Search Results (26)

Developing resource-efficient technologies for producing ceramic materials with specific properties and performance characteristics is one of the most important tasks in modern materials science. As natural resources face depletion, the use of anthropogenic wastes, including fly ash from coal combustion, for the development of new compositions and the production of ceramics with an improved microstructure is of particular significance. The use of PM₁₀ fly ash microspheres in ceramic production will help to reduce particulate matter emissions. In this study, fine narrow fractions of PM₁₀ microspheres were successfully separated from coal fly ash using aerodynamic and magnetic separation. Glass–ceramic materials with a homogeneous microstructure, an open porosity of 0.4–37%, a compressive strength of 5–159 MPa, and acid resistance of up to 99.9% were obtained using narrow fractions. The materials obtained are promising for application as highly porous ceramics, effective microfiltration membranes, and fine-structured technical ceramics, which can be used in installations operating in aggressive media and/or at high temperatures. The ceramic membranes were characterised by high liquid permeability values up to 1194 L·m⁻²·h⁻¹·bar⁻¹. Filtration tests showed that the retention coefficient for dispersed microsilica particles with d_av = 1.9 μm is 0.99. Full article

The physicochemical and adsorption properties of granular sorbents based on natural bentonite and modified sorbents based on it have been studied. It was found that modification of natural bentonite with iron (III) polyhydroxocations (mod. 1_Fe_5 GA) and aluminum (III) (mod. 1_Al_5 GA) by the “co-precipitation” method leads to a change in their chemical composition, structure, and sorption properties. It is shown that modified sorbents based on natural bentonite are finely porous (nanostructured) objects with a predominance of pores measuring 1.5–8.0 nm, with a specific surface area of 55–65 m²/g. Modification of bentonite with iron (III) and aluminum compounds by the “co-precipitation” method also leads to an increase in the sorption capacity of the obtained sorbents with respect to bichromate and arsenate anions and nickel cations by 5-10 times compared with natural bentonite. The obtained sorption isotherms were classified as Langmuir type isotherms. Kinetic analysis showed that at the initial stage the sorption process is controlled by an external diffusion factor, i.e. refers to the diffusion of sorbent from solution into a liquid film on the surface of the sorbent. Then the sorption process begins to proceed in a mixed diffusion mode, when it limits both the external diffusion factor and the internal diffusion factor (the diffusion of the sorbent to the active centers through the system of pores and capillaries). To determine the contribution of the chemical stage to the rate of adsorption of bichromate and arsenate anions and nickel(II) cations with the studied granular sorbents, kinetic curves were processed using the equations of chemical kinetics (pseudo-second-order model). As a result, it was found that the adsorption of the studied anions by modified sorbents based on natural bentonite is best described by a pseudo-second-order kinetic model. It is shown that the use of natural bentonite for the development of technology for the production of granular sorbents based on it has an undeniable advantage, firstly, in terms of its chemical and structural properties, it is easily and effectively modified, and secondly, having astringent properties, granules are easily made on its basis, which turn into ceramics during high-temperature firing. The result is a granular sorbent with high physical and mechanical properties. Since bentonite is an environmentally friendly product, the technology of recycling spent sorbents is also greatly simplified. Full article

Biomaterials have assumed a decisive role in modern medicine by enabling significant advancements in medical care practices. These materials are designed to interact with biological systems, offering substantial solutions for various medical needs. In this research, bioceramic materials consisting of a bioactive hydroxyapatite-based matrix with Ti nanoparticles were processed as promising materials. These bioceramics were obtained using mechanical milling, uniaxial pressing, and sintering as powder processing techniques. This study evaluates the effect of Ti additions on the structural, electrochemical, and mechanical properties of the hydroxyapatite ceramic material. Titanium additions were about 1, 2 and 3 wt%. The experimental results demonstrate that the biocomposite’s structure has two hexagonal phases: one corresponding to the hydroxyapatite matrix and the other to the Ti as a reinforced phase. The biomaterials’ microstructure is completely fine and homogeneous. The biomaterial reinforced with 1 wt. % Ti exhibits the best mechanical behavior. In this context, electrochemical tests reveal that bioceramics can achieve stability through an ion adsorption mechanism when exposed to a physiological electrolyte. Bioceramics, particularly those containing 1%Ti, develop their bioactivity through the formation of a high-density hydroxide film during a porous sealing process at potentials around −782.71 mV, with an ionic charge transfer of 0.43 × 10⁻⁹ A/cm². Finally, this biofilm behaves as a capacitor Cc = 0.18 nF/cm², resulting in lower ionic charge transfer resistance (Rct = 1.526 × 106 Ω-cm²) at the interface. This mechanism promotes the material’s biocompatibility for bone integration as an implant material. Full article

