High-Temperature Oxidation Resistance of PDC Coatings in Synthetic Air and Water Vapor Atmospheres.

This work is aimed at the development and investigation of the oxidation behavior of ferritic stainless-steel grade AISI 441 and polymer-derived ceramic (PDC) protective coatings. Double-layer coatings of a PDC bond coat below a PDC top coat with glass and ceramic passive fillers' oxidative resistance were studied at temperatures up to 1000 °C in a flow-through atmosphere of synthetic air and in air saturated with water vapor. Investigation of the oxide products formed at the surface of the samples in synthetic air and water vapor atmospheres, at different temperatures (900, 950, 1000 °C) and exposure times (24, 96 h) was carried out on both uncoated steel and steel coated with selected coatings by scanning electron microscopy (SEM) and X-Ray diffraction (XRD). The Fe, Cr2O3, TiO2, and spinel (Mn,Cr)3O4 phases were identified by XRD on oxidized steel substrates in both atmospheres. In the cases of the coated samples, m- ZrO2, c- ZrO2, YAG, and crystalline phases (Ba(AlSiO4)2-hexacelsian, celsian) were identified. Scratch tests performed on both coating compositions revealed strong adhesion after pyrolysis as well as after oxidation tests in both atmospheres. After testing in the water vapor atmosphere, Cr ions diffused through the bond coat, but no delamination of the coatings was observed.

Micro-/Mesoporous Platinum-SiCN Nanocomposite Catalysts (Pt@SiCN): From Design to Catalytic Applications.

The synthesis, characterization, and catalytic studies of platinum (Pt) nanoparticles (NPs) supported by a polymer-derived SiCN matrix are reported. In the first step and under mild conditions (110 °C), a block copolymer (BCP) based on hydroxyl-group-terminated linear polyethylene (PEOH) and a commercially available polysilazane (PSZ: HTT 1800) were synthesized. Afterwards, the BCP was microphase separated, modified with an aminopyridinato (Ap) ligand-stabilized Pt complex, and cross-linked. The green bodies thus obtained were pyrolyzed at 1000 °C under nitrogen and provided porous Pt@SiCN nanocomposite via decomposition of the PEOH block while Pt nanoparticles grew in situ within the SiCN matrix. Powder X-ray diffraction (PXRD) studies confirmed the presence of the cubic Pt phase in the amorphous SiCN matrix whereas transmission electron microscopy (TEM) measurements revealed homogeneously distributed Pt nanoparticles in the size of 0.9 to 1.9 nm. N2 sorption studies indicated the presence of micro- and mesopores. Pt@SiCN appears to be an active and robust catalyst in the hydrolysis of sodium borohydride under harsh conditions.

Novel multifibrillar carbon and oxidation-stable carbon/ceramic hybrid fibers consisting of thousands of individual nanofibers with high tensile strength.

In this study, multifibrillar carbon and carbon/ceramic (C/SiCON) fibers consisting of thousands of single nanofibers are continuously manufactured. The process starts with electrospinning of polyacrylonitrile (PAN) and PAN/oligosilazane precursors resulting in poorly aligned polymer fibers. Subsequent stretching leads to parallel aligned multifibrillar fibers, which are continuously stabilized and pyrolyzed to C or C/SiCON hybrid fibers. The multifibrillar carbon fibers show a high tensile strength of 911 MPa and Young's modulus of 154 GPa, whereas the multifibrillar C/SiCON fibers initially have only tensile strengths of 407 MPa and Young's modulus of 77 GPa, due to sticking of the nanofibers during the stabilization in air. Additional curing with electron beam radiation, results in a remarkable increase in tensile strength of 707 MPa and Young's modulus of 98 GPa. The good mechanical properties are highlighted by the low linear density of the multifibrillar C/SiCON fibers (~ 1 tex) compared to conventional C and SiC fiber bundles (~ 200 tex). In combination with the large surface area of the fibers better mechanical properties of respective composites with a reduced fiber content can be achieved. In addition, the developed approach offers high potential to produce advanced endless multifibrillar carbon and C/SiCON nanofibers in an industrial scale.

