Thermal Conductivity and Sintering Mechanism of Aluminum/Diamond Composites Prepared by DC-Assisted Fast Hot-Pressing Sintering.

A novel DC-assisted fast hot-pressing (FHP) powder sintering technique was utilized to prepare Al/Diamond composites. Three series of orthogonal experiments were designed and conducted to explore the effects of sintering temperature, sintering pressure, and holding time on the thermal conductivity (TC) and sintering mechanism of an Al-50Diamond composite. Improper sintering temperatures dramatically degraded the TC, as relatively low temperatures (≤520 °C) led to the retention of a large number of pores, while higher temperatures (≥600 °C) caused unavoidable debonding cracks. Excessive pressure (≥100 MPa) induced lattice distortion and the accumulation of dislocations, whereas a prolonged holding time (≥20 min) would most likely cause the Al phase to aggregate into clusters due to surface tension. The optimal process parameters for the preparation of Al-50diamond composites by the FHP method were 560 °C-80 MPa-10 min, corresponding to a density and TC of 3.09 g cm-3 and 527.8 W m-1 K-1, respectively. Structural defects such as pores, dislocations, debonding cracks, and agglomerations within the composite strongly enhance the interfacial thermal resistance (ITR), thereby deteriorating TC performance. Considering the ITR of the binary solid-phase composite, the Hasselman-Johnson model can more accurately predict the TC of Al-50diamond composites for FHP technology under an optimal process with a 3.4% error rate (509.6 W m-1 K-1 to 527.8 W m-1 K-1). The theoretical thermal conductivity of the binary composites estimated by data modeling (Hasselman-Johnson Model, etc.) matches well with the actual thermal conductivity of the sintered samples using the FHP method.

Effect of Sintering Mechanism towards Crystallization of Geopolymer Ceramic-A Review.

Globally, there is an increasing need for ceramic materials that have a variety of applications in the environment, for precision tools, and for the biomedical, electronics, and environmental industries. However, in order to obtain remarkable mechanical qualities, ceramics have to be manufactured at a high temperature of up to 1600 °C over a long heating period. Furthermore, the conventional approach presents issues with agglomeration, irregular grain growth, and furnace pollution. Many researchers have developed an interest in using geopolymer to produce ceramic materials, focusing on improving the performances of geopolymer ceramics. In addition to helping to lower the sintering temperature, it also improves the strength and other properties of the ceramics. Geopolymer is a product of polymerization involving aluminosilicate sources such as fly ash, metakaolin, kaolin, and slag through activation using an alkaline solution. The sources of the raw materials, the ratio of the alkaline solution, the sintering time, the calcining temperature, the mixing time, and the curing time may have significant impacts on the qualities. Therefore, this review aims to study the effects of sintering mechanisms on the crystallization of geopolymer ceramics, concerning the strength achieved. A future research opportunity is also presented in this review.

Effect of the Sintering Mechanism on the Crystallization Kinetics of Geopolymer-Based Ceramics.

This research aims to study the effects of the sintering mechanism on the crystallization kinetics when the geopolymer is sintered at different temperatures: 200 °C, 400 °C, 600 °C, 800 °C, 1000 °C, and 1200 °C for a 3 h soaking time with a heating rate of 5 °C/min. The geopolymer is made up of kaolin and sodium silicate as the precursor and an alkali activator, respectively. Characterization of the nepheline produced was carried out using XRF to observe the chemical composition of the geopolymer ceramics. The microstructures and the phase characterization were determined by using SEM and XRD, respectively. The SEM micrograph showed the microstructural development of the geopolymer ceramics as well as identifying reacted/unreacted regions, porosity, and cracks. The maximum flexural strength of 78.92 MPa was achieved by geopolymer sintered at 1200 °C while the minimum was at 200 °C; 7.18 MPa. The result indicates that the flexural strength increased alongside the increment in the sintering temperature of the geopolymer ceramics. This result is supported by the data from the SEM micrograph, where at the temperature of 1000 °C, the matrix structure of geopolymer-based ceramics starts to become dense with the appearance of pores.

Efficiently sintering of MSWI fly ash at a low temperature enhanced by in-situ pressure assistant: Process performance and product characterization.

Municipal solid waste incineration (MSWI) fly ash disposal is an urgent task with some technical bottlenecks. In this study, a novel pressure-assisted sintering method was employed to treat the MSWI fly ash. A series of pressure-assisted sintering experiments were carried out by varying mechanical pressures and sintering temperatures, and their properties of compressive strength, density and heavy metals leaching behavior were determined to screen out the optimal conditions. Instrumental analysis of XRF, SEM, XRD and TEM-EDX and calculation kinetics were conducted to explore the enhancement mechanism of pressure-assisted sintering. With the help of mechanical pressure, a high-strength ceramic product was produced from MSWI fly ash sintered at a low temperature (400 °C), which never occurred in the conventional low-temperature sintering process. Maximum compressive strength of 218.30 ± 4.08 MPa was obtained at 400 °C and 100 MPa, which was much higher than conventional construction materials of brick and cement. In addition, the leaching concentrations of heavy metals obtained from pressure-assisted sintering process were lower than the standard limitation. The SEM and XRD results revealed that the increased mechanical properties and the decreased heavy metals leaching concentration were mainly attributed to the increased density and crystalline degree. The kinetics calculation results indicated that the sintering activation energy was much lower than the sintering process without pressure, suggesting surface diffusion and grain boundary diffusion were main sintering mechanisms in the pressure-assisted sintering process. These findings proved that pressure-assisted sintering could be a promising method to treat fly ash together with producing high-value building materials.

Sintering Mechanism, Microstructure Evolution, and Mechanical Properties of Ti-Added Mo2FeB2-Based Cermets.

Four series of Mo2FeB2-based cermets with Ti contents between 0 wt.% and 1.5 wt.% in 0.5 wt.% increments were prepared by in situ reaction and liquid phase sintering technology. Influences of Ti on microstructure and mechanical properties of cermets were studied. It was found that Ti addition increases formation temperatures of liquid phases in liquid-phase stage. Ti atoms replace a fraction of Mo atoms in Mo2FeB2 and the solution of Ti atoms causes the Mo2FeB2 crystal to be equiaxed. In addition, the cermets with 1.0 wt.% Ti content exhibit the smallest particle size. The solution of Ti atoms in Mo2FeB2 promotes the transformation of Mo2FeB2 particles from elongated shape to equiaxed shape. With Ti content increasing from 0 wt.% to 1.5 wt.%, the hardness and transverse rupture strength (TRS) first increase and then decrease. The maximum hardness and TRS occur with 1.0 wt.% Ti content. However, the fracture toughness decreases as Ti content increases. The cermets with 1.0 wt.% Ti content show excellent comprehensive mechanical properties, and the hardness, fracture toughness, and TRS are HRA 89.5, 12.9 MPa∙m1/2, and 1612.6 MPa, respectively.