Synthesis and thermal properties of parent and modified DMN–<Emphasis Type="Italic">co</Emphasis>-GMA copolymers

The crystal structure, the unit cell parameters and the extent of mullitization were determined, using the Rietveld method, for range of mullite matrix formulations in which kyanite is used as particles reinforcement. The results combined with the mechanical properties and microstructure indicated the effectiveness of the kyanite particles to enhance the strength (>200 MPa), the Vickers hardness (>11 GPa) and the elastic modulus (150 GPa). The strengthening mechanism was particularly linked action of particles reinforcement. At low temperature, kyanite acts as fillers reducing the porosity and playing the role of nucleation sites for the crystallization of metakaolin to mullite. At high temperature (>1350 °C), kyanite decomposes to mullite avoiding the grain growth of the existing crystals and delaying the densification. The extent of the reduction in porosity and the extreme limitation of the liquid phase ensure the homogeneity and the refractoriness that justify the strength enhancement. The unit cell parameters and the crystal structure confirmed predominance of the mullite 3:2 with their small grain size being one of the most stable mullite phases. The small size of their particles and the continuity into the mullite matrix composites allow good packing process for the optimum characteristics achieved: strength, microstructure and thermal expansion coefficient.     

Mullite crystallization using fully hydrolyzed silica sol: the gelation temperature influence

Mullite is an aluminosilicate widely used as a structural material for high temperature applications. This paper studies the effect of the gelation temperature on the synthesis of two mullite precursors: polymeric and colloidal silica, using both in fully-hydrolyzed silica sol, derived from sodium silicate. The gels were synthesized using aqueous silicic acid and aluminum nitrate. Ethylene glycol was added into polymeric gels. Two gelation temperatures were used: 80 and 100 °C. In the polymeric precursor, the increasing of the gelation temperature caused an increase in the silica incorporation inside the mullite crystalline lattice at 1,000 °C, and it also generated an increase in the reaction extent at all calcination temperatures. In the colloidal precursors, these effects were more intense than in the polymeric precursors in terms of yield. Colloidal samples calcined at 1,250 °C crystallized cristobalite and alpha alumina in addition to mullite when they were previously gelled at 80 °C. On the other hand, the same sample gelled at 100 °C led to only crystallized mullite. The reaction extent increased by more than 20 % for colloidal samples gelled at 100 °C compared to colloidal samples gelled at 80 °C (calcined at 1,250 °C). This increase was due to the almost total incorporation of alumina and silica in the crystalline lattice of mullite.     

Effect of Aging on the Synthesis of Kaolin-Based Zeolite Y from Ahoko Nigeria Using a Novel Metakaolinization Technique

Zeolite Y was systematically synthesized from Ahoko Nigerian kaolin in a conventional hydrothermal system using novel metakaolinization technique. The effect of aging on the formation of zeolite phase was investigated during the course of the synthesis. A rapidly processed metakaolin at a temperature of 600°C and exposure time of 50 minutes, which is capable of reducing the energy and cost of producing it was used to study the synthesis of zeolite Y. It was found that aging conditions play a prominent role in the preparation of zeolite Y from Ahoko metakaolin. Aging played a significant role by increasing the crystallinity of the final product even though zeolite Y was obtain without aging. The outcome of zeolite Y synthesized from Ahoko kaolin in 9 hours at 100°C was different from most reports on the synthesis of zeolite Y from kaolin where longing time (72 hours) of crystallization are reported.     

Preparation of aluminum nitride fibers from alumina gel fibers by nitridation in ammonia

Aluminum nitride (AlN) fibers were prepared from alumina gel fibers and by heat-treatment in ammonia. The influence of silica on the formation of AlN was investigated. It was shown that phase transformation of alumina (γ-Al₂O₃ to α-Al₂O₃) and nitridation reaction took place above 1,100 °C for pure alumina fiber. The addition of a small amount of silica (3 wt%) suppressed the formation of α-Al₂O₃ and preserved the highly reactive metastable alumina, and nitridation rate was enhanced. Fine grain (~20 nm) AlN fibers were obtained for pyrolysis at 1,150–1,250 °C for 3 h in ammonia, and AlN was identified as the sole crystalline phase.     

