Search Results (41)

The rapidly increasing global demand for high-performance thermal insulation materials necessitates a significant shift towards more sustainable and cost-effective solutions. This study unveils a novel and efficient pathway to synthesize engineered cordierite, a highly coveted magnesium aluminosilicate ceramic, by intelligently harnessing biogenic silica extracted directly from rice husk. Rice husk, an abundant agricultural by-product, represents a readily available and often underutilized resource. The methodology involved a precise precipitation method to successfully yield high-purity silica from rice husk ash. This extracted silica was then meticulously combined with commercial magnesium oxide (MgO) and aluminum oxide (Al₂O₃) through a solid-state reaction to synthesize the desired cordierite. The study systematically investigated the profound impact of various sintering temperatures, ranging from 850 °C to 1100 °C, on both the cordierite yield and its crucial physicochemical properties. Our experiments revealed that a sintering temperature of 1100 °C achieved a remarkable 66.5% cordierite yield. Beyond yield, the material processed at 1100 °C exhibited exceptional mechanical and thermal characteristics: a compressive strength of 65 kN/m², a flexural strength of 44 kN/m², a tensile strength of 17.5 kN/m², and a remarkably low thermal conductivity of just 3.2 W/m·K. These attributes match the mechanical requirements for structural insulation, with a thermal conductivity of 3.2 W/m·K. While higher than some high-porosity commercial cordierites (typically 1.2–2.0 W/m·K), the biogenic version offers a 40% reduction in production energy and utilizes 100% recycled silica, balancing thermal performance with superior sustainability. By utilizing agricultural waste, this method reduces CO₂ emissions associated with mineral extraction and minimizes reliance on non-renewable raw materials, providing a practical pathway for the circular economy. Full article

Cordierite-based ceramics (Mg₂Al₄Si₅O₁₈) were successfully synthesized and comprehensively characterized to evaluate their structural and dielectric behavior for high-temperature electronic applications. Morphological, microstructural and vibrational analyses confirm the high phase purity and structural integrity of the synthesized material. Dielectric measurements reveal high real permittivity (ε′) values at low frequencies and elevated temperatures, mainly attributed to interfacial polarization arising from Schottky-type barriers at grain–grain and surface–volume interfaces, underscoring the crucial influence of heterogeneous interfaces on the dielectric response. The electrical conductivity follows a thermally activated hopping mechanism involving both intra-grain and grain-boundary charge transport. Analysis of the electric modulus formalism provides further insight into relaxation dynamics: the real (M′) and imaginary (M″) components highlight pronounced space-charge effects, with M″ exhibiting a distinct relaxation peak (M″) associated with grain contributions. The systematic shift of this peak toward higher frequencies with increasing temperature indicates enhanced charge-carrier mobility and a strongly thermally activated relaxation process. The frequency-dependent conductivity displays two regimes: a low-frequency plateau corresponding to dc conductivity and a high-frequency dispersive region following a power-law behavior characteristic of hopping conduction, with power-law exponents (α₁ and α₂) markedly lower than unity, confirming the non-Debye character of the relaxation processes. The hopping frequency (ω) increases with temperature, further supporting the thermally activated nature of charge transport. Activation energies extracted from Arrhenius plots of dc conductivity are 0.88 eV for grain boundaries and 0.83 eV for grains, demonstrating that both microstructural regions significantly contribute to the overall conduction process. Full article

To facilitate the development of low-cost LTCC substrate materials and the high-value utilization of industrial tailings, α-cordierite glass-ceramics with varying Na₂O additions were prepared from perlite tailings as the main raw material via the melt-quenching method followed by sintering-induced crystallization. The synergistic effects of sintering temperature and Na₂O addition on the parent glass structure, crystallization behavior, and properties were systematically investigated. The results demonstrated that the addition of Na₂O effectively depolymerized the degree of network polymerization of the parent glass, altered the crystallization pathway of cordierite crystal, and promoted the densification of glass-ceramics at lower sintering temperature. The calculations of crystallization kinetics revealed that the crystallization process of α-cordierite was mainly dominated by three-dimensional bulk growth, and its nucleation mechanism changed from “site saturation” to “continuous nucleation” with the increase of Na₂O addition. The α-cordierite glass-ceramics sintered at 850 °C with 0.6 wt.% Na₂O addition exhibited the optimal comprehensive properties, including low dielectric constant (5.82 @ 10 MHz) and dielectric loss (1.80 × 10⁻² @ 10 MHz), high flexural strength (147.3 MPa), a Vickers hardness (9.01 GPa), and suitable coefficient of thermal expansion (2.96 × 10⁻⁶ K⁻¹, close to Si). The glass-ceramics are expected to be an ideal candidate for low-cost LTCC substrate materials. Full article

