Search Results (113)

The continuous drive for higher efficiency in gas turbines has led to increased combustion temperatures, making the thermal shock resistance of thermal insulation tiles a critical factor limiting performance. Corundum–mullite multiphase ceramics are widely used in such applications; however, their performance is often constrained by an inherent trade-off between mechanical strength and thermal shock resistance. In this work, a synergistic modification strategy based on rare-earth disilicate phases was developed, wherein Y₂O₃ and SiC were incorporated into a corundum–mullite matrix to enable in situ formation and controlled distribution of Y₂Si₂O₇ via gel casting. During sintering, Y₂Si₂O₇ acts as a transient liquid phase, facilitating densification and grain boundary strengthening; upon thermal shock, it migrates to fill and heal grain boundaries and microcracks, thereby significantly enhancing thermal shock resistance. The optimized sample S5, sintered at 1400 °C, exhibited a bulk density of 2.12 g/cm³ and a bending strength of 68.43 MPa. Notably, after 30 thermal shock cycles (air cooling from 1000 °C to RT), its bending strength increased to 79.71 MPa, corresponding to a 16.48% enhancement. This work provides an effective strategy for incorporating rare-earth disilicates into multiphase ceramics and offers valuable guidance for the development of high-performance components for gas turbines. Full article

This study investigates a karst bauxite deposit from NE Spain with a dual objective incorporating the novel aspect of directly linking genetic processes to industrial ceramic performance. First, the bauxite is mineralogically and texturally characterized using X-ray diffraction and field emission scanning electron microscopy. Second, the mineralogical and textural transformations of the bauxite during firing at 1000, 1200 and 1300 °C are analyzed, together with their effects on the physical properties of the fired products. The Lower Cretaceous bauxite is autochthonous, shows a pisolithic structure, and formed in situ under tropical monsoon conditions through intense chemical weathering involving dissolution–crystallization processes. For ceramic testing, the bauxite was mixed with illitic–kaolinitic clays in a 90/10 proportion. During firing, kaolinite and illite destabilize and transform into mullite, initially by solid-state reactions at 1000 °C and subsequently by crystallization from a vitreous phase at higher temperatures, producing larger crystals and composition closer to the empirical mullite formula. The formation of vitreous phase and mullite leads to reduced porosity and increased density and linear shrinkage, particularly between 1000 and 1200 °C. Specimens fired at 1300 °C show higher mechanical strength, related to higher mullite content and a larger size of its crystals. The results demonstrate the potential interest of these bauxites for ceramic manufacturing. Full article

Digital Light Processing (DLP), which operates through a layer-by-layer deposition, has proven to be a promising technique for obtaining complex and customized architectures. However, there are still numerous unresolved challenges in ceramics additive manufacturing, among which is delamination due to suboptimal adhesion between the layers, which threatens the structural integrity and properties of samples. According to recent findings, excess surface hydroxyl groups were identified as being responsible for this defect; a suitable calcination pre-treatment of the ceramic powder could be effective in significantly mitigating delamination flaws in mullite DLP printed bodies. Therefore, in addition to optimizing the printable slurry formulation and printing parameters (mainly in terms of curing energy and layer resolution), this work aimed at investigating the influence of the calcination of a commercial mullite powder (added with magnesium nitrate hexahydrate, as a precursor of the sintering aid MgO) as a simple and effective treatment to additively shape ceramic bodies with limited flaws and enhanced density. The surface characteristics evolution of the mullite powder was investigated, specifically comparing samples after magnesium nitrate hexahydrate addition and ball-milling in water (labeled as BM), and after an additional calcination (BMC). In particular, the effect of the superficial -OH groups detected by FTIR analysis in the BM powder, but not in the BMC sample, was studied and correlated to the properties of the respective ceramic slurry in terms of rheological behavior and curing depth. The hydrophilicity of BM powders, due to superficial hydroxyls groups, affects ceramic powder dispersion and wettability by the resin, causing a weak interface. At the same time, it promotes photopolymerization of the light-sensitive resin, thus inducing the as-printed matrix embrittlement. Anyhow, its photopolymerization degree, equal to 67% and 55% for BM and BMC, respectively, was enough to guarantee the printability of both slurries. However, the use of BMC significantly reduced flaw occurrence in the as-printed bodies and the final density of the samples sintered at 1450 °C (without an isothermal step) was increased (approx. 60% and 50% of the theoretical value for BMC and BM, respectively). Thus, the target porosity of the ceramic bodies was guaranteed, and their structural integrity achieved without any increase in sintering temperature but with a simple powder treatment. Full article

