Improving the Strength of ZTA Foams with Different Strategies: Immersion Infiltration and Recoating
Abstract
:1. Introduction
2. Experimental Details
2.1. ZTA Foam Preparation
2.2. Immersion Infiltration of ZTA Foams
2.3. Recoating of ZTA Foams
2.4. Characterization
3. Results and Discussion
3.1. The Original ZTA Foams
3.2. Improving the Strength of ZTA Foams by Immersion Infiltration
3.3. Improving the Strength of ZTA Foams by Recoating
3.4. Comparison of Different Strengthening Methods
4. Conclusions
Acknowledgments
Author Contributions
Conflicts of Interest
References
- Gibson, L.J.; Ashby, M.F. Cellular Solids: Structure and Properties, 2nd ed.; Cambridge University Press: London, UK, 1997; pp. 1–500. [Google Scholar]
- Scheffler, M.; Colombo, P. Cellular Ceramics: Structure, Manufacturing, Properties and Applications; Weily-VCH: Weinheim, Germany, 2005; pp. 1–617. [Google Scholar]
- Colombo, P. Conventional and novel processing methods for cellular ceramics. Philos. Trans. A. Math. Phys. Eng. Sci. 2006, 364, 109–124. [Google Scholar] [CrossRef] [PubMed]
- Studart, A.R.; Gonzenbach, U.T.; Tervoort, E.; Gauckler, L.J. Processing routes to macroporous ceramics: A review. J. Am. Ceram. Soc. 2006, 89, 1771–1789. [Google Scholar] [CrossRef]
- Wang, J.; Stevens, R. Review zirconia-toughened alumina (ZTA) ceramics. J. Mater. Res. 1989, 24, 3421–3440. [Google Scholar]
- Hannink, R.H.J.; Kelly, P.M.; Muddle, B.C. Transformation toughening in zirconia-containing ceramics. J. Am. Ceram. Soc. 2000, 87, 461–487. [Google Scholar] [CrossRef]
- Chevalier, J.; Gremillard, L.; Virkar, A.V.; Clarke, D.R. The tetragonal-monoclinic transformation in zirconia: Lessons learned and future trends. J. Am. Ceram. Soc. 2009, 92, 1901–1920. [Google Scholar] [CrossRef]
- Hossen, M.; Chowdhury, F.Z.; Gafur, A.M.; Hakim, A.M.A. Structural and mechanical properties of zirconia toughened alumina (ZTA) composites. Int. J. Eng. Res. Tec. 2014, 3, 2128–2134. [Google Scholar]
- Biotteau, D.K.; Zych, L.; Gremillard, L.; Chevalier, J. Effects of Ca-, Mg- and Si-doping on microstructures of alumina–zirconia composites. J. Eur. Ceram. Soc. 2012, 32, 2711–2721. [Google Scholar] [CrossRef]
- Kern, F.; Palmero, P. Microstructure and mechanical properties of alumina 5 vol % zirconia nanocomposites prepared by powder coating and powder mixing routes. Ceram. Int. 2013, 39, 673–682. [Google Scholar] [CrossRef]
- Sommer, F.; Walcher, H.; Kern, F.; Maetzig, M.; Gadow, R. Influence of feedstock preparation on ceramic injection molding and microstructural features of zirconia toughened alumina. J. Eur. Ceram. Soc. 2014, 34, 745–751. [Google Scholar] [CrossRef]
- Nevarez-Rascon, A.; Aguilar-Elguezabal, A.; Orrantia, E.; Bocanegra-Bernal, M.H. Compressive strength, hardness and fracture toughness of Al2O3 whiskers reinforced ZTA and ATZ nanocomposites: Weibull analysis. Int. J. Ref. Met. Hard Mater. 2011, 29, 333–340. [Google Scholar] [CrossRef]
- Azhar, A.Z.A.; Mohamad, H.; Ratnam, M.M.; Ahmad, Z.A. The effects of MgO addition on microstructure, mechanical properties and wear performance of zirconia-toughened alumina cutting inserts. J. Alloys Compd. 2010, 497, 316–320. [Google Scholar] [CrossRef]
- Karl, S.; Somers, A.V. Method of Making Porous Ceramic Articles. U.S. Patent 3090094 A, 21 May 1963. [Google Scholar]
- Vogt, U.F.; Gorbar, M.; Dimopoulos-Eggenschwiler, P.; Broenstrup, A.; Wagner, G.; Colombo, P. Improving the properties of ceramic foams by a vacuum infiltration process. J. Eur. Ceram. Soc. 2010, 30, 3005–3011. [Google Scholar] [CrossRef]