Cordierite diesel particulate filters (DPFs) were prepared using pure cordierite powder with organic binders, sodium silicate aids and pore formers by extrusion technique. The orthogonal test method was adopted to investigate the optimal value of the multi-objective and multi-factor problems. Based on results from statistical analysis, sintering temperature is the most important factor. The optimal parameters for balanced overall performance were determined as a 3 h holding time, 10 wt.% pore former, 12 wt.% sintering aid, and a sintering temperature of 1150 °C, representing a compromise among the individually optimal conditions for porosity, compressive strength, and thermal shock resistance identified by range analysis. The sodium silicate liquid increased and viscosity decreased with the increasing of temperature, which led to the formation of glass phases and the improvement of density. Therefore, with increasing sintering temperature, the porosity and coefficient of thermal expansion decreased. Both the mechanical properties and chemical stability of the prepared samples are strengthened. When the sintering temperature was 1150 °C, the prepared samples with high porosity (56.04%), compressive strength (5.88 MPa), bending strength (13.10 MPa), and low thermal expansion coefficient (CTE, 1.82 × 10⁻⁶/°C) showed the best comprehensive performance of thermal shock resistance and filtration efficiency. These results demonstrate great potential for DPF applications and provide a reference for the design of other honeycomb ceramics with optimum level of liquid phase. Full article

The aim of this work was the preparation of ceramic monolithic catalysts for the catalytic oxidation of gaseous mixture of benzene, toluene, ethylbenzene and o-xylene BTEX. The possibility of using zirconium dioxide (ZrO₂) as a filament for the fabrication of 3D-printed ceramic monolithic carriers was investigated using fused filament fabrication. A mixed manganese and iron oxide, MnFeO_x, was used as the catalytically active layer, which was applied to the monolithic substrate by wet impregnation. The approximate geometric surface area of the obtained carrier was determined to be 53.4 cm², while the mass of the applied catalytically active layer was 50.3 mg. The activity of the prepared monolithic catalysts for the oxidation of BTEX was tested at different temperatures and space times. The results obtained were compared with those obtained with commercial monolithic catalysts made of ceramic cordierite with different channel dimensions, and with monolithic catalysts prepared by stereolithography. In the last part of the work, a kinetic analysis and the modeling of the monolithic reactor were carried out, comparing the experimental results with the theoretical results obtained with the 1D pseudo-homogeneous and 1D heterogeneous models. Although both models could describe the investigated experimental system very well, the 1D heterogeneous model is preferable, as it takes into account the heterogeneity of the reaction system and therefore provides a more realistic description. Full article

With the advancement of aero-engine thrust-to-weight ratios, turbine blades now incorporate complex hollow structures fabricated using ceramic cores. The emergence of light-curing 3D printing technology for ceramic cores offers a viable solution to producing such complex structural components. To avoid the breakage of the core when removing the support after the printing of the general paste, we used a rheological additive, organic bentonite, to prepare a light-curing 3D-printed silicon-based ceramic core paste that can allow for unsupported printing. This study pursues two primary research objectives: Firstly, the effect of organic bentonite on the rheological behavior and stability properties of silicon-based ceramic was investigated. Secondly, we conducted a comprehensive analysis of how organic bentonite modification influences the performance of silicon-based ceramics. The results show that, firstly, the addition of organic bentonite dramatically improves the rheology and stability of silicon-based ceramic paste, and that the optimal content is between 1 and 2 wt.% for the best effect. Second, after the primary sintering process (1250 °C), partial bentonite can produce a small amount of cordierite phase and promote the generation of cristobalite. The room-temperature performance of the ceramic core can be improved. However, organic bentonite, after secondary sintering at 1550 °C, completely forms cordierite and reduces the amount of square quartz produced. Then, it negatively affects the high-temperature performance of the ceramic core. Therefore, when the content of organic bentonite is 1 wt.%, the ceramic paste has superior rheology and stability, making unsupported printing possible. Our study revealed an apparent porosity of 32.43%, a bulk density of 1.64 g/cm³, a sintering shrinkage value of 2.94%, a room-temperature flexural strength of 24.7 MPa, a high-temperature (1550 °C) flexural strength of 10.1 MPa and a high-temperature deflection of 1.24 mm, which meet the requirements of core printing. Full article

