Processing and Properties of Advanced Ceramics and Composite Ceramic Transactions

246 Pages·2009·5.96 MB·English

by  Narottam P. Bansal

Processing and Properties
of Advanced Ceramics
and Composites
Processing and Properties
of Advanced Ceramics
and Composites
Ceramic Transactions, Volume 203
A Collection of Papers Presented at the 2008
Materials Science and Technology
Conference (MS&T08)
October 5-9, 2008
Pittsburgh, Pennsylvania
Edited by
Narottam P. Ban sal
J. P. Singh
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10 9 8 7 6 5 4 3 21
Contents
Preface ix
MICROWAVE PROCESSING
Continuous Microwave-Driven Polyol Process for Synthesizing 3
Ytterbium-Doped Yttria Powder
M. A. Imam, A. W. Fliflet, K. L. Siebach, A. David, R. W. Bruce, S. B. Qadri,
C. R. Feng and S. H. Gold
Microwave Irradiation-Assisted Method for the Rapid Synthesis of 15
Fine Particles of α-ΑΙ 0 and a-(AI .xCr ) 03 and Their Coatings
2 3 1 x 2
onSi(100)
Anshita Gairola, A. M. Umarji, and S. A. Shivashankar
CHEMICAL VAPOR DEPOSITION
Synthesis and Characterization of Si/Si2N 0/Si N4 Composites from 25
2 3
Solid-Gas Precursor System Via CVD
J. C. Flores-Garcia, A. L. Leal-Cruz, and M. I. Pech-Canul
Effect of Flow Rate, Nitrogen Precursor and Diluent on Si N 0 35
2 2
Deposition by HYSYCVD
A. L. Leal-Cruz, M. I. Pech-Canul, E. Lara-Curzio, R. M. Trejo, and R. Peascoe
COMBUSTION SYNTHESIS
MgAI 0 /SiC Composite Ceramic Material Produced by 4
2 4
Combustion Synthesis
Podbolotov Kirill Borisovich and Diatlova Evgenija Mihajlovna
v
Finite Element Analysis of Self-Propagating High-Temperature 53
Synthesis of Strontium-Doped Lanthanum Manganate
Sidney Lin and Jiri Selig
REACTION FORMING AND POLYMER PROCESSING
Comparison of Bulk and Nanoscale Properties of Polymer 65
Precursor Derived Silicon Carbide with Sintered Silicon Carbide
Arif Rahman, Suraj C. Zunjarra, and R. P. Singh
Process Design and Production of Boron Trichloride from Native 77
Boron Carbide in Lab-Scale
D. Agaogullari and I. Duman
SINTERING AND HOT PRESSING
Spark Plasma Sintered Alumina-Zirconia Nano-Composites by 93
Addition of Hydroxyapatite
S. F. Li, H. Izui, M. Okano, W. H. Zhang, and T. Watanabe
Comparison of Slip Cast to Hot Pressed Boron Carbide 10
T. Sano, E.S.C. Chin, B. Paliwal, and M. W. Chen
AMORPHOUS CERAMICS
Mechanically Driven Amorphization and Bulk Nanocrystalline 119
Synthesis of Ultra-High Temperature Ceramics
H. Kimura
Preparation and Characterization of Fused Silica Based Ceramic 131
Cores Used in Superalloy Casting
M. Arin, S. Sevik, and A. B. Kayihan
COATINGS AND FILMS
Photon Effects in Ultra-Thin Oxide Films: Synthesis and Functional 143
Properties
S. Ramanathan, M. Tsuchiya, C. L. Chang, and C. Ko
Faradayic Process for Electrophoretic Deposition of Thermal Barrier 153
Coatings for Use in Gas Turbine Engines
Joseph Kell and Heather McCrabb
A Novel Method to Spray Tungsten Carbide Using Low Pressure 161
Cold Spray Technology
J. Wang and J. Villafuerte
vi · Processing and Properties of Advanced Ceramics and Composites
COMPOSITES
Foreign Object Damage Versus Static Indentation Damage in an 171
Oxide/Oxide Ceramic Matrix Composite
Sung R. Choi, Donald J. Alexander, and David C. Faucett
Distinguished Functions Making the Best Use of the Unique 181
Composite Structures
Toshihiro Ishikawa
Effects of Environment on Creep Behavior of NEXTEL™720/ 193
Alumina-Mullite Ceramic Composite at 1200 °C
C. L Genelin and M. B. Ruggles-Wrenn
Performance of Composite Materials in Corrosive Conditions: 205
Evaluation of Adhesion Loss in Polymers Via Cathodic Disbondment
and a Newly Developed NDE Technique
Davion Hill, Colin Scott, Ayca Ertekin, and Narasi Sridhar
Effect of Variations in Process Shear on the Mixedness of an 215
Alumina-Titania System
C. August, M. Jitianu, and R. Haber
MODELING
Modeling of the Pressure in 1-D Green Ceramic Bodies during 229
Depressurization from Conditions of Supercritical Extraction
of Binder
Kumar Krishnamurthy and Stephen J. Lombardo
Models of the Strength of Green Ceramic Bodies as a Function of 239
Binder Content and Temperature
Stephen J. Lombardo and Rajiv Sachanandani
Finite Element Modeling of Steel Wire Drawing through Dies Based 249
on Encapsulated Hard Particles
Daniel J. Cunningham, Erik M. Byrne, Ivi Smid, John M. Keane
Author Index 255
Processing and Properties of Advanced Ceramics and Composites · vii
Preface
Two international symposia "Innovative Processing and Synthesis of Ceramics,
Glasses and Composites" and "Ceramic Matrix Composites" were held during Ma-
terials Science & Technology 2008 Conference & Exhibition (MS&TO8), Pitts-
burgh, PA, October 5-9, 2008. These symposia provided an international forum for
scientists, engineers, and technologists to discuss and exchange state-of-the-art
ideas, information, and technology on advanced methods and approaches for pro-
cessing, synthesis and characterization of ceramics, glasses, and composites. A total
of 105 papers, including 12 invited talks, were presented in the form of oral and
poster presentations. Authors from 15 countries (Belarus, Canada, China, France,
Germany, India, Iran, Japan, Mexico, Norway, Russia, South Korea, Taiwan,
Turkey, and the United States) participated. The speakers represented universities,
industries, and government research laboratories.
These proceedings contain contributions on various aspects of synthesis, process-