Synthesis and characterization of geopolymer-zeolites from Ghanaian Kaolin samples by variation of two synthesis parameters

Two kaolinitic clays from two Regions of Ghana: Western and Volta Regions, were first calcined at 600 °C for 2 h to transform into the amorphous aluminosilicate phases. The effects of kaolin and alkali ratio as well as aging on the amount and types of zeolite in the resultant geopolymers were characterized by X-ray diffraction, scanning electron microscopy, energy-dispersive X-ray spectroscopy, Fourier transformed spectroscopy, thermogravimetric analysis and specific surface area measurements. Alkali activation treatment of the metakaolin yielded bulk materials with different amounts and types of zeolite and different particle size distributions. The results showed that initial kaolin samples were dependent on the concentration of alkali treatment and crystallization time during the activation treatment and produced zeolite type A along with quartz which showed no reactivity regardless of the variation of the synthesis parameter.

     

Preparation and characterization of diphasic sol-gel derived unsupported mullite membranes

Diphasic gels prepared by mixing freshly prepared polymeric silica and polymeric boehmite sols through a modified Al-alkoxide route in mullite compositions led to the crystallization of mullite upon heat treatment at 775 °C. Mullite formation was observed at a 100 °C higher temperature when diphasic gels were formed by mixing aged polymeric sols containing about 2 nm in diameter boehmite species. These relatively low mullite formation temperatures were attributed to the nanoscale sizes of the polymeric species of the two amorphous phases present in the diphasic gels.     

Thermal transformations of floor tile pastes containing petroleum waste

This study focuses on the thermal and mineralogical transformations of floor tile pastes containing petroleum waste. The tile pastes prepared by the dry process contain up to 10 wt% of petroleum waste in replacement of kaolin. Thermal and mineralogical changes occurring during firing were characterized by differential thermal analysis, thermogravimetry analysis, derivative thermogravimetry, dilatometric analysis, open photoacoustic cell technique, X-ray diffraction, and scanning electron microscopy. During heating an endothermic transformation within the 511.4–577.5 °C range and an exothermic transformation within the 997.8–1001.6 °C range were identified. The endothermic transformation can be mainly attributed to the dehydroxylation of kaolinite. The exothermic transformation is mainly associated with the crystallization of primary mullite. TG measurements indicate that the total mass loss of the floor tile pastes is dependent on the amount of petroleum waste addition. It was found that the replacement of kaolin with petroleum waste, in the range up to 10 wt%, influenced the thermal expansion–shrinkage curve. In addition, the floor tile pastes containing petroleum waste have low values of thermal diffusivity.     

Thermal transformations up to 1200 °C of Al-pillared montmorillonite precursors prepared by different OH–Al polymers

Aluminum-pillared montmorillonites are useful materials for their application as catalysts, adsorbents and ceramic composites. The precursor is a pillared montmorillonite that is not thermally stabilized. The precursor preparation methods, textural properties and catalytic activity have been extensively investigated, but comparatively, studies concerning their thermal transformations at high temperature are limited. In this work, precursors were prepared using two types of montmorillonites, Cheto (Ch) and Wyoming (W), and using two different OH–Al polymer sources: hydrolyzed (H) and commercial (C) solutions. Structural and thermal transformations of the precursors with heating up to 1200 °C were determined by X-ray diffraction and thermogravimetric analysis. Thermal analysis of these precursors below 600 °C revealed the influence of OH–Al polymers from the two solutions. The major phases developed at 1200 °C from the original montmorillonites were mullite for W and cordierite for Ch. The content of these phases depended on the aluminum in the octahedral sheet of the pristine montmorillonites. Amorphous phase, cristobalite, spinel, sapphirine and others phases were also found. The intercalation of OH–Al polymers in montmorillonites caused an increase in amorphous content after treatment at 1030 °C; however, it favored mullite development above 1100 °C. Although total aluminum content of both W and Ch precursors was similar, the transformation to mullite was directly related to the octahedral aluminum/magnesium ratio. The phase composition of the products at 1200 °C was not dependent on the type of intercalated OH–Al polymers. The increase in mullite content of the thermally treated precursors contributes to its possible application as advanced ceramic products.     