SiCN nanofibers with a diameter below 100 nm synthesized via concerted block copolymer formation, microphase separation, and crosslinking.

SiCN fibers with a mean diameter of 50 nm and an aspect ratio of up to 100 are produced in a two-step process by R. Kempe and co-workers. The key step to fabricate the longitudinal and cross-sectional views of the mesofibers shown here is a concerted block-copolymer synthesis, microphase separation, and cross linking at 140 °C followed by pyrolysis at 1100 °C. Inexpensive components like a commercially available silazane and polyethylene are linked. The fibers may find application in electronic devices, as components of ceramic matrix composites, as fiber beds in high-temperature nano-filtering like diesel fine dust removal, or as thermally robust and chemically inert catalyst supports. Furthermore, the SiCN nanofibers introduced on page 984 are a promising alternative to ultrathin carbon fibers, due to their oxidation resistance.

Control of surface energy of silicon oxynitride films.

Microstructure and chemical composition determine the wetting property of solid surfaces. To achieve hydrophobicity or hydrophilicity, recent efforts have mostly focused on designed patterns and sophisticated surface modification. Here we show the fabrication of a dense amorphous silicon oxynitride (SiON) film by simple annealing of perhydropolysilazane (PHPS), which experiences significant and abrupt transition in surface energy as a function of temperature. The polar component of surface energy, derived from contact angle measurements, exhibits an increase of 20-40 times in an annealing temperature window of ~100 °C, which leads to a 5-fold increase of its total surface energy. On the basis of the chemical analyses, we propose a compositional gradient in the film. Due to this gradient, the hydrophilic SiON film, for instance, can be used as the bond coat material in a double-layer environmental barrier coating system with outstanding oxidation resistant properties.

Polymer derived non-oxide ceramics modified with late transition metals.

This tutorial review highlights the methods for the preparation of metal modified precursor derived ceramics (PDCs) and concentrates on the rare non-oxide systems enhanced with late transition metals. In addition to the main synthetic strategies for modified SiC and SiCN ceramics, an overview of the morphologies, structures and compositions of both, ceramic materials and metal (nano) particles, is presented. Potential magnetic and catalytic applications have been discussed for the so manufactured metal containing non-oxide ceramics.

Extremely low thermal conductivity and high electrical conductivity of sustainable carbon-ceramic electrospun nonwoven materials.

Materials with an extremely low thermal and high electrical conductivity that are easy to process, foldable, and nonflammable are required for sustainable applications, notably in energy converters, miniaturized electronics, and high-temperature fuel cells. Given the inherent correlation between high thermal and high electrical conductivity, innovative design concepts that decouple phonon and electron transport are necessary. We achieved this unique combination of thermal conductivity 19.8 ± 7.8 mW/m/K (cross-plane) and 31.8 ± 11.8 mW/m/K (in-plane); electrical conductivity 4.2 S/cm in-plane in electrospun nonwovens comprising carbon as the matrix and silicon-based ceramics as nano-sized inclusions with a sea-island nanostructure. The carbon phase modulates electronic transport for high electrical conductivity, and the ceramic phase induces phonon scattering for low thermal conductivity by excessive boundary scattering. Our strategy can be used to fabricate the unique nonwoven materials for real-world applications and will inspire the design of materials made from carbon and ceramic.

Low temperature in situ immobilization of nanoscale fcc and hcp polymorphic nickel particles in polymer-derived Si-C-O-N(H) to promote electrocatalytic water oxidation in alkaline media.