To enhance the mechanical properties and high-temperature performance of cordierite–mullite composite ceramics, yttrium oxide (Y₂O₃), a rare earth metal oxide, was employed as a sintering aid to fabricate these composites via in situ synthesis and non-pressure sintering. This study systematically investigated the formation mechanisms of the cordierite and mullite phases and examined the effects of yttrium oxide on the densification behavior, mechanical properties, volumetric stability, and thermal shock resistance. The results indicate that incorporating yttrium oxide (1.5–6.0 wt%) not only promoted the formation of the cordierite phase but also refined the microstructure and enhanced the thermal shock stability at a sintering temperature of 1350 °C. An optimal addition of 3 wt% yttrium oxide ensures that the primary phases are cordierite and mullite, with a microstructure characterized by uniformly distributed micropores, hexagonal short-columnar cordierite, and interlocking rod-like mullite, thereby significantly improving both the mechanical properties and thermal shock stability. Specifically, the room-temperature compressive strength increased by 121%, the flexural strength increased by 177%, and, after three thermal shock cycles at 1100 °C, the retention rates for compressive and flexural strengths were 87.66% and 71.01%, respectively. This research provides a critical foundation for enhancing the mechanical properties and high-temperature service performance of cordierite–mullite saggers used in lithium battery cathode materials. Full article

In this study, cordierite-based ceramics (2MgO·2Al₂O₃·5SiO₂) were synthesized using high-purity MgO, Al₂O₃, and SiO₂ as starting materials. The influence of the MgO/Al₂O₃ ratio on various properties, including the thermal behavior, pyrometric cone refractory behavior, phase formation, physical properties, and microstructure of the synthesized ceramics, was systematically analyzed. Increasing the MgO/Al₂O₃ ratio progressively weakened the cordierite network, leading to lower temperatures for liquid formation and melting. This resulted in reduced viscosity and increased fluidity. Subsequently, the thermal and refractory behaviors were observed at lower temperatures with higher deformation rates under higher MgO/Al₂O₃ ratios. The lower viscosity of the liquid formed at reduced temperatures contributed to an increase in the density of sintered bodies, reduced porosity, and enhanced shrinkage. X-ray diffraction analysis confirmed that cordierite was the predominant phase in samples sintered at 1300, 1350, and 1400 °C, with higher cordierite formation at higher temperatures. Conversely, the formation of secondary phases, such as spinel, cristobalite, and enstatite, decreased with increasing sintering temperature. Pyrometric cones were then constructed for a range of temperature settings, and their deformation characteristics at specific temperatures were used to evaluate the refractoriness under diverse conditions. Full article

This work is part of a research project aimed at producing ceramic-like materials, without the need for an initial sintering, for potential applications in catalysis or filtration at temperatures up to 1000 °C. In that context, cordierite-derived materials were prepared from recycled cordierite powder (automotive industry waste) bonded with metakaolin-potassium silicate geopolymer. The principle is that these materials, prepared at temperatures below 100 °C, acquire their final properties during the high-temperature commissioning. The focus is on the influence of the K/Al ratio and cordierite fraction on the stability of the dimensions and porosity during heating at 1000 °C, and on the final Young’s modulus and coefficient of thermal expansion. Conventional and high-temperature XRD evidenced the absence of crystallization of the geopolymer binder and interaction with the cordierite filler during the heating stage when K/Al = 1 or 0.75. By contrast, crystallization of kalsilite and leucite, and diffusion of potassium ions in the structure of cordierite is evidenced for K/Al = 1.5 and 2.3. These differences strongly influence the shrinkage due to sintering and the final properties. It is shown that a K/Al ratio of 0.75 or 1 is favorable to the stability of the porosity, around 25 to 30%. Moreover, a low coefficient of thermal expansion of 4 to 4.5 × 10⁻⁶ K⁻¹ and a Young’s modulus of 40 to 45 GPa is obtained. Full article