Preparation of γ-Alumina Membranes From Sulphuric Electrolyte Anodic Alumina and Its Transition to α-Alumina

Gamma-alumina membrane was prepared from anodic (amorphous) alumina (AA) obtained in a sulphuric acid electrolyte. The transformation scheme, i.e., the crystallization to form metastable alumina polymorphs and the final transition to α-Al₂O₃ with heating was studied by TG-DTA and X-ray diffraction (XRD) using fixed time (FT) method. When heating at a constant rate, the crystallization occurred at 900°C or higher and the final formation of α-Al₂O₃ occurred at 1250°C or higher, which temperatures were higher than the case of using anodic (amorphous) alumina prepared from oxalic acid electrolyte. Relative content of S of the products was obtained by transmission electron microscope (TEM)-energy dispersive spectroscopy (EDS). The proposed thermal change of anodic alumina membrane prepared from sulphuric acid is as follows: 1. At temperatures lower than ca 910°C: Formation of a quasi-crystalline phase or a polycrystalline phase (γ-, δ- and θ-Al₂O₃); 2. 910–960°C: Progressive crystallization by the migration of S toward the surface within the amorphous or the quasi-crystalline phase, forming S-rich region near the surface; 3. 960°C: Change of membrane morphology and the quasi-crystalline phase due to the rapid discharge of gaseous SO₂; 4. 960–1240°C: Crystallization of γ-Al₂O₃ accompanying δ-Al₂O₃; and 5. 1240°C: Transition from γ-Al₂O₃ (+tr. δ-Al₂O₃) into the stable α-Al₂O₃. The amorphization which occurs by the exothermic and the subsequent endothermic reaction suggests the incorporation of SO₃ groups in the quasi-crystalline structure. This revised version was published online in July 2006 with corrections to the Cover Date.     

Zeolite Y from kaolin clay of Kachchh,India: Synthesis,characterization and catalytic application

Kaolin clay obtained from Kachchh, Gujarat was used as alumina and silica source to synthesize zeolite Y by hydrothermal method. The synthesis route comprised of the following steps: sulfuric acid treatment at 110 ​°C (4 ​h) for impurity removal followed by calcination at 600 ​°C for 4 ​h, thermal activation of kaolin into metakaolin by NaOH fusion at 850 ​°C (8 ​h); aging of reaction mixtures at 50 ​°C (24 ​h); crystallization (24 ​h) followed by washing and drying. The synthesized zeolite Y was examined by multiple characterization techniques which revealed a pore volume of 0.22 ​cm³/g with pore size of 2.89 ​nm having essential surface area of 320 ​m²/g, indicating a porous material having majority of micropores and remaining mesopores. The zeolite exhibited good catalytic activity for succinic acid esterification using ethanol to produce monoethyl and diethyl succinate. The conversion of SA (72%) and yield (60%) of valuable diester indicated good conversion rate and selectivity at moderate reaction conditions. Detailed structural comparison with zeolite Y synthesized using standard chemical route is also carried out. This work demonstrated an effective way of preparing environmentally benign porous zeolite Y having high surface area and pore volume that can be useful for catalytic applications.     