We synthesized nickel (Ni) nanoparticles (NPs) in a high specific surface area (SSA) p-block element-containing inorganic compound prepared via the polymer-derived ceramics (PDC) route to dispatch the obtained nanocomposite towards oxygen evolution reaction (OER). The in situ formation of Ni NPs in an amorphous silicon carboxynitride (Si-C-O-N(H)) matrix is allowed by the reactive blending of a polysilazane, NiCl2 and DMF followed by the subsequent thermolysis of the Ni : organosilicon polymer coordination complex at a temperature as low as 500 °C in flowing argon. The final nanocomposite displays a BET SSA as high as 311 m2 g-1 while the structure of the NPs corresponds to face-centred cubic (fcc) Ni along with interstitial-atom free (IAF) hexagonal close-packed (hcp) Ni as revealed by XRD. A closer look into the compound through FEG-SEM microscopy confirms the formation of pure metallic Ni, while HR-TEM imaging reveals the occurrence of Ni particles featuring a fcc phase and surrounded by carbon layers; thus, forming core-shell structures, along with Ni NPs in an IAF hcp phase. By considering that this newly synthesized material contains only Ni without doping (e.g., Fe) with a low mass loading (0.15 mg cm-2), it shows promising OER performances with an overpotential as low as 360 mV at 10 mA cm-2 according to the high SSA matrix, the presence of the IAF hcp Ni NPs and the development of core-shell structures. Given the simplicity, the flexibility, and the low cost of the proposed synthesis approach, this work opens the doors towards a new family of very active and stable high SSA nanocomposites made by the PDC route containing well dispersed and accessible non-noble transition metals for electrocatalysis applications.

Superparamagnetic Silicon Carbonitride Ceramic Fibers Through In Situ Generation of Iron Silicide Nanoparticles During Pyrolysis of an Iron-Modified Polysilazane.

Ceramic fibers are high-tech structural key components of ceramic matrix composites (CMCs), which are a very promising class of materials for applications in next-generation turbines, especially nonoxide ceramic fibers, usually produced by the polymer-derived ceramics (PDC) route, which possess the enhanced mechanical and thermostructural properties necessary to withstand the harsh conditions (temperature and atmosphere) imposed on CMCs. However, recycling composite materials, such as fiber-reinforced polymers and CMCs, is still a big challenge. Here, we present for the first time the processing of superparamagnetic iron-containing ceramic fibers, which, due to their magnetic properties, can be separated from the matrix material of a composite. The synthesis strategy of the novel functional ceramic fibers is based on a tailored reaction of polyorganosilazane with an iron complex, resulting in a suitable, meltable polymer. After melt-spinning and curing, subsequent pyrolysis leads to superparamagnetic ceramic fibers with a saturation magnetization of 1.54 emu g-1 because of in situ-formed iron silicide nanoparticles of an average size of 7.5 nm, homogeneously dispersed in an amorphous SiCNO matrix. Moreover, the ceramic fibers exhibit a tensile strength of 1.24 GPa and appropriate oxidation resistance. The developed versatile reaction strategy allows also for the incorporation of other elements to implement further functionalities for processing of multifunctional composites.

Copper-containing SiCN precursor ceramics (Cu@SiCN) as selective hydrocarbon oxidation catalysts using air as an oxidant.

A molecular approach to metal-containing ceramics and their application as selective heterogeneous oxidation catalysts is presented. The aminopyridinato copper complex [Cu(2)(Ap(TMS))(2)] (Ap(TMS)H=(4-methylpyridin-2-yl)trimethylsilanylamine) reacts with poly(organosilazanes) via aminopyridine elimination, as shown for the commercially available ceramic precursor HTT 1800. The reaction was studied by (1)H and (13)C NMR spectroscopy. The liberation of the free, protonated ligand Ap(TMS)H is indicative of the copper polycarbosilazane binding. Crosslinking of the copper-modified poly(organosilazane) and subsequent pyrolysis lead to the copper-containing ceramics. The copper is reduced to copper metal during the pyrolysis step up to 1000 degrees C, as observed by solid-state (65)Cu NMR spectroscopy, SEM images, and energy-dispersive spectroscopy (EDS). Powder diffraction experiments verified the presence of crystalline copper. All Cu@SiCN ceramics show catalytic activity towards the oxidation of cycloalkanes using air as oxidant. The selectivity of the reaction increases with increasing copper content. The catalysts are recyclable. This study proves the feasibility of this molecular approach to metal-containing SiCN precursor ceramics by using silylaminopyridinato complexes. Furthermore, the catalytic results confirm the applicability of this new class of metal-containing ceramics as catalysts.

