Search Results (162)

The unique structural properties of porous ceramics, such as low thermal conductivity, high surface area, controlled permeability, and low density, make this material valuable for a wide range of applications. Its uses include insulation, catalyst carriers, filters, bio-scaffolds for tissue engineering, and composite manufacturing. However, existing processing methods for porous ceramics, namely replica techniques and sacrificial templates, are complex, release harmful gases, have limited microstructure control, and are expensive. In contrast, the direct foaming method offers a simple and cost-effective approach. By modifying the surface chemistry of ceramic particles in a colloidal suspension, the hydrophilic particles are transformed into hydrophobic ones using surfactants. This method produces porous ceramics with interconnected pores, creating a hierarchical structure that is suitable for applications like nano-filters. This review emphasizes the importance of interconnected porosity in developing advanced ceramic materials with tailored properties for various applications. Interconnected pores play a vital role in facilitating mass transport, improving mechanical properties, and enabling fluid or gas infiltration. This level of porosity control allows for the customization of ceramic materials for specific purposes, including filtration, catalysis, energy storage, and biomaterials. Full article

This study investigates the development and characterization of ceramic rod-reinforced TWIP (twinning-induced plasticity) steel matrix composites, produced using the lost foam casting technique. Mechanical tests revealed a substantial improvement in both flexural strength and ductility, with the composite demonstrating more than double the strength of unreinforced TWIP steel. Furthermore, a simple low-temperature heat treatment further enhanced these properties, increasing the flexural strength of the composite to 1023 MPa while also improving its ductility. The improvement in mechanical performance is attributed to the formation of additional twins in the TWIP steel matrix during deformation following heat treatment, which resulted in further strengthening of the matrix. Full article

Developing materials for efficient energy storage and effective electromagnetic interference (EMI) shielding is crucial in modern technology. This study explores the synthesis and characterization of carbonaceous shape-stabilized octadecane/MWCNT (multi-walled carbon nanotube) composites, utilizing activated carbon, expanded graphite or ceramic carbon foam, as shape stabilizers for phase change materials (PCMs) to enhance thermal energy storage and EMI shielding, for energy-efficient and advanced applications. The integration of octadecane, a phase change material (PCM) with carbonaceous stabilizers ensures the material’s stability during phase transitions, while MWCNTs contribute to improved thermal storage properties and EMI shielding capabilities. The research aims to develop novel composites with dual functionality for thermal storage and EMI shielding, emphasizing the role of carbon matrices and their MWCNT composites. SEM and CT microtomography analyses reveal variations in MWCNT incorporation across the matrices, influenced by surface properties and porosity. Leaching tests, infrared spectroscopy (FT-IR) and differential scanning calorimetry (DSC) confirm the composite’s stability and high latent heat storage. The presence of nanotubes enhances the thermal properties of octadecane and ΔH values almost reached their theoretical values. EMI shielding effectiveness measurements indicate that the composites show improved electric properties in the presence of MWCNTs. Full article

Volumetric ceramic receivers can be regarded as a promising technology to heat air above 1000 °C for solar thermal electricity production. In this study, the thermal shock behavior of commercial 10 ppi (A) and 20 ppi (B) oxide-bonded silicon carbide (ob-SiC) reticulated porous ceramic (RPC) foams was evaluated using the SF60 solar furnace at Plataforma Solar de Almería. The foams were subjected to well-controlled temperature cycles ranging from 800 to 1000, 1200, 1300 or 1400 °C, for 25, 100, and 150 cycles. The extent of the damage after thermal shock was determined by crushing tests. The damage was found to be critically dependent on both the bulk density and cell size. Decreasing both the bulk density and cell size resulted in better thermal shock resistance. The B foam exhibited approximately half the stress degradation compared to the A foam when exposed to a temperature difference of 600 K (in the range of 800 to 1400 °C) and subjected to 150 cycles. Full article

This study investigated the fabrication and characterization of large ceramic-reinforced TWIP (twinning-induced plasticity) steel matrix composites using the lost-foam casting technique. Various ceramic shapes and sizes, including blocky, flaky, rod-like, and granular forms, were evaluated for their suitability as reinforcement materials. The study found that rod-like and granular ceramics exhibited superior structural integrity and formed strong interfacial bonds with the TWIP steel matrix compared to blocky and flaky ceramics, which suffered from cracking and fragmentation. Detailed microstructural analysis using scanning electron microscopy (SEM) and industrial computed tomography (CT) revealed the mechanisms influencing the composite formation. The results demonstrated that rod-like and granular ceramics are better for reinforcing TWIP steel composites, providing excellent mechanical stability and enhanced performance. This work contributes to the development of advanced composite structures with potential applications in industries requiring high-strength and durable materials. Full article