A study of thermal treatment and hydrothermal crystallization stages in production of granulated NaA zeolite from mechanically activated metakaolin

NaA zeolite was synthesized from mechanically activated granulated mixtures of metakaolin, sodium hydroxide, and aluminum oxide. The thermal treatment and hydrothermal crystallization processes were studied. It is shown that the optimal temperature of thermal treatment of grains based on a mechanically activated metakaolin is 600°C at a NaA zeolite content of about 65 wt %. Raising the calcination temperature leads to a decrease in the content of the zeolite and to formation of nepheline. It was found that the optimal concentration of the crystallization solution of NaOH is 2–4 M. Under these conditions, the content of the zeolite exceeds 90 wt %. Raising the alkali concentration leads to a decrease in the content of the zeolite and to its recrystallization into sodalite.     

A comparative study of microstructural development in the sol–gel derived alumina–mullite nanocomposites using colloidal silica and tetraethyl orthosilicate

This paper compares the microstructure development of two alumina–15 vol% mullite composites during the sintering. The nanopowders of alumina–mullite composite were synthesized by the sol–gel method using aluminum chloride hexahydrate and two different silicon sources (colloidal silica in route 1 and tetraethyl orthosilicate in route 2). The alumina–mullite composites were prepared by pressing and sintering of the nanopowders. Although the intergranular mullites were observed in both routes, there were mullite particles in route 2 formed inside the alumina grains (intragranular mullite). Formation of the intragranular mullite is attributed to the drop in silica solubility, which occurs during the transition from metastable alumina to stable alumina. Compared to route 1, the relative density and the average grain size were increased and accelerated by route 2. The two-stage sintering is not useful for the mullite decomposition.     

Heat treatment of rapidly solidified Fe−Cr−Zr−B alloys

The crystallization behaviour of amorphous melt spun Fe_82?x?yCr₁₈Zr_xB_y (x=0–8, y=10–20) ribbons have been investigated using differential scanning calorimetry. The crystallization temperature and crystallization behaviour change with varzing Zr and B content. The microstructural development during annealing of amorphous Fe₆₄Cr₁₈Zr₈B₁₀ has been investigated by a combination of transmission electron microscopy and energy dispersive X-ray microanalysis. Isothermal annealing for 2 h at temperatures in the range 600–1000°C produces a variety of different microstructures depending on the annealing temperature. At 600°C, the amorphous alloy partially crystallizes to a form a microstructure consisting of 9 nm sized bee ferrite grains embedded in an amorphous matrix. At temperatures in the range 700–900°C, the alloy microstructure transforms into a mixture of bee ferrite, faulted fcc MB₁₂ boride particles and tetragonal M₃B boride particles. At 1000°C, the faulted fcc MB₁₂ boride particles are replaced by orthorhombic M₄B boride particles.     

Isoconversional Kinetics of Thermal Processes in Mixtures Based on Metakaolin and Sodium Hydroxide

This study investigated the thermal behavior of the mixtures 6Al₂Si₂O₇: 12NaOH and 6Al₂Si₂O₇: 12NaOH: 2Al₂O₃ which are designed for synthesis of LTA (Linde type A) zeolite. XRD, SEM, and Synchronous thermal analysis (STA) have been used. It was found that after evaporating suspensions, molding pellets, and drying, small amounts of LTA and sodium hydroaluminates have been formed in the sample. The removal of crystallization water occurs on heating up to 400°C. In the temperature range from 400 to 850°C, Na₆Al₄Si₄O₁₇ and Na₈Al₄Si₄O₁₈ are synthesized by interaction of metakaolin with sodium hydroxide. The formation of mullite and nepheline is also observed. It was shown that preactivation of powders in the vibratory mill allows reducing the starting temperature of synthesis at 50–100°C. For the range 400–850°C using Ozawa–Flynn–Wall analysis, the values of apparent activation energy and preexponential factor have been calculated. It was established that the apparent activation energy for mixtures without preactivation made 200–290 kJ mol⁻¹. After preactivation, E values decreased to 130–170 kJ mol⁻¹. Also it was shown that alumina excess inhibits nepheline and mullite formation.     