Titanium dioxide (TiO₂) is widely employed in the catalytic degradation of wastewater, owing to its robust stability, superior photocatalytic efficiency, and cost-effectiveness. Nonetheless, isolating the fine particulate photocatalysts from the solution post-reaction poses a significant challenge in practical photocatalytic processes. Furthermore, these particles have a tendency to agglomerate into larger clusters, which diminishes their stability. To address this issue, the present study has developed Al₂O₃–SiO₂–TiO₂ composite semiconductor porous ceramics and has systematically explored the influence of Al₂O₃ and SiO₂ on the structure and properties of TiO₂ porous ceramics. The findings reveal that the incorporation of Al₂O₃ augments the open porosity of the ceramics and inhibits the aggregation of TiO₂, thereby increasing the catalytic site and improving the light absorption capacity. On the other hand, the addition of SiO₂ enhances the bending strength of the ceramics and inhibits the conversion of anatase to rutile, thereby further enhancing its photocatalytic activity. Consequently, at an optimal composition of 55 wt.% Al₂O₃, 40 wt.% TiO₂, and 5 wt.% SiO₂, the resulting porous ceramics exhibit a methylene blue removal rate of 91.50%, and even after undergoing five cycles of testing, their catalytic efficiency remains approximately 83.82%. These outcomes underscore the exceptional photocatalytic degradation efficiency, recyclability, and reusability of the Al₂O₃–SiO₂–TiO₂ porous ceramics, suggesting their substantial potential for application in the treatment of dye wastewater, especially for the removal of methylene blue. Full article

The remarkable stability, suitable thermomechanical characteristics, and acceptable electrical properties of donor-doped strontium titanates make them attractive materials for fuel electrodes, interconnects, and supports of solid oxide fuel and electrolysis cells (SOFC/SOEC). The present study addresses the impact of processing and thermochemical treatment conditions on the electrical conductivity of SrTiO₃-derived ceramics with moderate acceptor-type substitution in a strontium sublattice. A-site-deficient Sr_0.85La_0.10TiO_3−δ and cation-stoichiometric Sr_0.85Pr_0.15TiO_3+δ ceramics with varying microstructures and levels of reduction have been prepared and characterized by XRD, SEM, TGA, and electrical conductivity measurements under reducing conditions. The analysis of the collected data suggested that the reduction process of dense donor-doped SrTiO₃ ceramics is limited by sluggish oxygen diffusion in the crystal lattice even at temperatures as high as 1300 °C. A higher degree of reduction and higher electrical conductivity can be obtained for porous structures under similar thermochemical treatment conditions. Metallic-like conductivity in dense reduced Sr_0.85La_0.10TiO_3−δ corresponds to the state quenched from the processing temperature and is proportional to the concentration of Ti³⁺ in the lattice. Due to poor oxygen diffusivity in the bulk, dense Sr_0.85La_0.10TiO_3−δ ceramics remain redox inactive and maintain a high level of conductivity under reducing conditions at temperatures below 1000 °C. While the behavior and properties of dense reduced Sr_0.85Pr_0.15TiO_3+δ ceramics with a large grain size (10–40 µm) were found to be similar, decreasing grain size down to 1–3 µm results in an increasing role of resistive grain boundaries which, regardless of the degree of reduction, determine the semiconducting behavior and lower total electrical conductivity of fine-grained Sr_0.85Pr_0.15TiO_3+δ ceramics. Oxidized porous Sr_0.85Pr_0.15TiO_3+δ ceramics exhibit faster kinetics of reduction compared to the Sr_0.85La_0.10TiO_3−δ counterpart at temperatures below 1000 °C, whereas equilibration kinetics of porous Sr_0.85La_0.10TiO_3−δ structures can be facilitated by reductive pre-treatments at elevated temperatures. Full article

