Search Results (1,118)

The sustainable valorization of electrolytic manganese residue (EMR) and fly ash (FA) presents critical environmental challenges. This study systematically investigates the performance optimization of EMR-FA ceramic composites through the coordinated regulation of raw material ratios, sintering temperatures, and additive effects. While the composite with 85 g FA exhibits the highest mechanical strength, lowest porosity, and minimal water absorption, the formulation consisting of 45 wt% EMR, 40 wt% FA, and 15 wt% kaolin is identified as a balanced composition that achieves an effective compromise between mechanical performance and solid waste utilization efficiency. Sintering temperature studies revealed temperature-dependent property enhancement, with controlled sintering at 1150 °C preventing the over-firing phenomena observed at 1200 °C while promoting phase evolution. XRD-SEM analyses confirmed accelerated anorthite formation and the morphological transformations of FA spherical particles under thermal activation. Additive engineering demonstrated that 8 wt% CaO addition enhanced structural densification through hydrogrossular crystallization, whereas Na₂SiO₃ induced sodium-rich calcium silicate phases that suppressed anorthite development. Contrastingly, ZrO₂ facilitated zircon nucleation, while TiO₂ enabled progressive performance enhancement through amorphous phase modification. This work establishes fundamental phase–structure–property relationships and provides actionable engineering parameters for sustainable ceramic production from industrial solid wastes. Full article

In this work, the development of Al-based metal matrix composites (MMCs) is achieved using hybrid SiC and ZrO₂ reinforcement particles for automotive applications. Powder metallurgy (PM) is employed with various combinations of important process parameters for the fabrication of MMCs. MMCs were characterized using scanning electron microscopy (SEM), X-ray diffractometry (XRD), and a microhardness study. All XRD graphs adequately exhibit Al, SiC, and ZrO₂ peaks, indicating that the hybrid MMC products were satisfactorily fabricated with appropriate mixing and sintering at all the considered fabrication conditions. Also, no impurity peaks were observed, confirming high composite purity. MMC products in all the XRD patterns, suitable for the desired applications. According to the SEM investigation, SiC and ZrO₂ reinforcement components are uniformly scattered throughout Al matrix in all produced MMC products. The occurrence of Al, Si, C, Zr, and O in EDS spectra demonstrates the effectiveness of composite ball milling and sintering under all manufacturing conditions. Moreover, an increase in interfacial bonding of fabricated composites at a higher sintering temperature indicated improved physical properties of the developed MMCs. The highest microhardness value is 86.6 HVN amid all the fabricated composites at 7% silica, 14% zirconium dioxide, 500° sintering temperature, 90 min sintering time, and 60 min milling time. An integrated Particle Swarm Optimization–Support Vector Machine (PSO-SVM) model was developed to predict microhardness based on the input parameters. The model demonstrated strong predictive performance, as evidenced by low values of various statistical metrics for both training and testing datasets, highlighting the PSO-SVM model’s robustness and generalization capability. Specifically, the model achieved a coefficient of determination of 0.995 and a root mean square error of 0.920 on the training set, while on the testing set, it attained a coefficient of determination of 0.982 and a root mean square error of 1.557. These results underscore the potential of the PSO-SVM framework, which can be effectively leveraged to optimize process parameters for achieving targeted microhardness levels for the developed Al-SiC-ZrO₂ Composites. Full article

The sintering of coal gangue ceramsites (CGCs) using belt roasting technology involves the recirculation of flue gases and variations in oxygen concentrations. This study investigates the effects of temperature and pyrolysis atmosphere on the pore structure of CGCs at three temperature levels: 600 °C, 950 °C, and 1160 °C. The results revealed that apparent porosity is primarily influenced by O₂-promoted weight loss and the densification process, while closed porosity is affected by pyrolysis reactions and crystal phase transformations. Below 950 °C, enhancing the oxidative atmosphere facilitates the preparation of porous CGCs, whereas above 950 °C, reducing the oxidative atmosphere favors the preparation of high-strength CGCs. These findings provide valuable insights for the industrial production of CGCs, offering a basis for optimizing sintering parameters to achieve the desired material properties. The latest production equipment, furnished with adjustable atmospheres (such as belt sintering roasters), can better regulate the mechanical properties of the products. Full article

