Porous Si3N4-based ceramics with uniform pore structure originated from single-shell hollow microspheres

Zhang, Xiaoyan; Huo, Wenlong; Lu, Yuju; Yan, Shu; Liu, Jingjing

doi:10.1007/s10853-018-3118-2

Cited by 17 publications

(10 citation statements)

References 38 publications

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“…The blending of glycerol and binders could increase the energy absorption, and then sintering can carried out in air. The SEM image of silica hollow spheres and fly ash hollow spheres (Zhang et al 2019) are shown in Fig. 14.…”

Section: Hollow Sphere Sinteringmentioning

confidence: 99%

Porous Ceramic Properties and Its Different Fabrication Process

Uthaman¹,

Lal²,

Thomas³

2021

Engineering Materials

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The unique compositions and outstanding properties of porous ceramic products make them useful in various application fields such as high-temperature thermal insulation, filtration, and catalytic reactions. This chapter aims to review the porous ceramics properties, classifications, and the different types of fabrication methods of porous ceramics. The readers can get a profound view of porous ceramic materials and their different fabrication methods such as particle stacking sintering, the addition of foaming, gel casting, sol-gel process, polymeric sponge, and freezedrying method. The fabrication process of porous ceramics can influence the quality of the final products.Recently, the utilization of porous ceramics has become great consideration due to its outstanding mechanical strength, chemical, abrasion resistance, etc. (Eom et al. 2013;Colombo 2008). Some benefits of porous ceramics are illustrated in Fig. 1. The broadly considering porous ceramics are silica, alumina, titania, magnesium oxide, zirconia, etc. (Colombo 2002). The pore structure, morphology, pore size, pore wall, porosity, the density of the pore strut, and interconnection of pores have a significant role in the properties of porous ceramics (Sakka 2005; Liu and Chen 2014). The particle size distribution of ceramic powders, the concentration of binder, types of binders, fabrication, etc., can influence the porosity and pore size (Ohji and Fukushima 2012). Typically, the particle size of raw ceramic powder is about two to five times greater than pores, for acquiring the needed pore size. And, the greatest service temperature of porous ceramics is around 1000-2000 °C. The pores are

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Section: Hollow Sphere Sinteringmentioning

confidence: 99%

Porous Ceramic Properties and Its Different Fabrication Process

Uthaman¹,

Lal²,

Thomas³

2021

Engineering Materials

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“…The active oxidation process may occur at temperatures above 1300 C and can be assisted by a low oxygen pressure in the furnace atmosphere or the abundance of metal ions, e.g., Al 3þ or Y 3þ originating from the sintering aids. [128][129][130][131][132][133] The aforementioned generation of β-Si 3 N 4 parts from tape-casted LOM multilayers has been successfully conducted by Rodrigues et al, [65] who tested the infiltration of the LOMed green body by a polyurea-silazane-based resin (Figure 15, on the left), and by Park and Cho, [133] who added β-Si 3 N 4 whiskers to the filler powder. Both groups of authors sintered the LOMed green bodies at temperatures of at least 1750 C and in nitrogen atmosphere.…”

Section: Monolithic Ceramic Materialsmentioning

confidence: 99%

“…If Si 3 N 4 oxidizes passively, whereas nitrogen gas is released and a SiO 2 layer is formed on the outside of the ceramic, which is also referred to as “scale layer.” In the active oxidation process of Si 3 N 4 , however, the material can decompose into gaseous SiO (silicon monoxide) and nitrogen. The active oxidation process may occur at temperatures above 1300 °C and can be assisted by a low oxygen pressure in the furnace atmosphere or the abundance of metal ions, e.g., Al 3+ or Y 3+ originating from the sintering aids . The aforementioned generation of β‐Si 3 N 4 parts from tape‐casted LOM multilayers has been successfully conducted by Rodrigues et al, who tested the infiltration of the LOMed green body by a polyurea–silazane‐based resin (Figure , on the left), and by Park and Cho, who added β‐Si 3 N 4 whiskers to the filler powder.…”