A substantial amount of bauxite tailings (BTs) at abandoned mine sites have been stored in waste reservoirs for long periods, leading to significant land occupation and environmental degradation. Although many studies of the resource utilization of BTs were conducted to address this challenge, there is still a lack of efforts to systematically review the state of the art in BTs. In the present paper, a systematic literature review was carried out to summarize and analyze the properties, treatment, and resource utilization of BTs. Physical characteristics and the mineral and chemical composition of BTs are introduced. The efficacy of physical, chemical, and microbial treatment methods for BTs in terms of dehydration are outlined, and their respective benefits and limitations are discussed. Moreover, the extraction process of valuable elements (e.g., Si, Al, Fe, Li, Na, Nd, etc.) from BTs is examined, and the diverse applications of BTs in adsorption materials, ceramic materials, cementitious materials, lightweight aggregates, foamed mixture lightweight soil, among others, are studied. Finally, an efficient and smart treatment strategy for BTs was proposed. The findings of the present review provide a scientific basis and reference for future research focusing on the treatment and resource utilization of BTs. Full article

The aim of the study was to compare conventional sintering with additive manufacturing techniques for β-TCP bioceramics, focusing on mechanical properties and biocompatibility. A “critical” bone defect requires surgical intervention beyond simple stabilization. Autologous bone grafting is the gold standard treatment for such defects, but it has its limitations. Alloplastic bone grafting with synthetic materials is becoming increasingly popular. The use of bone graft substitutes has increased significantly, and current research has focused on optimizing these substitutes, whereas this study compares two existing manufacturing techniques and the resulting β-TCP implants. The 3D printed β-TCP hybrid structure implant was fabricated from two components, a column structure and a freeze foam, which were sintered together. The conventionally fabricated ceramics were fabricated by casting. Both scaffolds were characterized for porosity, mechanical properties, and biocompatibility. The hybrid structure had an overall porosity of 74.4 ± 0.5%. The microporous β-TCP implants had a porosity of 43.5 ± 2.4%, while the macroporous β-TCP implants had a porosity of 61.81%. Mechanical testing revealed that the hybrid structure had a compressive strength of 10.4 ± 6 MPa, which was significantly lower than the microporous β-TCP implants with 32.9 ± 8.7 MPa. Biocompatibility evaluations showed a steady increase in cell proliferation over time for all the β-TCP implants, with minimal cytotoxicity. This study provides a valuable insight into the potential of additive manufacturing for β-TCP bioceramics in the treatment of bone defects. Full article

Foamed ceramics with high closed porosity were prepared using granite scrap as the raw material and silicon carbide as a foaming agent, and the effects of Na₂O, K₂O, and MgO on the pore structure and properties of the foamed ceramics were investigated. The results show that both Na₂O and K₂O could reduce the viscosity of the melt and promote the formation of the liquid phase, and the increase in content could enhance the foaming ability of the blank. When the dosage of Na₂O was 4–6 wt% and the dosage of K₂O was 6–8 wt%, the homogeneity of the pore structure of the foamed ceramics could be effectively improved, and the samples exhibited an optimal performance, including a bulk density of 510.36–593.33 kg/m³, a closed porosity of 68.24–78.04%, a compressive strength of 1.33–2.66 MPa, and a water absorption capacity of 0.57–1.31%. A further increase in the Na₂O and K₂O dosages destroyed the uniformity of the pore structure, resulting in a large number of irregular macropores. MgO had a slight effect on regulating the pore structure of the foamed ceramics, and the increase in dosage promoted the precipitation of forsterite crystals, creating conditions suitable for the preparation of foamed ceramics with small pores. Full article