The improvement of densification and fracture toughness in high-entropy ceramics is important to realizing their practical applications. In this study, SiC whiskers and metal Ni additions were incorporated to solve these problems of high-entropy boride ceramics. The influence of sintering temperatures (1450–1650 °C) on the densification, microstructure, hardness, fracture toughness, and bending strength of (M_0.2Ti_0.2Ta_0.2V_0.2Nb_0.2)B₂-SiC_w-Ni (M=Hf, Zr, or Cr) composites prepared by hot-pressing technology were studied. Results showed that when SiC whiskers and metal Ni additions were used as additives, increasing sintering temperatures from 1450 to 1600 °C promoted the densification of high-entropy boride ceramics. This was mainly attributed to the high sintering driving force. However, when the temperature further increased to 1650 °C, their densification behavior decreased. At a sintering temperature of 1600 °C, these high-entropy borides ceramics all had the highest densification behavior, leading to their high hardness and fracture toughness. The highest relative density was 96.3%, the highest hardness was 22.02 GPa, and the highest fracture toughness was 13.25 MPa·m^1/2, which was improved by the co-function of SiC whiskers and plastic metal Ni. Meanwhile, in the adopted sintering temperature range of 1450 to 1650 °C, the highest bending strength at room temperature of these high-entropy boride ceramics could reach 320.8 MPa. Therefore, this research offers an effective densification, strengthening, and toughening method for high-entropy boride composites at a low sintering temperature. Full article

The report of the first room-temperature, ambient-pressure superconductivity in copper-doped lead apatite Pb_10−xCu_x(PO₄)₆O has attracted lots of attention. However, subsequent studies revealed the presence of numerous impurity phases in the polycrystalline sample, and the sharp superconducting-like transition is not due to a superconducting transition but most likely due to a reduction in resistivity caused by the first-order structural phase transition of Cu₂S at around 385 K from the β phase at high temperature to the γ phase at low temperature. Before now, only bulk measurements have been performed on a Pb_10−xCu_x(PO₄)₆O powder sample, which could be affected by the impurity phases, masking the intrinsic properties of Pb_10−xCu_x(PO₄)₆O. In this study, ³¹P and ^63/65Cu nuclear magnetic resonance (NMR) measurements have been performed on a Pb_10−xCu_x(PO₄)₆O powder sample to investigate its physical properties from a microscopic point of view. Our NMR data evidence the non-magnetic insulating nature of Pb_10−xCu_x(PO₄)₆O without any trace of electron correlation effects. Furthermore, the ^63/65Cu NMR results suggest that no copper or very little copper is substituted for Pb in Pb₁₀(PO₄)₆O prepared by sintering Pb₂SO₅ and Cu₃P. Full article

Lead-free (Bi_1/2Na_1/2)(Ti_1−x(Mg_1/3Nb_2/3)_x)O₃ ceramics were synthesized using the solid-phase method, and the effects of varying (Mg_1/3Nb_2/3)⁴⁺ content, substituting for Ti⁴⁺ ions at the B-site of the BNT perovskite lattice, on piezoelectric performance were systematically investigated. The influence of sintering temperature on both piezoelectric and ferroelectric properties was also explored, revealing that sintering temperature significantly affects both the microstructure and the electrical properties of the ceramics. The results indicate that the incorporation of (Mg_1/3Nb_2/3)⁴⁺ significantly enhances the piezoelectric and ferroelectric properties of BNT ceramics. Specifically, a maximum piezoelectric constant of 91 pC/N was achieved at a sintering temperature of 1160 °C and a doping concentration of x = 0.01. By comparing the ferroelectric properties across different doping levels and sintering temperatures, this study provides valuable insights for further design and process optimization of BNT-based piezoelectric materials. Full article