Thermal behaviour of sericite clays as precursors of mullite materials

Thermal analysis of some sericite clays, from several deposits in Spain, which are not exploited at this time, has been studied. The samples have been previously characterized by mineralogical and chemical analysis. Sericite clays have interesting properties, with implications in ceramics and advanced materials, in particular concerning the formation of mullite by heating. According to this investigation by differential thermal and thermogravimetric analysis (DTA-TG), the sericite clay samples can be classified as: Group (I), sericite–kaolinite clays, with high or medium sericite content, characterized by an endothermic DTA peak of dehydroxylation of kaolinite with mass loss, which overlapped with dehydroxylation of sericite, and Group (II), sericite–kaolinite–pyrophyllite clays, with broader endothermic DTA peaks, in which kaolinite is dehydroxylated first and later sericite and pyrophyllite with the main mass loss, appearing the peaks overlapped. X-ray diffraction analysis of the heated sericite clay samples evidenced the decomposition of dehydroxylated sericite and its disappearance at 1050 °C, with formation of mullite, the progressive disappearance of quartz and the formation of amorphous glassy phase. The vitrification temperature is ~ 1250 °C in all these samples, with slight variations in the temperatures of maximum apparent density (2.41–2.52 g mL^?1) in the range 1200–1300 °C. The fine-grained sericite content and the presence of some mineralogical components contribute to the formation of mullite and the increase in the glassy phase by heating. Mullite is the only crystalline phase detected at 1400 °C with good crystallinity. SEM revealed the dense network of rod-shaped and elongated needle-like mullite crystals in the thermally treated samples. These characteristics are advantageous when sericite clays are applied as ceramic raw materials.     

The non-isothermal kinetics of mullite formation in boehmite–zircon mixtures

In this work, we studied the kinetics of mullite formation in different composites under non-isothermal conditions using DTA. Different composites based of mullite, alumina, zircon and zirconia were prepared by reaction sintering of boehmite (as alumina source) and zircon. Several mixtures were used while varying the percentage of the boehmite from 30 to 70 mass% with a step of 10. Five compositions marked as B30, B40, B50, B60 and B70 corresponding to boehmite–zircon ratios (mass%) of 30/70, 40/60, 50/50, 60/40 and 70/30 were fabricated and studied. The DTA conducted at heating rates of 10, 20 and 30 K min^?1 showed an endothermic peak in all composites at about 1,603 K associated with mullite formation. The activation energies measured from non-isothermal treatments for five compositions (30, 40, 50, 60 and 70 mass% of boehmite) were 1,029, 1,085, 1,262, 1,508 and 1,321 kJ mol^?1, respectively. The n values (Avrami parameter) for all compositions are larger than 2.5, the mullite crystallization of these composites is followed by three-dimensional growth.     

Crystallization of Anodic Alumina Membranes Studied by Simultaneous TG-DTA/FTIR

The thermal change of anodic alumina (AA), particularly the exothermic peak followed by the endothermic peak at ca 950°C was studied in detail by mainly using simultaneous TG-DTA/FTIR. The gradual loss of mass up to ca 910°C is attributed to dehydration. When heated at a constant rate by using TG-DTA, an exothermic peak with subsequent endothermic peak is observed at ca 950°C, but the exothermic peak becomes less distinct with decreasing heating rate. It has been found that gaseous SO₂ accompanying a small amount of CO₂ is mainly discharged at this stage. The reaction in this stage can be considered roughly in two schemes. The first scheme can be said collectively as crystallization, in which the migration of S or C trapped inside the crystal lattice of the polycrystalline phase (γ-, δ-, and θ-Al₂O₃, which presumably accompanies a large amount of amorphous or disordered phase) occurs. In the second scheme, the initial polycrystalline (+amorphous) phase crystallizes into a quasi-crystallineγ-Al₂O₃-like metastable phase after amorphization. Conclusively,after the distinct exo- and endothermic reactions, the amorphous phase crystallizes intoγ-Al₂O₃, presumably accompanying small amount of δ-Al₂O₃. It is also found that, when maintained isothermally, the metastable phases undergo transformation into the stable α-Al₂O₃ at 912°C. This revised version was published online in July 2006 with corrections to the Cover Date.     