PDC Glass/Ceramic Coatings Applied to Differently Pretreated AISI441 Stainless Steel Substrates.

In this work, the influence of different cleaning procedures on adhesion of composite coatings containing passive ceramic and commercial glasses was investigated. Two compositions (C2c, D2-PP) of double-layer polymer-derived ceramic (PDC) coating systems, composed from bond coat and a top coat, were developed. In order to obtain adherent coatings, stainless steel substrates were cleaned by four different cleaning procedures. The coatings were then deposited onto the steel substrate via spray coating. Pretreatment by subsequent ultrasonic cleaning in acetone, ethanol and deionised water (procedure U) was found to be the most effective, and the resultant C2c and D2-PP coatings, pyrolysed at 850 °C, indicated strong adhesion without delamination or cracks, propagating at the interface steel/bond coat. In the substrate treated by sandblasting and chemical etching, small cracks in the bond coat were observed under the same pyrolysis conditions. After oxidation tests, all coatings, except for those subjected to the U-treated substrates, showed significant cracking in the bond coat. The D2-PP coatings were denser than C2c, indicating better protection of the substrate.

Oxidation Resistance and Microstructure Evaluation of a Polymer Derived Ceramic (PDC) Composite Coating Applied onto Sintered Steel.

Powder metallurgy is a competitive technology to produce ferrous near net shape parts for diverse engineering applications. However, their inherent porosity increases the susceptibility to oxidation and sealing their surface is mandatory to avoid premature degradation. Alongside, polymer derived ceramics (PDCs), such as silicon-carbonitride, have drawn attention concerning their high temperature and chemical stability. However, PDCs undergo volume shrinkage during ceramization that leads to defect formation. The shrinkage can be compensated by the addition of fillers, which are also capable of tailoring the ceramic resulting properties. This work evaluates the processing of PDC-based coatings loaded with ZrO2 and glass fillers to compensate for the shrinkage, densify the coating and seal the sintered steel surface. Therefore, polymeric slurries were sprayed onto sintered steel substrates, which were pyrolyzed at different temperatures for microstructural and oxidation resistance evaluation. Microstructural modifications caused by the enhanced glass viscous flow during pyrolysis at 800 °C resulted in more homogeneous, dense and protective coatings, which reduced the mass gain up to 40 wt% after 100 h of oxidation at 450 °C in air in comparison to the uncoated substrate. Moreover, no macrocracks or spallation were detected, confirming the feasibility of PDC composite barrier coatings for sintered steels.

Molecular design of melt-spinnable co-polymers as Si-B-C-N fiber precursors.

Two series of co-polymers with the general formula [B(C2H4SiCH3(NH)x(NCH3)y)3]n, i.e., composed of C2H4SiCH3(NH)x and C2H4SiCH3(NCH3)y (C2H4 = CHCH3, CH2CH2) building blocks in a well defined x : y ratio, have been synthesized by hydroboration of dichloromethylvinylsilane with borane dimethyl sulfide followed by successive reactions with lithium amide and methylamine according to controlled ratios. The role of the chemistry behind their syntheses has been studied in detail by solid-state NMR, FT-IR and elemental analyses. Then, the intimate relationship between the chemistry and the melt-spinnability of these polymers was discussed. By keeping x = 0.50 and increasing y above 0.50, i.e., obtaining methylamine excess, the co-polymers contained more ending groups and especially more tetracoordinated boron, thus allowing tuning very precisely the chemical structure of the preceramic polymer in order to meet the requirements for melt-spinning. The curing treatment under ammonia at 200 °C efficiently rendered the green fibers infusible before their subsequent pyrolysis under nitrogen at 1000 °C to generate Si-B-C-N ceramic fibers. Interestingly, it could be possible to produce also low diameter hollow fibers with relatively high mechanical properties for a further exploration as membrane materials.

Meso-Structuring of SiCN Ceramics by Polystyrene Templates.