In the present study, glass/ceramic hybrid fibers were chosen as a paper matrix, which effectively balance toughness and high-temperature resistance for soot combustion applications. In order to address the issue of unevenness in the performance of paper-type catalysts caused by the differences in the dispersion behavior of glass fibers and ceramic fibers in water, a facile foam-forming technology was proposed. The obtained glass fiber/mullite composite paper with various mass ratios (1:1, 2:1, 3:1, 4:1, and 5:1) exhibit high evenness, and better high-temperature resistance than the pure glass fibers. After impregnating K-Mn active ingredients, 15K5Mn-GFF-3G1C (GF/CF = 3:1) demonstrates high tensile strength, excellent catalytic activity (T50 = 388 °C), reusability (five cycles), and high-temperature stability (800 °C, 12 h). Full article

This study focuses on preparing mullite grogs derived from selected waste materials and kaolin treated with advanced technologies to achieve high thermal resistance and low thermal expansion. The investigated waste materials include dust removal RON, slurry DE, feldspar dust removal from Halamky, and waste generated during the feldspar grinding at the Halamky I deposit. These materials (Red kaolin from Vidnava, Slurry DE, Dust-off RON, Feldspar dust-off Halamky) were processed into grogs and subsequently applied for the production of high-mullite ceramics. The influence of cristobalite admixture was also assessed. The chemical composition was determined by X-ray fluorescence (XRF), while the phase composition was analysed by X-ray diffraction (XRD). Amorphous mullite grogs with mullite contents greater than 40% were successfully prepared. Despite the relatively high iron content, the resulting products exhibited the desired white colour after firing and demonstrated properties that make them promising candidates for advanced refractory applications. The study highlights the potential to valorise industrial waste materials for high-value ceramic applications. Full article

This study investigates ceramic bricks produced by partially replacing clay with Pb–Zn metallurgical residues (lead furnace dust and cyclone dust), fly ash, and carbonaceous additives. The novelty lies in the integrated multi-waste formulation and the combined FTIR–TGA–XRD analytical approach used to elucidate phase-formation mechanisms. The results show that firing promotes the development of quartz, mullite, iron oxides, and an extensive Fe–Pb–Zn–Si–O amorphous network, while higher residue contents enhance amorphization and suppress mullite crystallization. These microstructural changes correlate with reduced compressive strength (1.6–3.1 MPa) and high water absorption (32–36%), although all samples completed 15 freeze–thaw cycles. Heavy-metal leaching assessed by atomic absorption spectroscopy (AAS) revealed very low Pb (0.08–0.20 mg/L) and Zn (0.25–0.45 mg/L) release, well below international safety limits, demonstrating effective immobilization of hazardous ions within the glassy matrix. Overall, the study provides new insight into multi-waste interactions during sintering and confirms that controlled residue incorporation enables environmentally safe, non-load-bearing ceramic materials with reduced clay consumption. Full article