Kaolinite is able to assure the high binding affinity of the filler particles of raw ceramic bodies. It acts as a matrix that strongly holds the other constituents’ particles in a compact structure. The slurry samples were characterized by XRD, mineralogical microscopy and SEM coupled with an EDX elemental analysis. The slurry collected from the ceramic tile production wastewaters had a significant amount of kaolinite (36%), mostly fine particles of 3 µm, less surrounding quartz (37%) and mullite (19%) particles of 5–100 µm in diameter and traces of lepidocrocite (8%). It is a dense paste with a relative moisture of 25%. The square bar of the slurry as received, pressed at a load of 350 N, had a flexural strength of 0.61 MPa. Increasing the moisture to 33% using regular water, followed by mechanical attrition at 2000 rpm for 5 min, resulted in a porous bar with a flexural strength of 0.09 MPa; by increasing the attrition speed to 6000 rpm, the microstructural homogenization was improved and the flexural strength was about 0.68 MPa. It seems that regular water does not assure an optimal moisture for the kaolinite matrix conditioning. Therefore, we used technological water at pH = 10, a moisture of 33% and attrition at 6000 rpm for 5 min, and the bar pressed at a load of 350 N had a flexural strength of 1.17 MPa. The results demonstrate that the bar moistened with technological water and an attrition regime assured a proper conditioning for the kaolinite matrix, achieving the optimal binding of the quartz and mullite particles under the pressing load. Bars with the optimal mixture were pressed at several loads, including 70, 140, 210 and 350 N, and the flexural strength was progressively increased from 0.56 MPa to 1.17 MPa. SEM fractography coupled with atomic force microscopy (AFM) revealed that the optimal moisture facilitated a proper kaolinite particle disposal regarding the quartz and mullite filler particles, and the progressive load assured the strong binding of the finest kaolinite platelets onto their surface. Full article

Multicomponent clay and cenosphere linings protecting ceramic parts exposed to contact with liquid metal during continuous steel casting (CSC) are intended to diminish thermo-mechanical stresses at the beginning of this process. They are effective in their role, but due to their brittle nature, parts of them come off during transport or mounting. The admixture of polypropylene fibers into linings helps to alleviate problems with handling such parts, though the interaction of such a modified material with liquid steel should be re-assessed. The present experiment involved the preparation of a crucible with a Thermacoat™ (Vesuvius, Skawina, Poland) lining with the addition of Belmix™ (Belgian Fibers Group NV, Mouscron, Belgium) fibers and filling it with a drop of liquid steel. Next, the crucible was sectioned and the changes in its microstructure and phase composition were investigated with optical, scanning and transmission electron microscopy (OM/SEM/TEM) methods. This showed that the modified lining retained its non-wetting property against the steel of the non-modified material. The part with the lining, being in direct contact with the liquid steel, developed a highly porous layer filled with AlSiOx amorphous flakes with some larger blocky Al₂O₃ and SiO₂ particles. Right below this, a heat-affected zone (HAZ) consisting of fine γ-Al₂O₃ platelets immersed in amorphous silica was formed. Some of the voids with a size corresponding to polymer fiber diameter carried significant carbon deposits on their walls. The performed investigation indicated that the polymer fiber-modified linings were capable of withstanding at least short-term contact with liquid steel without instantaneous defragmentation, i.e., they retained the good high-temperature properties of the non-modified material. Full article

ZrO₂-toughened Al₂O₃ (ZTA) ceramic composites with a porosity gradient and with improved mechanical properties have a wide range of possible applications. We fabricated nanofibrous and nanogranular Y-ZTA and Ce-ZTA composites with a gradient microstructure by creating a temperature gradient during SPS sintering, with the use of asymmetric graphite tool arrangement (ASY). In this study, we examined the morphology effect of the starting materials on the sintering process and on the final microstructure, as well as the mechanical properties of the composites. A large temperature difference was established for both the granular and fibrous samples fabricated in the ASY configuration, which resulted in gradient porosity along the ceramics bodies: the upper part of the ceramics showed a highly porous fine microstructure, while the opposite side was highly densified. The final microstructure of the composites can be tailored by varying the morphology of the starting ceramics or the graphite configuration. A highly porous skeleton-like structure was formed by sintering fibres in the ASY configuration, whereas the granular precursors resulted in a much less porous composite. The microstructure affected the mechanical properties of the composite. Improved hardness and more than 50% higher compression strength were obtained for the granular Ce-ZTA samples as compared to the fibrous sample. Gradient porosity with fibrous or granular morphology promotes the penetration of bioactive nanosized hydroxyapatite (HAp) into the pore structure. Fibrous ZTA absorbs HAp more effectively due to its higher porosity as well as its bimodal pore structure. Full article

