Effect of Al(OH)3 content on properties, microstructure, and sintering mechanism of mullite ceramics from bauxite
Journal of the Australian Ceramic Society - Trang 1-11 - 2023
Tóm tắt
Mullite ceramics were fabricated by reaction sintering using bauxite and kaolin as raw materials and Al(OH)3 as an additive. Enhanced mullite ceramic performance was achieved by optimizing sintering temperature and amount of added Al(OH)3. Results show that higher amount of Al(OH)3 led to increased mullite content. Furthermore, scanning electron microscopy results revealed better interfacial bonding due to interlocking structures of columnar mullite at high sintering temperatures (≥ 1500 °C) in samples prepared with the addition of Al(OH)3. This led to significant improvement in bulk density and mechanical strength of mullite ceramics. Thus, compared with samples prepared without Al(OH)3, the addition of Al(OH)3 was beneficial to formation, growth, and development of mullite. The optimum bulk density of 2.75 g/cm3 was achieved with apparent porosity of 0.79%, and the highest flexural strength of 129.25 MPa was achieved in samples with 12 wt.% Al(OH)3 after sintering at 1550 °C for 3 h.
Tài liệu tham khảo
Cameron, W.E.: Nonstoichiometry in sillimanite: mullite compositions with sillimanite-type superstructures. Phys. Chem. Min. 1, 265–272 (1977)
Sahraoui, T., Belhouchet, H., Heraiz, M., Brihi, N., Guermat, A.: The effects of mechanical activation on the sintering of mullite produced from kaolin and aluminum powder. Ceram. Int. 42, 12185–12193 (2016)
Ananthakumar, S., Jayasankar, M., Warrier, K.G.K.: Microstructural, mechanical and thermal characterisation of sol–gel-derived aluminium titanate–mullite ceramic composites. Acta. Mater. 54, 2965–2973 (2006)
Schneider, H., Schreuer, J., Hildmann, B.: Structure and properties of mullite—A review. J. Eur. Ceram. Soc. 28, 329–344 (2008)
Alves, H.P.A., Silva, J.B., Campos, L.F.A., Torres, S.M., Dutra, R.P.S., Macedo, D.A.: Preparation of mullite based ceramics from clay–kaolin waste mixtures. Ceram. Int. 42, 19086–19090 (2016)
Almeida, R.S.M., Bergmüller, E.L., Eggert, B.G.F., Tushtev, K., Schumacher, T., Lührs, H., Clauß, B., Grathwohl, G., Rezwan, K., Reimanis, I.: Thermal Exposure Effects on the Strength and Microstructure of a Novel Mullite Fiber. J. Am. Ceram. Soc. 99, 1709–1716 (2016)
Zhu, Z., Wei, Z., Shen, J., Zhu, L., Xu, L., Zhang, Y., Wang, S., Liu, T.: Fabrication and catalytic growth mechanism of mullite ceramic whiskers using molybdenum oxide as catalyst. Ceram. Int. 43, 2871–2875 (2017)
Chen, X., Li, T., Ren, Q., Wu, X., Li, H., Dang, A., Zhao, T., Shang, Y., Zhang, Y.: Mullite whisker network reinforced ceramic with high strength and lightweight. J. Alloy. Compd. 700, 37–42 (2017)
Bouchetou, M., Ildefonse, J., Poirier, J., Daniellou, P.: Mullite grown from fired andalusite grains: the role of impurities and of the high temperature liquid phase on the kinetics of mullitization and consequences on thermal shocks resistance. Ceram. Int. 31, 999–1005 (2005)