Red ceramics remain essential in construction worldwide, but face challenges associated with high energy demand and CO₂ emissions. Sustainable alternatives require valorization of local georesources and adoption of circular economic approaches. This study evaluated two ceramic pastes formulations designed from locally available raw materials in southern Portugal: batch AD2, a 1:1 blend of residual clays from Corval, and batch XB1, a 1:1 blend of residual clay from Corval and a clay-schist from Barrancos. Raw materials were selected to balance contrasting properties, i.e., smectite-rich clays with high plasticity and shrinkage versus illitic (coarser) schists with lower plasticity and tempering effects. Batches were extruded, dried, fired at 1100 and 1150 °C, and tested for shaping moisture, shrinkage, water absorption, flexural strength, and mineralogical evolution. Results showed that the residual clays batch required high shaping moisture (20.04%) but achieved controlled drying shrinkage and high dry strength due to the smectite/temper balance. After firing, the material exhibited total shrinkage of 9.12 ± 0.28 and 9.78 ± 0.11%, water absorption of 11.57 ± 0.30 and 9.85 ± 0.27%, and flexural strength of 13.95 ± 2.30 and 14.85 ± 2.68 MPa, with mullite formation enhancing its performance. Clay and schist batch, after drying at 110 °C displayed low shaping moisture (6.22%), minimal drying shrinkage (0.15 ± 0.06%), and moderate fired (1100 and 1150 °C) shrinkage (1.59 ± 0.06 and 2.77 ± 0.04%). Water absorption decreased from 12.10 ± 0.77 to 9.91 ± 0.80% as the temperature increased, while flexural strength rose significantly from 13.60 ± 0.74 to 19.69 ± 1.54 MPa. Both blends developed desirable red tones without efflorescence. These findings demonstrated that residual clays and clay-schist can be effectively blended to produce sustainable, high-quality red ceramics, meeting structural requirements while promoting resource efficiency, reducing transport, and supporting decarbonization strategies. Full article

Corundum–mullite duplex ceramics were fabricated via a solid-state reaction technique using high-alumina fly ash and α-alumina powders. The effects of magnesium oxide on bulk density, apparent porosity, compressive strength, and microstructure of the duplex ceramics were investigated by scanning electronic microscopy, mechanical testing, and X-ray diffraction, respectively. Results showed that the prepared ceramics were mainly dominated by mullite and corundum phases, and the mullite was in the form of columns and crosses to form a net-like structure. The bulk density and the compressive strength increased with the increase in MgO addition, while the porosity decreased contrariwise. Optimal performance among tested compositions was observed at 12 wt% MgO addition, yielding a bulk density of 3.012 g·cm⁻³, a porosity of 8.12%, and a compressive strength of 263 MPa, demonstrating the potential of this composite for high-performance ceramic applications. Full article

Developing sustainable ceramic formulations that integrate industrial by-products addresses the high energy and raw material demands of refractory manufacturing while advancing circular economy goals. This study investigates the recycling of chamotte waste from rejected fired electrical porcelain as a partial substitute (5 and 10 wt.%) for flint clay in aluminosilicate refractory castables. Samples were fired at 110, 815, 1050, and 1400 °C and evaluated for bulk density, apparent porosity, cold crushing strength, and flexural strength. Microstructural and mineralogical changes were analyzed by SEM and XRD. Incorporating 10 wt.% chamotte waste fostered an in situ mullite-reinforced microstructure, enhancing mechanical strength (58 MPa—CCS, 18.8 MPa—MOR) and lowering porosity (24.4%), demonstrating chamotte’s dual role as recycled raw material and reinforcement phase for densification and durability. These properties matched or surpassed those of the conventional formulation, with strength improvements of up to 44%. The findings demonstrate that high-temperature industrial waste can be effectively valorized in advanced refractories, reducing reliance on virgin raw materials, diverting waste from landfills, and promoting industrial symbiosis within the ceramics and metallurgical sectors. Full article