- Liang, X.; Li, Y.; Liu, J.; Sang, S.; Chen, Y.; Li, B.; Aneziris, C.G. Fabrication of SiC reticulated porous ceramics with multi-layered struts for porous media combustion. Ceram. Int. 2016, 42, 13091–13097. [Google Scholar] [CrossRef]
- Jun, I.K.; Kong, Y.M.; Lee, S.H.; Kim, H.E.; Kim, H.W.; Goretta, K.C. Reinforcement of a reticulated porous ceramic by a novel infiltration technique. J. Am. Ceram. Soc. 2006, 89, 2317–2319. [Google Scholar] [CrossRef]
- Rannabauer, S.; Söffker, G.M.; Scheunemann, M.; Betke, U.; Scheffler, M. Increased mechanical stability and thermal conductivity of alumina reticulated porous ceramics (RPC) by nanoparticle infiltration processing. Adv. Eng. Mater. 2017. [Google Scholar] [CrossRef]
- Pu, X.; Liu, X.; Qiu, F.; Huang, L. Novel method to optimize the structure of reticulated porous ceramics. J. Am. Ceram. Soc. 2004, 87, 1392–1394. [Google Scholar] [CrossRef]
- Yao, X.; Tan, S.; Huang, Z.; Jiang, D. Effect of recoating slurry viscosity on the properties of reticulated porous silicon carbide ceramics. Ceram. Int. 2006, 32, 137–142. [Google Scholar] [CrossRef]
- Yao, X.; Yang, Y.; Liu, X.; Huang, Z. Effect of recoating slurry compositions on the microstructure and properties of SiC reticulated porous ceramics. J. Eur. Ceram. Soc. 2013, 33, 2909–2914. [Google Scholar] [CrossRef]
- Voigt, C.; Jäckel, E.; Aneziris, C.G.; Hubálková, J. Investigations of reticulated porous alumina foam ceramics based on different coating techniques with the aid of μ-CT and statistical characteristics. Ceram. Int. 2013, 39, 2415–2422. [Google Scholar] [CrossRef]
- Vogt, U.F.; Györfy, L.; Herzog, A.; Graule, T.; Plesch, G. Macroporous silicon carbide foams for porous burner applications and catalyst supports. J. Phys. Chem. Solids 2007, 68, 1234–1238. [Google Scholar] [CrossRef]
- Herrera, A.M.; Martins de Oliveira, A.A.; Novaes de Oliveira, A.P.; Hotza, D. Processing and characterization of yttria-stabilized zirconia foams for high-temperature applications. J. Ceram. 2013, 2013, 1–8. [Google Scholar] [CrossRef]
- Ren, F.; Zhai, G.; Ma, Z.; Volinsky, A.A.; Tian, B. Recoating slurry process effects on the SiC-based casting foam filter properties. J. Ceram. Process. Res. 2014, 15, 71–75. [Google Scholar]
- Han, F.; Zhong, Z.; Yang, Y.; Wei, W.; Zhang, F.; Xing, W.; Fan, Y. High gas permeability of SiC porous ceramics reinforced by mullite fibers. J. Eur. Ceram. Soc. 2016, 36, 3909–3917. [Google Scholar] [CrossRef]
- Yao, X.; Tan, S.; Huang, Z.; Dong, S.; Jiang, D. Growth mechanism of β-SiC nanowires in SiC reticulated porous ceramics. Ceram. Int. 2007, 33, 901–904. [Google Scholar] [CrossRef]
- Washbourne, C. Catalyst Carriers. U.S. Patent 3972834 A, 3 August 1976. [Google Scholar]
- Blome, C.J. Molten Metal Filter. U.S. Patent 4265659 A, 5 May 1981. [Google Scholar]
- Brockmeyer, J.W.; Hendersonville, N.C. Ceramic Foam Filter and Aqueous Slurry for Making Same. U.S. Patent 4391918 A, 5 July 1983. [Google Scholar]
- Pu, X.; Jia, L.; Zhang, D.; Su, C.; Liu, X. Surface treatment of templates for fabrication of reticulated porous ceramics. J. Am. Ceram. Soc. 2007, 90, 2998–3000. [Google Scholar] [CrossRef]
- Jun, I.-K.; Koh, Y.-H.; Song, J.-H.; Lee, S.-H.; Kim, H.-E. Improved compressive strength of reticulated porous zirconia using carbon coated polymeric sponge as novel template. Mater. Lett. 2006, 60, 2507–2510. [Google Scholar] [CrossRef]
- Ravaunt, F. Production of Porous Ceramic Materials. U.S. Patent 4004933 A, 25 January 1977. [Google Scholar]