Rahman, S., Feustel, U., Freimann, S.: Structure description of the thermic phase transformation sillimanite–mullite. J. Eur. Ceram. Soc. 21, 2471–2478 (2001)
Chen, C.Y., Lan, G.S., Tuan, W.H.: Preparation of mullite by the reaction sintering of kaolinite and alumina. J. Eur. Ceram. Soc. 20, 2519–2525 (2000)
Guo, H., Li, W., Ye, F.: Low-cost porous mullite ceramic membrane supports fabricated from kyanite by casting and reaction sintering. Ceram. Int. 42, 4819–4826 (2016)
Xu, X., Lao, X., Wu, J., Zhang, Y., Xu, X., Li, K.: Microstructural evolution, phase transformation, and variations in physical properties of coal series kaolin powder compact during firing. Appl. Clay. Sci. 115, 76–86 (2015)
Sahnoune, F., Chegaar, M., Saheb, N., Goeuriot, P., Valdivieso, F.: Algerian kaolinite used for mullite formation. Appl. Clay. Sci. 38, 304–310 (2008)
Alima, M., Hadda, R., Sihem, B., Afef, A., Yasmina Taïbi, Sabrina, L., Naima, T., Azzedine, G., Sabri, B.: Effect of chamotte on the structural and microstructural characteristics of mullite elaborated via reaction sintering of Algerian kaolin. J. Mater. Res. Technol. 8, 4010–4018 (2019)
Hugo, P.A.A., Rubens, A.J., Liszandra, F.A.C., Ricardo, P.S.D., João, P.F.G., Francisco, J.A.L., Daniel, A.M.: Structural study of mullite based ceramics derived from a mica-rich kaolin waste. Ceram. Int. 43, 3919–3922 (2017)
Ebrahim, K.S., Touradj, E., Esmaeil, S.: Preparation of mullite from alumina/aluminum nitrate and kaolin clay through spark plasma sintering process. Ceram. Int. 44, 21053–21066 (2018)
Ma, J., Ye, F., Zhang, B., Jin, Y.C., Yang, C., Ding, J., Zhang, H.Q., Liu, Q.: Low-temperature synthesis of highly porous whisker-structured mullite ceramic from kaolin. Ceram. Int. 44, 13320–13327 (2018)
Rashad, M., Balasubramanian, M.: A quantitative analysis of in-situ gases on the properties of porous mullite developed from clay and AlF3·3H2O. Ceram. Int. 45, 1420–1423 (2019)
Maldhure, A.V., Tripathi, H.S., Ghosh, A., Das, S.K.: Mullite-Corundum Composites from Bauxite: Effect of Chemical Composition. T. Indian. Ceram. Soc. 73, 31–36 (2014)
Li, J.H., Ma, H.W., Huang, W.H.: Effect of V2O5 on the properties of mullite ceramics synthesized from high-aluminum fly ash and bauxite. J. Hazard. Mater. 166, 1535–1539 (2009)
Du, X., Wang, Y., Su, X., Li, J.: Influences of pH value on the microstructure and phase transformation of aluminum hydroxide. Powder. Technol. 192, 40–46 (2009)
Yuan, W., Kuang, J., Huang, Z., Yu, M.: Effect of aluminum source on the kinetics and mechanism of mullite preparation from kaolinite. Chem. Phys. Lett. 787, 139242–139248 (2022)
Guo, H., Li, W.: Effects of Al2O3 crystal types on morphologies, formation mechanisms of mullite and properties of porous mullite ceramics based on kyanite. J. Eur. Ceram. Soc. 38, 679–686 (2018)
Liu, Z., Xie, N., Zhang, H., Huang, S., Wu, C., He, S., Zhu, J., Liu, Y.: Effect of Al(OH)3 addition on densification mechanism and properties of reaction-sintered mullite-corundum composite ceramics. J. Asian. Ceram. Soc. 10, 703–712 (2022)