In this study, the effects of batch and continuous grinding on the ceramic floor tile body were investigated in terms of cost, capacity, and technical aspects. In batch milling, a changing speed during grinding was more efficient than a constant speed. Capacity and energy consumption increased as the mill rotation speed increased in continuous grinding. Specific energy consumptions were measured as 36 kW/ton and 43.1 kW/ton, with 1.6 ton/h and 8.375 t/h capacities. Additionally, d₁₀, d₅₀, and d₉₀ values for ground ceramic floor tile bodies were determined to be 2.5, 9.5, and 47.2 µm and 2.5, 9.4, and 48.1 µm for batch and continuous grinding, respectively. No significant difference was observed in the color and shrinkage values, while water absorptions were calculated to be 1.1% and 0.3% as sintering properties for batch and continuous methods, respectively. In the phase analysis of a sintered body prepared using the continuous method, mullite and quartz were observed, while microcline was also analyzed differently from such minerals for the batch one. Structural changes, surface morphology, and roughness were also interpreted by DTA/TG, SEM, and AFM analysis. The presence of plastic clay minerals during the grinding process in batch milling caused non-plastic raw materials not to be ground sufficiently, and sintering characteristics changed. Full article

Aluminum and its alloys are widely used in aerospace and industrial sectors due to their high specific strength, low density, and abundance. However, their low hardness, high corrosion susceptibility, and poor wear resistance limit broader applications. Surface treatments such as electroplating, PVD/CVD, and anodizing have been used to enhance surface properties. Plasma electrolytic oxidation (PEO), also known as micro-arc oxidation (MAO), has emerged as a promising technique for producing durable ceramic coatings on light metals like Al, Mg, and Ti alloys. In this study, PEO was applied to AA6061 aluminum alloy using an AC power source in potentiostatic mode at 350 V and 400 V, 1000 Hz, and 80% duty cycle for 30 min in a silicate-based electrolyte (5 g/L Na₂SiO₃ + 5 g/L KOH) maintained at 25–40 °C. The effect of voltage on the coating morphology, thickness, and corrosion resistance was investigated. The coatings exhibited porous structures with pancake-like, crater, and nodular features, and thicknesses ranged from 0.053 to 83.64 µm. XRD analysis confirmed the presence of Al, α-Al₂O₃, Ƴ-Al₂O₃, and mullite. The 400 V-coated sample showed superior corrosion resistance ( $E_{corr}= -0.77 \mathrm{V}$; $i_{corr}=0.28 \mu \mathrm{A}/{\mathrm{c}\mathrm{m}}^2$) and improved hardness (up to 233 HV), compared to 89 HV for the bare AA6061. Full article

Fly ash, as the main solid waste of coal-fired power plants, is an environmental problem that needs to be solved due to its massive accumulation. The mechanical properties and optimization mechanism of lightweight aggregate concrete prepared by using new single-cylinder rotary kiln fly ash ceramic granules as aggregate were systematically investigated. Through orthogonal experimental design, combined with macro-mechanical testing and microscopic characterization techniques, the effects of cement admixture and ceramic granule admixture on the properties of concrete, such as compressive strength, split tensile strength, and modulus of elasticity, were analyzed, and the optimization scheme of key parameters was proposed. The results show that the new single rotary kiln fly ash ceramic particles significantly improve the mechanical properties of concrete by optimizing the porosity (water absorption ≤ 5%), and its 28-day compressive strength reaches 46~50.9 MPa, which is 53.3~69.7% higher than that of the ordinary ceramic concrete, and the apparent density is ≤1900 kg/m³, showing lightweight and high-strength characteristics. X-ray diffraction (XRD) analysis shows that the new ceramic grains form a more uniform, dense structure through the synergistic effect of internal mullite crystals and dense glass phase; computed tomography (CT) scanning shows that the total volume rate of cracks of the new ceramic concrete was reduced by up to 63.8% compared with that of ordinary ceramic concrete. This study provides technical support for the utilization of fly ash resources, and the prepared vitrified concrete meets the demand of green building while reducing structural deadweight (20~30%), which has significant environmental and economic benefits. Full article