A simple one-pot synthesis of well-defined PS-silazane nano-composites (polystyrene, PS) is described. In contrast to the, thus far, used two-step procedure ((1) assembly of a PS template bed and (2) careful filling of the voids between the PS spheres), which is restricted to macro structuring, we are able to simply mix the PS template and a commercially available silazane precursor HTT-1800 in toluene. The key is the alteration of the zeta potential of the PS template leading to a homogeneous dispersion in the silazane-toluene mixture. Removal of solvent gives rise to a highly ordered PS-silazane nano-composites and subsequent pyrolysis leads to mesoporous silicon carbonitride (SiCN) materials. The one-pot procedure has two advantages: easy upscaling and the use of PS spheres smaller than 100 nm in diameter, here 60 nm. The PS template was characterized by photon correlation spectroscopy, zeta potential measurements, scanning electron microscopy (SEM), and thermal gravimetric analysis (TGA). The resulting mesoporous SiCN materials were analyzed by SEM, transmission electron microscopy (TEM), nitrogen sorption analysis, and Fourier transform infrared measurements (FT-IR).

The preparation of HfC/C ceramics via molecular design.

Polymer derived ceramics have received lots of attention throughout the last few decades. Unfortunately, only a few precursor systems have been developed, focusing on silicon based polymers and ceramics, respectively. Herein, the synthesis of novel hafnium containing organometallic polymers by two different approaches is reported. Dialkenyl substituted hafnocene monomers were synthesized and subsequently polymerized via a free radical mechanism. Salt metathesis reactions of hafnocene dichloride with bifunctional linkers led to the formation of polymeric materials. NMR spectroscopic methods--in solution as well as in the solid state--were used to characterize the organometallic polymers. Ceramics were finally obtained after cross-linking and thermal treatment under argon (T(max) = 1800 °C). SEM investigations, elemental analyses, Raman spectroscopy and XRD investigations identified the pyrolyzed products as partially crystalline HfC/C mixed phases.

Metal-metal bonding in sterically frustrated dipalladium species.

Stoichiometric-deficient lithiation of (2,6-diisopropylphenyl)(4-methylpyridin-2-yl)amine and reaction with [(cod)PdCl2] (cod = 1,5-cyclooctadiene) yield a dimeric Pd complex. X-ray structural analysis of this complex reveals a very short Pd-Pd distance (2.429 A). Topological analysis of the electron density and the electron localization function from scalar relativistic density functional theory calculations clearly indicate a Pd(I)-Pd(I) sigma-bonding interaction, for which the corresponding occupied localized orbital can be identified.

Group 10 metal aminopyridinato complexes: synthesis, structure, and application as aryl-Cl activation and hydrosilane polymerization catalysts.

(4-Methyl-pyridin-2-yl)(trimethylsilanyl)amine (ApSi-H) and tert-butyl(4-methyl-pyridin-2-yl)amine (AptBu-H) were synthesized via salt metathesis and aryl amination reactions, respectively. Lithiation of these two aminopyridines using n-BuLi and the reactions with [(dme)NiCl2] (dme = dimethoxyethane) or [(cod)PdCl2] (cod = cyclooctadiene) in THF at low temperature gave rise--after workup in hexane--to group 10 amido compounds, [(ApSi)4Ni2], [(AptBu)2Pd], [(AptBu-H)(AptBu)2Ni], [(AptBu)3(C2H5O)3Ni3OLi(thf)], and [(AptBu)2Ni(tBupy)2] (tBupy = 4-tert-butylpyridine). The aminopyridinato complexes were characterized by X-ray crystal structure analysis. The highly strained binding situation of the aminopyridinato ligands suggested that these compounds might be efficiently converted into catalytically active species. The applications of some of the synthesized complexes as Suzuki cross-coupling catalysts (activation of aryl chlorides) are described and [(ApSi)4Ni2] is a rare example of a "phosphine-free" catalyst system. A number of late transition metal complexes were found to successfully catalyze polymerization of MeH2SiSiH2Me toward soluble, linear poly(methylsilane). Remarkable activity was observed for [(ApSi)2Pd].