Phase transition of syndiotactic polypropylene in electrospun nanofibers during progressive heating

By means of high-temperature electrospinning process, syndiotactic polypropylene (sPP) nanofibers with an average diameter of 127 nm were obtained using a rotating disc as a collector. The aligned fibers were subjected to progressive heating for fiber melting. During heating, structural evolution of the sPP nanofibers was investigated in situ by means of two-dimensional wide-angle and small-angle X-ray scattering with synchrotron radiation sources. It was found that the as-spun fibers consist of the antichiral form I (9 %), mesophase (31 %), and amorphous phase (60 %), in the absence of isochiral form II. Upon heating, the mesophase started to melt and completely disappeared at 90 °C. The melting of the mesophase directly produced amorphous chains at 35–60 °C, and brought up the isochiral form II at low temperatures (60–70 °C), as well as the antichiral form I at high temperatures (70–110 °C). These events were in accordance with the DSC heating curve, which exhibited a small endotherm centered at 52 °C for the mesophase melting, followed by a shallow and broad exotherm associated with two phase-transition events, i.e., the crystal reorganization and the crystallization of supercooled liquid. The former is likely due to the solid–solid transition of meso→II phase as suggested by Lotz et al. (Macromolecules 31:9253, 1998), and the latter is relevant with crystallization of amorphous chains to develop the thermodynamic stable form I phase at high temperatures.     

Rigid amorphous fraction and melting behavior of poly(ethylene terephthalate)

The multiple melting behavior of poly(ethylene terephthalate) (PET) is generally attributed to the fusion of original crystals recrystallized during the heating at conventional scanning rate. In the present study, the triple and double melting behavior that is observed after isothermal crystallization at T _c lower and higher than 215 °C, respectively, is put in relation with the presence and absence of rigid amorphous fraction around the original primary crystal lamellae. The complex melting behavior is explained by assuming that two different morphologies of primary crystals develop during crystallization at temperatures lower than 215 °C, in a proportion that is a function of the crystallization temperature: chain cluster aggregations with a high percentage of rigid amorphous fraction on the boundaries and small crystals with a high percentage of adjacent reentry folding and reduced constraints at the amorphous/crystal interphase. These distinct morphologies differently transform upon heating at low scanning rate, originating two endotherms. On the contrary, after crystallization at T _c ?>?215 °C, all the primary crystalline structure, which probably are characterized by the same morphology made of tightly chain folded lamellae and absence of rigid amorphous fraction, undergo the same reorganization route, originating a single endotherm.     

Use of noncontact dilatometry for the assessment of the sintering kinetics during mullitization of three kaolinitic clays from Cameroon

Noncontact dilatometry, compared to differential scanning calorimetry (DSC), was used together with scanning electron microscopy and densification behavior studies to investigate the parameters that govern the kinetics of transformation of kaolin to mullite during sintering. Three kaolinitc clays from Cameroon, with different SiO₂/Al₂O₃ molar ratio, were examined. The temperatures of mullite nucleation were 973, 979, and 984 °C at 5 °C/min heating rate, respectively, for values of SiO₂/Al₂O₃ molar ratio equal to 4.22, 2.22, and 2.08. At 20 °C/min heating rate, the temperatures are shifted to higher values, 992, 997, and 1,001 °C. The mullitization phenomenon, which includes a first step of nucleation and a second one of crystal growth, presented activation energy in the range of 650–730 kJ/mol, depending on the nature of the sample investigated. These values, obtained by noncontact dilatometer measurements, were comparable to those obtained by means of DSC and are in agreement with literature values. The difference in sintering kinetics for the three kaolinitic clays could explain the different morphologies obtained for the mullite grains.