In this investigation, TiB₂–TiC composite powders, synthesized via the boron/carbon thermal reduction process, were employed as precursor materials. SiC, serving as the tertiary constituent, was incorporated to fabricate TiB₂–TiC–SiC composite ceramics utilizing spark plasma sintering technology. The present study initially elucidates the densification mechanisms and investigates the influence of sintering temperature on the densification behavior, microstructural evolution, and mechanical properties of the resultant ceramics. The experimental findings reveal that the sintering process of TiB₂–TiC–SiC ceramics exhibits characteristics consistent with solid-phase sintering. As the sintering temperature escalates, both the relative density and mechanical properties of the ceramics initially improve, reaching a maximum at an optimal sintering temperature of 1900 °C, before subsequently declining. Microstructural examinations conducted at this optimal temperature indicate a homogeneous distribution of the two primary phases, with no evidence of excessive grain growth. Furthermore, this research explores the effects of SiC addition on the mechanical performance and oxidation resistance of TiB₂–TiC–SiC composite ceramics. The results demonstrate that the incorporation of SiC effectively suppresses grain growth and promotes the formation of rod-like TiB₂ microstructures, thereby enhancing the mechanical attributes of the ceramics. Additionally, the addition of SiC significantly improves the oxidation resistance of the composite ceramics compared to their TiB₂–TiC binary counterparts Full article

The efficient simultaneous removal of NO_x and CO from sintering flue gas under low-temperature conditions (110–180 °C) in iron and steel enterprises remains a significant challenge in the field of environmental catalysis. In this study, we present an innovative strategy to enhance the performance of CuSmTi catalysts through silver modification, yielding a bifunctional system capable of oxygen structure regulation and demonstrating superior activity for the combined NH₃-SCR and CO oxidation reactions under low-temperature, oxygen-rich conditions. The modified AgCuSmTi catalyst achieves complete NO conversion at 150 °C, representing a 50 °C reduction compared to the unmodified CuSmTi catalyst (T_100% = 200 °C). Moreover, the catalyst exhibits over 90% N₂ selectivity across a broad temperature range of 150–300 °C, while achieving full CO oxidation at 175 °C. A series of characterization techniques, including XRD, Raman spectroscopy, N₂ adsorption, XPS, and O₂-TPD, were employed to elucidate the Ag-Cu interaction. These modifications effectively optimize the surface physical structure, modulate the distribution of acid sites, increase the proportion of Lewis acid sites, and enhance the activity of lattice oxygen species. As a result, they effectively promote the adsorption and activation of reactants, as well as electron transfer between active species, thereby significantly enhancing the low-temperature performance of the catalyst. Furthermore, in situ DRIFTS investigations reveal the reaction mechanisms involved in NH₃-SCR and CO oxidation over the Ag-modified CuSmTi catalyst. The NH₃-SCR process predominantly follows the L-H mechanism, with partial contribution from the E-R mechanism, whereas CO oxidation proceeds via the MvK mechanism. This work demonstrates that Ag modification is an effective approach for enhancing the low-temperature performance of CuSmTi-based catalysts, offering a promising technical solution for the simultaneous control of NO_x and CO emissions in industrial flue gases. Full article

This study investigates the thermally induced phase transformation of Ni-exchanged LTA zeolite as a dual-purpose method for nickel immobilization and the synthesis of stable ceramic pigments. The process describes a cost-effective and sustainable alternative to conventional pigment production, aligning with circular economy principles. Upon thermal treatment at temperatures ranging between 900 °C and 1300 °C, Ni-exchanged LTA zeolite undergoes a transformation to NiAl₂O₄ spinel, confirmed by XRPD, FTIR, and thermal analysis. Initially, NiO is formed, but as the temperature increases, it dissolves and transforms into NiAl₂O₄. Colorimetric studies revealed intensified blue pigmentation with increasing temperature, correlating with crystallite growth and structural evolution. SEM analysis showed morphological changes from cubic particles to sintered agglomerates, enhancing pigment stability and hardness. The Ni-LTA sample calcined at 1300 °C showed the highest hue angle, which was consistent with the formation of over 99 wt.% of the nickel aluminate crystalline phase at this temperature. The results demonstrate that Ni-LTA zeolite can be effectively transformed into durable greenish-blue pigments suitable for application in porcelain. This transformation is especially evident at 1300 °C, where a spinel phase (NiAlSi₂O₄) forms, with colorimetric values: L = 58.94, a* = –16.08, and b* = –15.90. Full article