This study presents a comprehensive mineralogical, chemical, and technological characterization of clay schist samples from Barrancos (southern Portugal), aiming to evaluate their suitability for sustainable ceramic production. The work integrated X-ray diffraction (XRD), X-ray fluorescence (XRF), thermal analysis (TGA, DTA, and dilatometry), and other assays. After simple dry milling, the clay schist samples’ texture supported their use in plastic ceramic pastes but indicated a need for blending with coarser materials to meet extrusion requirements. Mineralogical analysis confirmed a dominance of illite (82%–85%), with minor kaolinite and chlorite. Chemical composition revealed significant Al₂O₃ (21.65%–28.24%) and SiO₂ (52.27%–58.99%) contents, while Fe₂O₃ (4.41%–8.89%) supported their use in red ceramics. The presence of K₂O (up to 5.43%) and Na₂O (up to 1.63%) contribute to the fluxing capacity, promoting vitrification. Cation exchange capacity and specific surface area were low, consistent with the mineralogy dominated by illite and kaolinite. Thermal analysis confirmed the formation of mullite after firing at 1100 and 1150 °C, alongside residual quartz and hematite. The ceramic bodies exhibited progressive densification and strength enhancement with increasing temperature. The mixture of two selected samples showed good mechanical properties and lower porosity, with no efflorescence observed. These results underscore the potential of these schists as sustainable raw materials for ceramic production, promoting regional economic valorization and reducing environmental impact by utilizing local resources. Full article

This study investigates the potential of residual clays from a traditional ceramic-producing region in southern Portugal as raw materials for red ceramic applications. This work aims to support more sustainable ceramic practices through the local valorization of naturally available, underutilized clay resources. A multidisciplinary approach was employed to characterize clays, integrating mineralogical (XRD), chemical (XRF), granulometric, and thermal analyses (TGA/DTA/TD), as well as technological tests on plasticity, extrusion moisture, shrinkage, and flexural strength. These assessments were designed to capture both the intrinsic properties of the clays and their behavior across key ceramic processing stages, such as shaping, drying, and firing. The results revealed a broad diversity in mineral composition, particularly in the proportions of kaolinite, smectite, and illite, which strongly influenced plasticity, water demand, and thermal stability. Clays with higher fine fractions and smectitic content exhibited excellent plasticity and workability, though with increased sensitivity to drying and firing conditions. Others, with coarser textures and illitic or feldspathic composition, demonstrated improved dimensional stability and lower shrinkage. Thermal analyses confirmed expected dehydroxylation and sintering behavior, with the formation of mullite and spinel-type phases contributing to densification and strength in fired bodies. This study highlights that residual clays from varied geological settings can offer distinct advantages when matched appropriately to ceramic product requirements. Some materials showed strong potential for direct application in structural ceramics, while others may serve as additives or tempering agents in formulations. These findings reinforce the value of integrated characterization for optimizing raw material use and support a more circular, resource-conscious approach to ceramic production. Full article

A ceramic–metal composite was synthesized using sol–gel and electrospinning methods to serve as a SERS substrate. The precursors used were tetraethyl orthosilicate, aluminum nitrate, and zirconium, and polyvinylpyrrolidone was added to electrospun nonwoven fibrous membranes. The membranes were sintered, decorated with silver nanoparticles. The enhancement substrates were made of fibers of cylindric morphology with an average diameter of approximately 190 nm, a smooth surface, and 9 nm spherical particles decorating the surface of the fibers. The enhancement capacity of the substrates was tested using pyridine, methyl orange, methylene blue, crystal violet, and Eriochrome black T at different concentrations with Raman spectroscopy to determine whether the size and complexity of the analyte has an impact on the enhancement capacity. Enhancement factors of 2.53 × 10², 3.06 × 10¹, 2.97 × 10³, 4.66 × 10³, and 1.45 × 10³ times were obtained for the signal of pyridine, methyl orange, methylene blue, crystal violet, and Eriochrome black T at concentrations of 1 nM. Full article