Section: Types Of Ceramic‐based Products Obtained From Lommentioning

confidence: 99%

Laminated Object Manufacturing of Ceramic‐Based Materials

2020

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Since their inception, additive manufacturing (AM) techniques have been the go‐to methods for obtaining highly complex‐shaped rapid prototypes (RPs) and specialized parts, which were produced in small lot sizes. The AM technique of laminated object manufacturing (LOM) is an immensely convenient and cost‐effective method for quickly producing millimeter‐sized to meter‐sized parts, while incorporating micrometer‐sized constructive features. LOM machines offer an open work space, within which nontoxic and highly filled sheet materials can be processed at a high production velocity. The unique property profile of ceramic‐based materials from LOM may be indispensable for applications calling for materials that unite high temperature resistance, mechanical strength, and light weight. Optionally, local material functionalization may engender the electrical conductivity, chemical stability, ferroelectricity, radiation shielding, or filter membrane stability of a limited portion of the material. Herein, a detailed evaluation of the applicability of LOM in the near net shaping ceramic‐based materials is presented. Optional technical adjustments for the LOM process and extensions of the LOM machine configuration can improve the economic feasibility its operation. Previously successful LOM‐printed ceramic‐based materials are showcased within a comprehensive overview on the state of the art and potential novel composite materials are presented.

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“…49,50 Owing to their silicon-aluminum-based composition similar to SAD, they can form pores without introducing excess impurities unlike other pore-forming agents. 51,52 More importantly, another main component, metallic aluminum, could be oxidized to form Al 2 O 3 during elevated temperature, which will lead to volume expansion to compensate for the shrinkage caused by sintering, and ultimately produce a low sintering shrinkage effect. 53 In view of the chemical composition of SAD, a simple, versatile, effective method has been proposed here, namely, directly sintering dry-pressed green bodies from SAD as the sole raw materials to obtain alumina-based porous ceramics, which is free of AlN and salt removal process unlike traditional way for recycling of SAD.…”

Section: Introductionmentioning

confidence: 99%

Porous ceramics with near‐zero shrinkage and low thermal conductivity from hazardous secondary aluminum dross

Zhang

Shen

et al. 2022

J Am Ceram Soc

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Herein, a simple, versatile, and low-cost approach has been proposed to realize the green utilization of secondary aluminum dross, the hazardous solid waste, namely directly sintering dry-pressed green bodies from secondary aluminum dross to fabricate porous ceramics according to high-temperature foaming process spontaneously without adding spare foaming agents. Aluminum nitride (AlN) in secondary aluminum dross was employed to realize high-temperature foaming due to its oxidation, which makes traditional AlN and salts removal process needless. Moreover, near-zero shrinkage or even expansion during sintering of porous ceramics have occurred because in-situ foaming process together with the oxidation of Al particles well offset the sintering shrinkage. After sintering at 1400 • C for 2 h, porous ceramics composed of α-Al 2 O 3 and spinel phases with open porosity of 37.91%, sintering expansion rate of 1.13%, flexural strength of 45.67 MPa, and thermal conductivity of 0.97 W/(m⋅K) have been prepared. Cenospheres as pore-forming agents have been added to further improve the porosity, and alumina-based porous ceramics with open porosity of 28.39%-43.20% and flexural strength of 15.80-52.48 MPa have been obtained. This effective solution for recycling secondary aluminum dross could supply high-performance porous ceramics, which is expected to be applied in the fields of light-weight structural components and thermal insulations.

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Porous Si3N4-based ceramics with uniform pore structure originated from single-shell hollow microspheres

Cited by 17 publications

References 38 publications

Porous Ceramic Properties and Its Different Fabrication Process

Porous Ceramic Properties and Its Different Fabrication Process

Laminated Object Manufacturing of Ceramic‐Based Materials

Porous ceramics with near‐zero shrinkage and low thermal conductivity from hazardous secondary aluminum dross

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