Iron ore sintering is a critical process in steelmaking, where the produced sinter is the main raw material for blast furnace ironmaking. The quality and yield of sinter ore directly affect the cost and efficiency of iron and steel production. Accurately predicting the burn-through point (BTP) temperature is of paramount importance for controlling quality and yield. Traditional BTP temperature prediction only utilizes data from bellows, neglecting the information contained in sinter images. This study combines color temperature information extracted from the cross-sectional frame at the discharge end with bellows data. Due to the non-stationarity of the BTP temperature, a hybrid prediction model of the BTP temperature integrating bidirectional long short-term memory and extreme gradient boosting is presented. By combining the advantages of deep learning and tree ensemble learning, a hybrid prediction model of the BTP temperature is established using the color temperature information in the cross-sectional frame at the discharge end and time-series data. Experiments were conducted with the actual running data in an iron and steel enterprise and show that the proposed method has higher accuracy than existing methods, achieving an approximately 4.3% improvement in prediction accuracy. The proposed method can provide an effective reference for decision-making and for the optimization of operating parameters in the sintering process. Full article

This study systematically investigates the effects of heat treatment at 800–1000 °C on the microstructure and mechanical properties of 10 wt.% TiB₂@Ti/AlCoCrFeNi_2.1 eutectic high-entropy alloy matrix composites (EHEAMCs) prepared by vacuum hot-pressing sintering. The results show that the materials consist of FCC, BCC, TiB₂, and Ti phases, with a preferred orientation of the (111) crystal plane of the FCC phase. As the temperature increases, the diffraction peak of the BCC phase separates from the main FCC peak and its intensity increases, while the diffraction peak positions of the FCC and BCC phases shift at small angles. This is attributed to the diffusion of TiB₂@Ti from the grain boundaries into the matrix, where the Ti solid solution increases the lattice constant of the FCC phase. Microstructural observations reveal that the eutectic region transforms from lamellar to island-like structures, and the solid solution zone narrows. With increasing temperature, the Ti concentration in the solid solution zone increases, while the contents of elements such as Ni decrease. Element diffusion is influenced by binary mixing enthalpy, with Ti and B tending to solidify in the FCC and BCC phase regions, respectively. The mechanical properties improve with increasing temperature. At 1000 °C, the average hardness is 579.2 HV, the yield strength is 1294 MPa, the fracture strength is 2385 MPa, and the fracture strain is 19.4%, representing improvements of 35.5% and 24.9% compared to the as-sintered state, respectively, without loss of plasticity. The strengthening mechanisms include enhanced solid solution strengthening due to the diffusion of Ti and TiB₂, improved grain boundary strength due to the diffusion of alloy elements to the grain boundaries, and synergistic optimization of strength and plasticity. Full article

Using the combination of Concentrated solar power (CSP) and calcium looping (CaL) technology is an effective way to solve the problems of intermittent solar energy, but calcium-based materials are prone to sintering due to the densification of the surface structure during high-temperature cycling. In this study, the enhancement mechanism of Co and Cr doping in terms of the adsorption properties of CaO was investigated by Density Functional Theory (DFT) calculations. The results indicate that Co and Cr doping shortens the bond length between metal and oxygen atoms, enhances covalent bonding interactions, and reduces the oxygen vacancy formation energy. Meanwhile, the O²⁻ diffusion energy barrier decreased from 4.606 eV for CaO to 3.648 eV for Co-CaO and 2.854 eV for Cr-CaO, which promoted CO₂ adsorption kinetics. The CO₂ adsorption energy was significantly increased in terms of the absolute value, and a partial density of states (PDOS) analysis indicated that doping enhanced the C-O orbital hybridization strength. In addition, Ca₄O₄ cluster adsorption calculations indicated that the formation of stronger metal–oxygen bonds on the doped surface effectively inhibited particle migration and sintering. This work reveals the mechanisms of transition metal doping in optimizing the electronic structure of CaO and enhancing CO₂ adsorption performance and sintering resistance, which provides a theoretical basis for the design of efficient calcium-based sorbents. Full article

