintering and reaction occurred after the thermal treatments. Reaction progress and densification evolutions were established. Dense Triplex composite materials were achieved after 1500 1C treatments. The reaction-sintering was followed by XRD, TG-DTA, and dilatometry. Densification started at 1100 1C and the chemical reactions only started above 1300 1C. Aluminum titanate (Al 2 TiO 5 ) was found to be an intermediate of the reaction after 1400 1C treatments. Materials treated below 1300 1C presented a partial densification of the unreacted starting powders. Resulting ceramic materials were characterized. The crystalline phases were evaluated, as well as the texture properties. The achieved microstructure consisted in interlocked multiphase ceramic with zirconia (monoclinic) grains. The achieved Hv and K IC reached 9 GPa and 4.3 MPa m 1/2 respectively. The dense and interlocked ceramic microstructure and relative high mechanical properties of the developed material encourages several high temperature applications. Finally it can be pointed out that after 1500 1C treatments some detrimental grain growth was observed.

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“…The use of minerals available in the beach sand (sillimanite, zircon), kaolin or the wastes of industry, like fly ash, will be caught the attention of the researchers to synthesize the product at low cost. [5][6][7][8][9][10] In most of the synthesis technique, the raw material used for MUZ is derived from zircon sand, which is a mixture of 67% of zirconia and 33% of silica (approximately). Zircon dissociates into zirconia and silica at about 1450°C-1700°C, depends on the impurities.…”

Section: Introductionmentioning

confidence: 99%

“…More synthesis work has been carried out from the zircon and alumina mixture. [6][7][8] But, it is important to note that sea beach sand also contains valuable minerals, like sillimanite (a mixture of alumina and silica in the ratio of 63 and 37, respectively). Hence, it can be possible to synthesize MUZ from sillimanite and zircon mixture.…”

Section: Introductionmentioning

confidence: 99%

Preparation of Fused Zirconia/Mullite Aggregates from Sillimanite, Zircon, and Alumina Mixtures via Plasma

et al. 2011

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The mineral sillimanite and zircon recovered from beach sand were considered as the sources of alumina, silica, and zirconia for the synthesis of fused zirconia mullite (MUZ). The mullite phase appears as a primary phase up to the zirconia percentages of 20, whereas it appears as a secondary phase in the higher percentages of zirconia (>20) in the MUZ composites. The thermal plasma provides higher temperature up to 2100°C to favor the transformation of monoclinic phases of zirconia to tetragonal/cubic zirconia for which a mixture of monoclinic, tetragonal, and cubic zirconia is observed in the X‐ray diffraction pattern. The electron probe microstructure analysis reveals the presence of glass phase (SiO2) in the lower (5%) and higher (>15%) percentage of zirconia composites. A variation in the optical band gap (2.06–2.63 eV) and enhancement in the hardness are observed with the increasing concentration of zirconia in the MUZ composites.

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Development of mullite/zirconia composites from a mixture of aluminum dross and zircon

Cited by 49 publications

References 6 publications

Synthesis and mechanical properties of a calcium sulphoaluminate cement made of industrial wastes

Synthesis and mechanical properties of a calcium sulphoaluminate cement made of industrial wastes

Dense mullite–zirconia–zirconium titanate ceramic composites by reaction sintering

Preparation of Fused Zirconia/Mullite Aggregates from Sillimanite, Zircon, and Alumina Mixtures via Plasma

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