Hubbard, C.R., Snyder, R.L.: RIR - Measurement and Use in Quantitative XRD. Powder. Diffr. 3, 74–77 (2013)
Peng, L., Qin, S.: Sintering Behavior and Technological Properties of Low-Temperature Porcelain Tiles Prepared Using a Lithium Ore and Silica Crucible Waste. Minerals-Basel. 9, 731–746 (2019)
Ren, Q., Li, H., Wu, X., Huo, Z., Hai, O., Lin, F.: Effect of the calcining temperatures of low-grade bauxite on the mechanical property of mullite ceramics. Int. J. Appl. Ceram. Tec. 15, 554–562 (2018)
Chen, Y., Wang, M., Hon, M.: Phase transformation and growth of mullite in kaolin ceramics. J. Eur. Ceram. Soc. 24, 2389–2397 (2004)
Li, S., Du, H., Guo, A., Xu, H., Yang, D.: Preparation of self-reinforcement of porous mullite ceramics through in situ synthesis of mullite whisker in flyash body. Ceram. Int. 38, 1027–1032 (2012)
Romero, M., Padilla, I., Contreras, M., López-Delgado, A.: Mullite-Based Ceramics from Mining Waste: A Review. Minerals-Basel. 11, 332–370 (2021)
Yan, M., Li, Y., Sun, Y., Li, L., Tong, S., Sun, J.: Controllable preparation and synthetic mechanism of mullite from the bauxite with Fe-rich oxide content. Mater. Chem. Phys. 202, 245–250 (2017)
Yue, X., Li, Y., Ma, C., Zheng, Q., Wu, X., Li, B.: Novel process for synthesizing fused mullite from titanium-rich medium/low grade or waste bauxite. Ceram. Int. 48, 8228–8234 (2022)
Liu, X., Deng, C., Deng, C., Liu, M., Zhou, K.: Mullite-modified ZrB2-MoSi2 coating for carbon/carbon composites to withstand long term ablation. Ceram. Int. 44, 4330–4337 (2018)
Zhao, D., Wu, D., Shi, J., Niu, F., Ma, G.: Microstructure and mechanical properties of melt-grown alumina-mullite/glass composites fabricated by directed laser deposition. J. Adv. Ceram. 11, 75–93 (2021)
Goren, R., Gocmez, H., Ozgur, C.: Synthesis of cordierite powder from talc, diatomite and alumina. Ceram. Int. 32, 407–409 (2006)
Chen, Y., Wang, Y., Hon, M.: Secondary Mullite Formation in Kaolin–Al2O3 Ceramics. J. Mater. Res. 19, 806–814 (2004)
Chen, Y., Wang, M., Hon, M.: Transformation kinetics for mullite in kaolin–Al2O3 ceramics. J. Mater. Res. 18, 1355–1362 (2003)
Li, J.G., Sun, X.D.: Synthesis and sintering behavior of a nanocrystalline α-alumina powder. Acta. Mater. 48, 3103–3112 (2000)
Rashad, M., Sabu, U., Logesh, G., Srishilan, C., Lodhe, M., Joy, A., Balasubramanian, M.: Mullite phase evolution in clay with hydrated or anhydrous AlF3. J. Eur. Ceram. Soc. 40, 5974–5983 (2020)
Lee, W.E., Jayaseelan, D.D., Zhang, S.: Solid–liquid interactions: The key to microstructural evolution in ceramics. J. Eur. Ceram. Soc. 28, 1517–1525 (2008)
Zhang, J., Ke, C., Wu, H., Zhang, S., Yu, J.: Anisotropic Grain Growth Mechanism of Mullite Derived from Cobalt Oxide Doped Diphasic-Gels. Rare. Metal. Mat. Eng. 44, 323–326 (2015)
Liu, X.Y., Maiwa, K., Tsukamoto, K.: Heterogeneous two-dimensional nucleation and growth kinetics. J. Chem. Phys. 106, 1870–1879 (1997)
Bai, C., Li, Y., Liu, Z., Liu, P., Deng, X., Li, J., Yang, J.: Fabrication and properties of mullite-bonded porous SiC membrane supports using bauxite as aluminum source. Ceram. Int. 41, 4391–4400 (2015)