The use of solid waste such as ceramic sludge, ceramic rollers, and magnesite was studied to obtain cheap refractory ceramics at temperatures of 1300 °C based on XRF, XRD SEM, EDX, bending strength, and dielectric properties. The prepared samples were examined. The results showed that the significant crystalline phases formed were mullite, spinel, and corundum. They also showed that mullite hindered the formation of cordierite and enhanced spinel formation. With increased cordierite content, the microstructure varied from fine grained to coarse grained. Bending strength increased with increasing mullite content and bulk density, ranging from 10.80 to 13.50 MPa. Bulk density increased with the increase in mullite content and sintering temperature and ranged from 1.99 to 1.94 g/cm³, while the percentage of porosity and water absorption decreased and ranged from 29.40 to 38.83, respectively. To examine the effect of the produced phases on the dielectric characteristics, the permittivity (ε′), dielectric loss (ε″), and AC conductivity (σ_ac) were measured in the frequency range of 10⁻¹ Hz to 10⁶ Hz. As the concentration of cordierite increased, there was a noticeable drop in ε′ from 35.6 to 8.2 and σ_ac from 10⁻⁸ s/cm to around 10⁻¹¹ s/cm and high values of resistivity from 10⁸ cm/s to about 10¹⁰ cm/s, suggesting that this material might be an excellent insulator. Full article

This study aimed to evaluate the effect of ceramic type, firing tray, and firing substrate on the density, shrinkage, biaxial flexural strength, Martens’ hardness, and elastic indentation modulus of zirconia veneering ceramics. Disk-shaped specimens were fabricated from a high-fusing (HFZ) and a low-fusing (STR) zirconia veneering ceramic. These specimens were then divided into 10 groups according to firing trays (round, small honeycomb-shaped, cordierite [RSC]; round, large honeycomb-shaped, aluminum oxide [RLA]; rectangular, plane, silicon nitride [RCPS]; round, plane, silicon nitride [RPS]; and rectangular, plane, calcium silicate [RCPC]) and firing substrates (firing cotton and platinum foil) used (n = 12). The density, shrinkage, biaxial flexural strength, Martens’ hardness, and indentation modulus were measured, and analyzed with generalized linear model analysis (α = 0.05). The interaction between the ceramic type and firing substrate affected density (p < 0.001), and the other outcomes were affected by the interaction among all main factors (p ≤ 0.045). Higher density was observed with HFZ or platinum foil (p ≤ 0.007). RSC and RLA led to a higher density than RCPS within HFZ and led to the lowest density within STR (p ≤ 0.046). STR had a higher shrinkage (p < 0.001). RSC mostly led to a lower shrinkage of HFZ (p ≤ 0.045). The effect of ceramic type and firing substrates on the biaxial flexural strength, Martens’ hardness, and indentation modulus was minimal while there was no clear trend on the effect of firing tray on these properties. Ceramic type, firing tray, and firing substrate affected the mechanical properties of the tested zirconia veneering ceramics. Firing the tested zirconia veneering ceramics over a round and small honeycomb-shaped cordierite firing tray with firing cotton mostly led to improved mechanical properties. Full article

Clays and clay minerals are common natural materials, the unique properties of which have attracted the interest of the industry, especially because these materials are easily available, cheap, and non-toxic. Clays and clay minerals are widely used in many applications, such as in ceramic production, in the clarification of liquids, pollutant adsorbers, filler in composites and nanocomposites, soil amendments, in pharmacy, etc. This review assesses the development in the area of clay application in nanocomposites and ceramics. The first part of this study covers polymer/clay nanocomposites. Topics of interest include nanofiller sources for polymer nanocomposites, the possible ways of clay modification, polymer/clay nanocomposite classification and their processing, and polymer matrix overview with possible enhancement of nanocomposite properties. Some of the applications have already been commercialized. Approximately 80% of the polymer/clay nanocomposites are destined for the automotive, aeronautical, and packaging industries. The second part of this study describes ceramic materials with a focus on silicate ceramics. Talc and kaolinite represent the main natural raw materials for traditional ceramic applications. Less traditional cordierite, steatite, and forsterite could offer property enhancement and seem to be useful in electronics, electrical engineering, catalysts, solar thermal storage, or medical applications. Full article