Recirculating aquaculture systems (RASs) offer significant advantages in aquaculture by markedly decreasing water usage and increasing culture density. A vital component within a RAS is the filler material, which serves as a surface for microbial colonization. Effective microbial treatment is crucial for the efficient operation of a RAS as it assists in purifying the wastewater generated within the system. Nevertheless, traditional fillers often show low efficiency in biofilm formation. The commercial silicon carbide used in this study is a foam ceramic filter with a density of about 0.4–0.55 g/cm³, a number of holes of about 10, and a through porosity of 80.9%, with a diameter of about 5 cm. This research investigates the utilization of a titanium dioxide–silicon carbide (TiO₂-SiC) composite filler to improve the purification efficiency of ammonia nitrogen and chemical oxygen demand (COD) in aquaculture wastewater. The study involved the application of titanium dioxide films onto the surface of silicon carbide to produce the composite filler. This method takes advantage of the dipole interaction between titanium dioxide and microorganisms, which enhances biofilm culturing efficiency on the silicon carbide surface. The performance of three different fillers was assessed for their ability to purify aquaculture wastewater. Results showed that the TiO₂-SiC composite filler was 1.67 times more effective in removing COD and 1.07 times more effective in removing ammonia nitrogen compared to using silicon carbide alone. These results demonstrate that the incorporation of a titanium dioxide coating substantially boosts the microbial colonization efficiency of silicon carbide, thereby enhancing the overall wastewater purification efficiency in RAS. Full article

Precise management of the inverse correlation between the total porosity and compressive strength is crucial for the progress of foaming glass–ceramics (FGCs). To deeply understand this relationship, we investigated the atomic-level transformations of five CO₂-foaming FGC samples using molecular dynamics simulation. The short-range and intermediate-range structures of the FGCs with varying total porosities (36.68%, 66.28%, 66.96%, 72.21%, and 79.88%) in the system were elucidated. Na cations were observed to exhibit a strong interaction with CO₂, accumulating at the surface of the pore wall and influencing the oxygen species. Therefore, the change in the atomic structure of the matrix was accompanied by an increase in the total porosity with an increasing CO₂ content. Specifically, as the total porosity increased, the bridging oxygen content within the FGCs rose accordingly. However, once the total porosity exceeded 66.96%, the bridging oxygen content began to decline. This observation was significant considering the role of the bridging oxygen content in forming a continuous cross-linked network of chemical bonds, which contributed to the enhanced mechanical strength. Consequently, the influence of the total porosity on the oxygen species resulted in a two-stage reduction in the compressive strength. This study offers valuable insights for the development of high-strength lightweight FGCs. Full article

Porous β-tricalcium phosphate (Ca₃(PO₄)₂; β-TCP) was prepared via freeze-drying and the effects of this process on pore shapes and sizes were investigated. Various samples were prepared by freezing β-TCP slurries above a liquid nitrogen surface at −180 °C with subsequent immersion in liquid nitrogen at −196 °C. These materials were then dried under reduced pressure in a freeze-dryer, after which they were sintered with heating. Compared with conventional heat-based drying, the resulting pores were more spherical, which increased both the mechanical strength and porosity of the β-TCP. These materials had a wide range of pore sizes from 50 to 200 µm, with the mean and median values both approximately 100 µm regardless of the freeze-drying conditions. Mercury porosimetry data showed that the samples contained small, interconnected pores with sizes of 1.24 ± 0.25 µm and macroscopic, interconnected pores of 25.8 ± 4.7 µm in size. The effects of nonionic surfactants having different hydrophilic/lipophilic balance (HLB) values on foaming and pore size were also investigated. Materials made with surfactants having lower HLB values exhibited smaller pores and lower porosity, whereas higher HLB surfactants gave higher porosity and slightly larger macropores. Even so, the pore diameter could not be readily controlled solely by adjusting the HLB value. The findings of this work indicated that high porosity (>75%) and good compressive strength (>2 MPa) can both be obtained in the same porous material and that foaming agents with HLB values between 12.0 and 13.5 were optimal. Full article

Online monitoring and real-time feedback on inclusions in molten metal are essential for metal quality control. However, existing methods for detecting aluminum melt inclusions face challenges, including interference, prolonged processing times, and latency. This paper presents the design and development of an online monitoring system for molten metal inclusions. Initially, the system facilitates real-time adjustment of signal acquisition parameters through a multiplexer. Subsequently, it employs a detection algorithm capable of swiftly extracting pulse peaks, with this task integrated into our proprietary host computer software to ensure timely detection and data visualization. Ultimately, we developed a monitoring device integrated with this online monitoring system, enabling the online monitoring of the aluminum alloy filtration process. Our findings indicate that the system can accurately measure the size and concentration of inclusions during the filtration process in real time, offering enhanced detection speed and stability compared to the industrial LiMCA CM (liquid metal cleanliness analyzer continuous monitoring) standard. Furthermore, our evaluation of the filtration process demonstrates that the effectiveness of filtration significantly improves with the increase in inclusion sizes, and the synergistic effect of combining CFF (ceramic foam filter) and MCF (metallics cartridge filter) filtration methods exceeds the performance of the CFF method alone. This system thus provides valuable technical support for optimizing filtration processes and controlling inclusion quality. Full article