- Luyten, J.; Thijs, I.; Vandermeulen, W.; Mullens, S.; Wallaeys, B.; Mortelmans, R. Strong ceramic foams from polyurethane templates. Adv. Appl. Ceram. 2005, 104, 4–8. [Google Scholar] [CrossRef]
- Paiva, A.; Sepulveda, P.; Pandolfelli, V. Processing and thermomechanical evaluation of fiber-reinforced alumina filters. J. Mater. Sci. 1999, 34, 2641–2649. [Google Scholar] [CrossRef]
- Zhu, X.; Jiang, D.; Tan, S. Improvement in the strength of reticulated porous ceramics by vacuum degassing. Mater. Lett. 2001, 51, 363–367. [Google Scholar] [CrossRef]
- Brown, D.D.; Green, J.D. Investigation of strut crack formation in open cell alumina ceramics. J. Am. Ceram. Soc. 1994, 77, 1467–1472. [Google Scholar] [CrossRef]
- Betke, U.; Dalicho, S.; Rannabauer, S.; Lieb, A.; Scheffler, F.; Scheffler, M. Impact of slurry composition on properties of cellular alumina: A computed tomographic study. Adv. Eng. Mater. 2017. [Google Scholar] [CrossRef]
- Nikolay, D.; Kollenberg, W.; Deller, K.; Oswald, M.; Tontrup, C. Manufacturing and properties of ZTA-ceramics with nanoscaled ZrO2. Ceram. Forum Int. 2006, 83, 35–37. [Google Scholar]
- Lange, F.F.; Hirlinger, M.M. Hindrance of grain growth in Al2O3 by ZrO2 inclusions. J. Am. Ceram. Soc. 1984, 67, 164–168. [Google Scholar] [CrossRef]
- Brezny, R.; Green, J.D.; Dam, Q.C. Evaluation of strut strength in open-cell ceramics. J. Am. Ceram. Soc. 1989, 72, 885–889. [Google Scholar] [CrossRef]
- Dam, Q.C.; Brezny, R.; Green, J.D. Compressive behavior and deformation-mode map of an open cell alumina. J. Mater. Res. 1990, 5, 163–171. [Google Scholar] [CrossRef]
Foams | Density [g·cm−3] | Porosity [%] | Mean Strut Thickness [mm] | Weight Gain [%] | Compression Strength [MPa] | Weibull Modulus | Linear Shrinkage [%] |
---|---|---|---|---|---|---|---|
The first coating step | |||||||
ZTA16-70 | 0.26 ± 0.02 | 93.9 | 0.49 ± 0.19 | — | 0.08 ± 0.01 | 9.47 | 15.55 |
ZTA16-80 | 0.45 ± 0.05 | 89.3 | 0.56 ± 0.17 | — | 0.91 ± 0.40 | 8.48 | 12.62 |
ZTA20-70 | 0.27 ± 0.02 | 93.7 | — | — | 0.14 ± 0.02 | 2.30 | 15.38 |
ZTA20-80 | 0.43 ± 0.05 | 89.9 | — | — | 1.06 ± 0.30 | 4.23 | 12.63 |
The immersion infiltration step | |||||||
ZTA20-50-10 | 0.56 ± 0.05 | 86.8 | 0.57 ± 0.18 | 20.31 ± 6.11 | 2.20 ± 0.33 | 9.04 | — |
ZTA20-50-60 | 0.54 ± 0.03 | 87.3 | 0.55 ± 0.16 | 14.10 ± 4.37 | 2.55 ± 0.41 | 7.69 | — |
ZTA20-60-10 | 0.55 ± 0.02 | 87.1 | 0.56 ± 0.16 | 16.19 ± 5.12 | 2.09 ± 0.29 | 9.08 | — |
ZTA20-60-60 | 0.59 ± 0.02 | 86.3 | 0.55 ± 0.17 | 20.81 ± 7.17 | 2.66 ± 0.33 | 6.26 | — |
The recoating step | |||||||
ZTA20-R1 | 0.74 ± 0.05 | 82.4 | 0.82 ± 0.23 | 49.74 ±15.05 | 3.26 ± 0.71 | 4.04 | — |
ZTA20-R2 | 1.11 ± 0.07 | 73.6 | 0.95 ± 0.28 | 127.16 ±18.02 | 5.61 ± 0.87 | 7.62 | — |
ZTA20-R4 | 1.74 ± 0.08 | 58.5 | 1.41 ± 0.45 | 250.91 ± 28.41 | 11.44 ± 1.44 | 8.80 | — |
© 2017 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
Share and Cite
Chen, X.; Betke, U.; Rannabauer, S.; Peters, P.C.; Söffker, G.M.; Scheffler, M. Improving the Strength of ZTA Foams with Different Strategies: Immersion Infiltration and Recoating. Materials 2017, 10, 735. https://doi.org/10.3390/ma10070735
Chen X, Betke U, Rannabauer S, Peters PC, Söffker GM, Scheffler M. Improving the Strength of ZTA Foams with Different Strategies: Immersion Infiltration and Recoating. Materials. 2017; 10(7):735. https://doi.org/10.3390/ma10070735
Chicago/Turabian StyleChen, Xiaodong, Ulf Betke, Stefan Rannabauer, Paul Clemens Peters, Gerrit Maximilian Söffker, and Michael Scheffler. 2017. "Improving the Strength of ZTA Foams with Different Strategies: Immersion Infiltration and Recoating" Materials 10, no. 7: 735. https://doi.org/10.3390/ma10070735