ing and properties of ceramics, glasses, and composites that were discussed at the
symposium. Twenty two papers describing the latest developments in the areas of
combustion synthesis, microwave processing, reaction forming, polymer processing,
chemical vapor deposition, electrophoresis, spark plasma sintering, mechanical
amorphization, thin films, composites, etc. are included in this volume. Each manu-
script was peer-reviewed using The American Ceramic Society review process.
The editors wish to extend their gratitude and appreciation to all the authors for
their cooperation and contributions, to all the participants and session chairs for
their time and efforts, and to all the reviewers for their useful comments and sug-
gestions. Financial support from The American Ceramic Society is gratefully ac-
knowledged. Thanks are due to the staff of the meetings and publications depart-
ments of The American Ceramic Society for their invaluable assistance.
It is our earnest hope that this volume will serve as a valuable reference for the
researchers as well as the technologists interested in innovative approaches for syn-
thesis and processing of ceramics and composites as well as their properties.
NAROTTAM P. BANSAL
NASA Glenn Research Center
J. P. SINGH
U.S. Army International Technology, Center-Pacific (ITC-PAC)
ix
Processing and Properties of Advanced Ceramics and Composites
Edited by Narottam P. Bansal and J. P. Singh
Copyright O 2009 The American Ceramic Society.
Microwave Processing
Processing and Properties of Advanced Ceramics and Composites
Edited by Narottam P. Bansal and J. P. Singh
Copyright O 2009 The American Ceramic Society.
CONTINUOUS MICROWAVE-DRIVEN POLYOL PROCESS FOR SYNTHESIZING
YTTERBIUM-DOPED YTTRIA POWDER
M.A. Imam, A.W. Fliflet, K.L. Siebach*, A. David*, R.W. Bruce**, S. B. Qadri,
C. R. Feng and S.H. Gold
Materials Science and Component Technology Directorate, Naval Research Laboratory,
Washington, DC, USA
ABSTRACT
The continuous microwave polyol process is a promising novel approach to the
synthesis of metallic and ceramic nanopowders. Current efforts are directed toward synthesizing
ytterbia-doped yttria (Yb0:Y,0) for use as a polycrystalline laser host material. The process
2 3 3
involves pumping a mixture of yttrium nitrate and ytterbium nitrate dissolved in hydrated
diethylene glycol through a pressurized quartz tube contained in an S-Band waveguide driven by
a 2.45 GHz microwave source at powers up to 6 kW. As the solution moves along the
waveguide, it absorbs the co-propagating microwave energy and is heated rapidly to a
temperature above 200°C causing a reaction to occur. Condensation reactions then form
particles with ytterbium-doped yttria crystal structure. The rapid heating and cooling serve to
limit the growth of the crystals so that they are on submicron and fairly uniform in size. The
production of doped yttria was confirmed by x-ray diffraction.
INTRODUCTION
In the polyol process, an organic solvent such as glycol or alcohol is used to reduce a
dissolved metal salt to the metal [1,2J. This is commonly done in a boiling, reflux system where
the glycol solution of the metal salt is heated to boiling, and the evaporating solvent is condensed
and fed back into the solution. At the elevated boiling temperature, the glycol solvent acts as a
reducing agent, converting the dissolved metal salt first to a metal oxide and then to the metal.
The process results first in the formation of metal atoms suspended in the glycol solvent. These
then aggregate, first into clusters and then into larger metallic particles. The process is capable
of producing metallic particles in the nanometer size range (1-100 nm), and the particles
produced are protected from oxidation or nitridation by the organic solvent and can also be
further protected by organic coatings generated during the process from additives.
This process has been used for about a decade in production of nanophase powders of
metals and mixtures of such metals and films or coatings of these [3], and a wide range of metals
can be produced in this manner. The process can also be used to produce metal oxides, sulfides
and selenides [4,5]. The limiting factor is the chemical energy available from the solvent vs. the
enthalpy of formation of the metal oxides. This makes it very difficult to obtain nanophase
metals such as lithium, aluminum, yttrium, magnesium, zirconium, e.g., Groups I-IV, without
resorting to much higher processing temperatures, although nanophase oxides of many of these
metals can be produced [6]. However, most of the balance of the metals in the periodic table can
be produced by this process, e.g., Fe, Co, Ni, Cu, Ru, Rh, Pt, Au, etc., as well as intimate
mixtures of these-Fe/Co, Co/Pt, Fe/Pt, Ni/Ag, Cu/Ni, Co/Ni, Co/Ni/Cu, etc.
The conventional polyol process, where the processing is done with a high boiling point
solvent such as ethylene glycol, heated in a reflux system by a heating mantle, is adequate for
production of small quantities of experimental powders, e.g., 1-10 g of product from a 1 liter
batch that may take 0.5-2 hours to process. However, the process is intrinsically limited in
scalability. In the heating mantle/flask system, scaling to larger volumes results in much greater
product variability from varying thermal histories in the larger volume with different convection
3