Cordierite-based supported noble-metal-free catalysts for ozone decomposition are elaborated. The cordierite ceramic surface is pretreated with oxalic acid and NaOH, and Mn-Cu-Ni oxide catalysts are prepared by the impregnation method. The mass ratio of the supported oxides in the resulting catalysts is MnO₂:CuO:NiO = 3:2:1, and their loadings are from 1.8 to 7.0 wt.%. The pretreated supports and catalysts are characterized by low-temperature N₂ adsorption, scanning electron microscopy (SEM), powder X-ray diffraction analysis (XRD), and temperature-programmed reduction with H₂ (TPR-H₂). The catalysts are tested in ozone decomposition with high airflow rates (20 and 50 L/min) and with initial ozone concentrations of 1 and 2 ppm at temperatures in the range of 25–120 °C. It is shown that a combined treatment of cordierite with oxalic acid and NaOH leads to a developed porous structure and stabilization of supported Mn-Cu-Ni oxides in a highly dispersed state. The high activity of catalysts in ozone decomposition at room temperature and high airflow is demonstrated. The developed catalysts can be recommended for application in purification of air from the ozone because of their high catalytic activity, high mechanical stability, and relatively low weight and cost. Full article

Because of their excellent properties, glass-ceramics have been widely developed and applied in many fields, and there are many potential application values to be disseminated. The preparation of glass-ceramics from industrial slag and metallurgical waste provides a new way for the comprehensive utilization of solid waste. Coal gangue is the largest of all kinds of industrial waste slag, while iron tailings and high-carbon ferrochrome slag also occupy a large proportion of China’s industrial solid waste. With cheap industrial solid waste as the main raw material, the production of high-value-added glass-ceramics can reduce pollution, protect the ecological environment, and have good economic and social benefits. Cordierite glass-ceramics were prepared using the sintering method with coal gangue, iron tailings, and high-carbon ferrochrome slag as the main raw materials. Meanwhile, an iron silicon alloy containing chromium was obtained. The heat treatment system of basic glass was determined by differential scanning calorimetry (DSC), and the sintered product was analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). An orthogonal test was used to analyze the effects of the mass of basic glass powder, molding pressure, and holding time on the grain size and crystallinity of the samples. The hardness, acid and alkali resistance, density, and water absorption of the sintered products were determined. The results show that the main crystal phase of the prepared glass-ceramics is cordierite. The optimal combination for the green body is “basic glass powder mass 6 g, molding pressure 35 MPa, holding time 10 min”. The properties of glass-ceramics are good. At the crystallization temperature of 970 °C, the Vickers hardness is up to 866 HV, and the bulk density is up to 2.99 g/cm³. This study may provide a useful reference for the treatment of industrial solid waste. Full article

The synthesis of Co and Ce oxide nanoparticles using precipitation of precursor salt solutions in the form of microdroplets generated with a nebulizer proved to be an efficient, fast and inexpensive method. Different morphologies of single oxides particles were obtained. Ceria nanoparticles were almost cube-shaped of 8 nm average size, forming 1.3–1.5 μm aggregates, whereas cobalt oxide appeared as rounded-edged particles of 37 nm average size, mainly forming nanorods 50–500 nm. Co₃O₄ and CeO₂ nanoparticles were used to generate structured catalysts from both metallic (stainless steel wire mesh monoliths) and ceramic (cordierite honeycombs) substrates. Ceria Nyacol was used as a binder to favor the anchoring of catalytic particles thus enhancing the adhesion of the coating. The resulting structured catalysts were tested for the combustion of diesel soot with the aim of being used in the regeneration of particulate filters (DPFs). The performance of these structured catalysts was similar to or even better than that exhibited by the catalysts prepared using commercial nanoparticles. Among the catalysts tested, the structured systems using ceramic substrates were more efficient, showing lower values of the maximum combustion rate temperatures (T_M = 410 °C). Full article