Complex antimony pyrochlores Bi_2.7M_0.46Ni_0.70Sb₂O_10+Δ (M = Zn, Mg) were synthesized from oxide precursors, using the solid-state reaction method. For each composition variant, the pyrochlore phase formation process was studied during solid-state synthesis in the range of 500–1050 °C. The influence of zinc and magnesium on the phase formation process was established. The interaction of oxide precursors occurs at a temperature of 600 °C and higher, resulting in the formation of bismuth stibate (Bi₃SbO₇) as a binary impurity phase. Oxide precursors, including bismuth(III) and antimony(III,V) oxides, are fixed in the samples up to 750 °C, at which point the intermediate cubic phase Bi₃M_2/3Sb_7/3O₁₁ (sp. gr. Pn-3, M = Zn, Ni) is formed in the zinc system. Interacting with transition element oxides, it is transformed into pyrochlore. An intermediate phase with the Bi_4.66Ca_1.09VO_10.5 structure (sp. gr. Pnnm) was found in the magnesium system. The unit cell parameter of pyrochlore for two samples has a minimum value at 800 °C, which is associated with the onset of high-temperature synthesis of pyrochlore. The synthesis of phase-pure pyrochlores is confirmed by high-resolution Raman spectroscopy. The data interpretation showed that the cations in Ni/Zn pyrochlore are more likely to be incorporated into bismuth positions than in Ni/Mg pyrochlore. The nickel–magnesium pyrochlore is characterized by a low-porosity microstructure, with grain sizes of up to 3 μm, according to SEM data. Zinc oxide has a sintering effect on ceramics. Therefore, the grain size in ceramics is large and varies from 2 to 7 μm. Full article

This paper presents the possibilities of using the reaction sintering method for the production of tool steel used in medicine. The applied method enables the sintering of powders in one technological process. The SPS (spark plasma sintering) process is a technology in which electric pulses generate heat and pressure, which allows for the quick and effective connection of powder particles into a homogeneous material with high density and good mechanical properties. As a result, a product of small dimensions and a precisely defined chemical composition, established at the stage of preparing the powder mixture, is obtained. The advantages of the applied production process are the sintering time and small amounts of post-production waste compared to conventional methods of producing a finished product from steel. The method of producing a semi-finished product is particularly useful in the case of small-scale and small-sized production. The subject of the research was the analysis of the conditions for obtaining X30Cr13 martensitic steel used for the production of surgical instruments. This paper analyzes the effect of sintering temperature and time on sinterability and on selected physical and mechanical properties of the obtained materials. The sintering parameters of the starting mixture have been optimized to obtain the highest possible sinter properties, such as density and hardness. Based on the analysis of the results, it was found that the powder preparation method for the SPS process and the grain size significantly affect the microstructure and mechanical properties of the final product. The optimal sintering parameters for X30Cr13 steel are a temperature of 950 °C and a sintering time of 12 min. Furthermore, the use of the SPS method allows for a reduction in the manufacturing costs of martensitic steel semi-finished products. Full article

We present an alternative process for production of binary Nb_1−βSn_β superconducting phases using pre- and post-treatment of arc-melted Nb + Sn ingots. This process combines sequential sintering, arc melting, and annealing procedures that provide dense, bulk samples of Nb_1−βSn_β with varying stoichiometry between 0.18 < β < 0.25 depending on annealing time and temperature. We show, through magnetization measurements of these Nb_1−βSn_β bulks, that annealing of arc-melted samples at 900 °C for 3 h significantly enhances J_c values compared with arc-melted Nb_1−βSn_β samples without annealing. Microstructural analyses show that optimum grain size and orientation are achieved by sintering and annealing at lower temperatures (i.e., 720 °C and 900 °C, respectively) with short annealing times (i.e., <10 h). Processing at higher temperatures and for longer times enhances grain growth and results in fewer pinning centres. The optimum process creates effective pinning centres that deliver a J_c = 6.16 × 10⁴ A/cm² at 10 K (and ~0.2 T), compared with J_c = 3.4 × 10⁴ A/cm² for Nb_1−βSn_β subjected to a longer annealing time at a higher temperature and J_c = 775 A/cm² for an arc-melted sample without post-annealing. We suggest that further work addressing post-treatment annealing times between 3 h < t_post < 60 h at temperatures between 900 °C and 1000 °C will provide the opportunity to control stoichiometric and microstructural imperfections in bulk Nb_1−βSn_β materials. Full article