This study created ceramic preforms with a 3D network structure (TAD_3D) by using treated aluminum dross (TAD) and kaolin slurry, with 30 ppi polyurethane foam as a template via the sacrificial template method. TAD_3D/5A05Al composites were then produced via pressureless infiltration of 5A05Al aluminum alloy into TAD_3D. The corrosion behavior and resistance of TAD_3D/5A05Al in salt spray were assessed via neutral salt spray corrosion (NSS), scanning electron microscopy (SEM), potentiodynamic polarization (PDP), and electrochemical impedance spectroscopy (EIS) tests. The results showed that after 24 to 360 h of NSS corrosion, the corrosion of the 5A05 matrix was primarily pitting, with pits expanding and deepening over time, and showing a tendency to interconnect. The main corrosion products were MgAl₂O₄, Al(OH)₃, and Al₂O₃. As corrosion progressed, these products increased and filled cracks, pits, and grooves at the composite interface on the material’s surface. Corrosion products transferred to the grooves at the composite interface and grew on the ceramic surface. Corrosion products on the ceramic framework and the Al matrix can form a continuous passivation film covering the composite surface. PDP and EIS results indicated that the composite’s corrosion resistance decreased by 240 h but increased after that time. After 240 h, the surface passivation film can weaken corrosion effects and enhance the composite’s resistance, although it remained weaker than that of the uncorroded samples. Additionally, grooves at the composite interface deepened over time, with loosely structured corrosion products inside, potentially leading to severe localized corrosion. Full article

To improve the shock resistance of personal protective equipment and reduce casualties due to shock wave accidents, this study prepared four types of carbon fiber/polymethacrylimide (PMI) foam sandwich panels with different face/back layer thicknesses and core layer densities and subjected them to quasi-static compression, low-speed impact, high-speed impact, and non-destructive tests. The mechanical properties and energy absorption capacities of the impact-resistant panels, featuring ceramic/ultra-high molecular-weight polyethylene (UHMWPE) and carbon fiber/PMI foam structures, were evaluated and compared, and the feasibility of using the latter as a raw material for personal impact-resistant equipment was also evaluated. For the PMI sandwich panel with a constant total thickness, increasing the core layer density and face/back layer thickness enhanced the energy absorption capacity, and increased the peak stress of the face layer. Under a constant strain, the energy absorption value of all specimens increased with increasing impact speed. When a 10 kg hammer impacted the specimen surface at a speed of 1.5 m/s, the foam sandwich panels retained better integrity than the ceramic/UHMWPE panel. The results showed that the carbon fiber/PMI foam sandwich panels were suitable for applications that require the flexible movement of the wearer under shock waves, and provide an experimental basis for designing impact-resistant equipment with low weight, high strength, and high energy absorption capacities. Full article

The porous TiCO ceramic was synthesized through a one-step sintering method, utilizing phenolic resin, TiO₂ powder, and KCl foaming agent as raw materials. Ni(NO₃)₂·6H₂O was incorporated as a catalyst to facilitate the carbothermal reaction between the pyrolytic carbon and TiO₂ powder. The influence of Ni(NO₃)₂·6H₂O catalyst content (0, 5, 10 wt.% of the TiO₂ powder) on the microstructure, compressive strength, and thermal conductivity of the resultant porous TiCO ceramic was examined. X-ray diffraction and X-ray photoelectron spectroscopy results confirmed the formation of TiC and TiO in all samples, with an increase in the peak of TiC and a decrease in that of TiO as the Ni(NO₃)₂·6H₂O content increased from 0% to 10%. Scanning electron microscopy results demonstrated a morphological change in the pore wall, transforming from a honeycomb-like porous structure composed of well-dispersed carbon and TiC-TiO particles to rod-shaped TiC whiskers, interconnected with each other as the catalyst content increased from 0% to 10%. Mercury intrusion porosimetry results proved a dual modal pore-size distribution of the samples, comprising nano-scale pores and micro-scale pores. The micro-scale pore size of the samples minorly changed, while the nano-scale pore size escalated from 52 nm to 138 nm as the catalyst content increased from 0 to 10%. The morphology of the pore wall and nano-scale pore size primarily influenced the compressive strength and thermal conductivity of the samples by affecting the load-bearing capability and solid heat-transfer conduction path, respectively. Full article