The properties of porous and lightweight ceramic foam that can be cured at room temperature using metakaolin-based geopolymers were studied. A geopolymer slurry was prepared using metakaolin and a potassium-based alkaline medium at room temperature, and the obtained viscous paste was expanded via gaseous methods, by means of the decomposition of peroxide at room temperature. Therefore, geopolymer (GP) foam developed in this study through multivariate geopolymer, foaming agents, and surfactants can be cured at room temperature (within 5 days) without a separate heat treatment process. The homogeneous micropores were obtained through the stabilization of the interface between geopolymer slurry and oxygen gas bubbles generated through the base-catalyzed decomposition of hydrogen peroxide. The porosity was confirmed to be 29% and 54% before and after using sodium dodecyl sulfate (SDS). The compressive strengths and densities were 1.57 MPa and 0.75 g/cm³ for GP foam without SDS, and 3.63 MPa and 0.48 g/cm³ for GP foam with SDS. Through the mercury intrusion porosimetry analysis, the pores were further refined from 100 µm to 30 µm when SDS was used, and at the same time, the variation of pore size was minimized, so that a relatively uniform pore size was maintained. In addition, the thermal conductivity is 0.0803 W/m·K and the pore size is 33.2 $\mathsf{\mu }\mathrm{m}$, which is smaller in pore diameter than the geopolymer containing only hydrogen peroxide. As a result, although the hydrogen peroxide alone sample has excellent thermal conductivity, the use of a surfactant is recommended for fine micropore size control. While reducing the non-uniform distribution of pores and the size of micropores generated through the direct foaming method as an inorganic binder, the possibility of an insulation finish was also confirmed by reducing the weight. Full article

The aim of the current work was to study the physicochemical properties and biological activity of different types of porous granules containing silver or gallium ions. Firstly, hydroxyapatites powders doped with Ga³⁺ or Ag⁺ were synthesized by the standard wet method. Then, the obtained powders were used to fabricate ceramic microgranules (AgM and GaM) and alginate/hydroxyapatite composite granules (AgT and GaT). The ceramic microgranules were also used to prepare a third type of granules (AgMT and GaMT) containing silver or gallium, respectively. All the granules turned out to be porous, except that the AgT and GaT granules were characterized by higher porosity and a better developed specific surface, whereas the microgranules had very fine, numerous micropores. The granules revealed a slow release of the substituted ions. All the granules except AgT were classified as non-cytotoxic according to the neutral red uptake (NRU) test and the MTT assay. The obtained powders and granules were subjected to various antibacterial test towards the following four different bacterial strains: Staphylococcus aureus, Staphylococcus epidermidis, Pseudomonas aeruginosa and Escherichia coli. The Ag-containing materials revealed high antibacterial activity. Full article

The present COVID-19 emergency has dramatically increased the demand for pharmaceutical containers, especially vials. End-of-life containers, however, cannot be easily recycled in the manufacturing of new articles. This paper presents some strategies for upcycling of pharmaceutical glass into various porous ceramics. Suspensions of a fine glass powder (70 vol%) are used as a starting material. Highly uniform cellular structures may be easily prepared by vigorous mechanical stirring of partially gelified suspensions with added surfactant, followed by drying and firing at 550–650 °C. Stabilization of the cellular structures at temperatures as low as the glass transition temperature (T_g) of the used glass is facilitated by thermal decomposition of the gel phase, instead of viscous flow sintering of glass. This finding enabled the preparation of glass membranes (∼78 vol% open porosity), by direct firing of hardened suspensions, avoiding any surfactant addition and mechanical stirring. The powders obtained by crushing of hardened suspensions, even in unfired state, may be used as a low-cost sorbent for dye removal. Full article

Porous glass-ceramic materials are used in the construction engineering and repair of various objects. The article investigates the method for obtaining porous glass ceramics from siliceous rock with a high calcite content. To obtain samples with an even fine porous structure, a small amount (≤0.386%) of chloride (NaCl, KCl, MgCl₂·6H₂O, CaCl₂) was added to the charge mixture. At the first stage, mechanochemical activation of raw materials was carried out. Siliceous rock, Na₂CO₃ and additives (chlorides) were grinded together in a planetary ball mill. The resulting charge was annealed at a temperature of 850 °C. The influence of the type and amount of chloride on the properties of the charge mixture and glass ceramics has been defined by thermal analysis (TA), X-ray diffraction (XRD), scanning electron microscopy (SEM), etc. The chlorides in the charge mixture decreased the calcite’s decarbonization temperature and had an effect on the macro- and microstructure of the material. As a result, samples of glass ceramics with an even finely porous structure in the form of blocks were obtained. The samples consist of quartz, wollastonite, devitrite, anorthoclase and an amorphous phase. On average, 89–90% of the resulting material consists of with small pores. The apparent density of the samples is in the range of 245–267 kg/m³. Bending and compressive strength reaches 1.75 MPa and 3.8 MPa, respectively. The minimum thermal conductivity of the modified samples is 0.065 W/(m∙°C). The limiting operating temperature is 860 °C, and the minimum thermal shock resistance is 170 °C. The material has a high chemical stability. They can be used as thermal insulation for some types of industrial and civil facilities. Full article

Cracks are one of the most common issues affecting colored pottery relics; these can be divided into macroscopic cracks, recognizable by the human eye, and micron cracks, which cannot be observed by the naked eye. The gradual development of micron cracks eventually leads to large-scale cracks and the shedding of the coating layer. The repair of such micron cracks poses a key technical difficulty in restoring painted pottery remnants from the Western Han Dynasty. We attempt to solve this problem by reporting on a method that entails the use of a water-borne fluoropolymer material as the adhesive agent, as well as ultra-depth-of-field, digital microscopic imaging technology to build an operating platform for an optical imaging monitoring system. By making simulated ceramic samples, we systematically investigated the influences of water-borne fluoropolymer on chromaticity, adhesion, contact angle, surface morphology, and thermal stability of the paint layer. The results indicate that the color of the painted layer, when treated with the water-borne fluoropolymer, did not change, and the adhesion and contact angle of the painted layer were improved. Additionally, the outcomes of the SEM analysis show that the adhesion and hydrophobicity of the painted layer were improved because the water-borne fluoropolymer filled up the porous structure of the painted layer and covered the pigment particles. These findings demonstrate that aqueous, water-borne fluoropolymer can be used as an adhesive agent for micron cracks. Meanwhile, via the operating platform of the optical imaging monitoring system, the micron cracks of the painted terracotta warriors and horses from the Western Han Dynasty were successfully repaired using the water-borne fluoropolymer. The results imply that the microstructure, size, and geometric spaces of the cracks can be obtained directly utilizing microscopic imaging technology. The dynamic monitoring and imaging system described above can be employed to assist prosthetists in visualizing micro-repair operations in real time, assist with fine visual operations during the repair process, and realize dynamic video recording of the entire repair process. Our work provides a simple visualization method to repair micron-scale cracks in painted pottery relics by applying modern fluoropolymer and ultra-depth-of-field digital microscopic imaging technology. Full article

The resource and large-scale utilization of waste ceramic materials, magnesium slag, and coal gangue are one of the important ways for the sustainable development in metallurgy, coal, and other related enterprises. In this paper, waste ceramic materials were used as aggregates; coal gangue and magnesium slag were used as mixed binder; and the all solid-waste-based permeable bricks with excellent performance were prepared by forming pressure at 5 MPa. The mechanical properties and water permeability of the all-solid-waste-based permeable bricks were evaluated. The results proved that the porous channel of permeable brick is mainly composed of waste ceramic materials with a particle size of 2–3 mm. Pore structures below 200 μm were mainly composed of fine aggregate and mixed binder. Using 60% coarse aggregate, 20% fine aggregate, 10% coal gangue, and 10% magnesium slag as raw materials, the all-solid-waste-based permeable bricks were obtained by pressing at 6 MPa and sintering at 1200 °C, which exhibited the best performance, and its water permeability, compressive strength, and apparent porosity were 1.56 × 10⁻² cm/s, 35.45 MPa, and 13.15%, respectively. Excellent water permeability, compressive strength, and apparent porosity of the all solid-waste-based permeable bricks were ascribed to the high content of connecting open pores, and closely adhesive force were ascribed to the porous microstructure constructed by the grading of waste ceramic materials and the tight conjoined points of the liquid phases in coal gangue and magnesium slag at a high sintering temperature. Full article

Dynamic tests of fine-grained fired dioxide-zirconia ceramics under compression under uniaxial stress conditions were carried out. The influence of the specimen length on the obtained strength and deformation properties of ceramics is investigated. The thickness of the specimen has a significant impact on the course of the obtained dynamic stress–strain diagrams: short specimens have a much more sloping area of active loading branch. The main contribution to the modulus of the load branch resulting from tests of brittle porous media is made by the geometry of the specimens and the porosity of the material. When choosing the length of specimens for dynamic tests, the optimal geometry of the tested specimens is preferable in accordance with the Davies–Hunter criterion, when the contributions of axial and radial inertia are mutually compensated, and the contribution of the effects of friction in the resulting diagram is minimal. When choosing the geometry of specimens of brittle porous media, the structure of the material should be taken into account so that the size of the specimen (both length and diameter) exceeds the size of the internal fractions of the material by at least five times. Full article