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.     

Reaction sintering and microstructural evolution in metakaolin-metastable alumina composites

Fine needles of mullite grains were obtained successfully in a compact and low porous matrix using solid state sintering. We treated high-grade kaolin and sand-rich kaolin at 750 °C to amorphous metakaolins, and bauxite at 1,000 °C to metastable alumina. By designing a stochiometric composition of mullite, each amorphous metakaolin was added to metastable alumina. Fine grains of mullite with almost complete crystallization were obtained from 1,350 °C in a case of amorphous metakaolin from high-grade kaolin and at 1,550 °C in the other case where amorphous metakaolin is from sand-rich kaolin. The difference in the temperatures of mullitization was linked to the late dissolution of silica from the cristobalite and quartz phases which were still present in the sand-rich metakaolin sample at 1,350 °C. The use of metastable alumina and metakaolin instead of kaolin to design the mullite matrix allows the increase in number of mullite nucleation sites. This results to high densification and crystallization, fine grain size, and high mechanical properties of the final matrix.     

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.     

Mullite Based Compositions Prepared by Sol-Gel Techniques

Ceramic powders and gels in the multi-alumina system with different compositions were prepared by sol-gel method. The preparation of gels was done in strong acidic conditions and also with the addition of ammonia. The powders were prepared by dropping the sols on a hot plate. The effect of water/alkoxide and ethanol/alkoxide ratios was studied together with the type of catalyst used (hydrochloric acid or ammonia). The thermal evolution of materials was followed by thermal analysis, X-ray diffraction, specific surface area measurements and electron microscopy. The morphology of powders was also studied. The characteristic exothermic peak attributed to a good mixing degree of the Al and Si species was observed at ∼980°C. The intensity of this exothermic peak was more pronounced in gels than in sol-gel derived powders. The crystalline phases formed are related with the preparation conditions and with the thermal treatment. The crystallisation of mullite and transient phases of alumina were observed in powder samples heat treated at 1000°C while in gel samples mullite was the only crystalline phase detected.     

Sol–gel synthesis of macroporous TiO2 from ionic precursors via phase separation route

Monolithic macroporous titanium dioxide (TiO₂) derived from ionic precursors has been successfully prepared via the sol–gel route accompanied by phase separation in the presence of formamide (FA) and poly(vinylpyrrolidone) (PVP). The addition of FA promotes the gelation, whereas PVP enhances the polymerization-induced phase separation. Appropriate choice of the starting compositions allows the production of cocontinuous macroporous TiO₂ monoliths in large dimensions, and controls the size of macropores. The resultant dried gel is amorphous, whereas anatase and rutile phases are precipitated at 500 and 900 °C respectively, without spoiling the macroporous morphology. Nitrogen adsorption–desorption measurements revealed that the dried gels exhibits mesostructure with a median pore size of about 3 nm and BET surface area of 228 m²/g, whereas 15 nm and 73 m²/g for the gels calcined at 600 °C.     

Preparation of zirconium diboride ultrafine hollow spheres by a combined sol–gel and boro/carbothermal reduction technique

In this work, we introduce a modified novel silica sol–gel process to synthesize hexagonal close-packed (hcp) and face-centered cubic (fcc) nickel (Ni) nanoparticles supported on amorphous carbon and silica matrix. The supporting of amorphous carbon and silica can prevent the Ni nanoparticles from aggregating and being oxided which would result in the loss of their magnetism and dispersibility. The phase structure of the Ni nanoparticles which were obtained from the gels pyrolyzed from 250 to 350 °C is hcp structure, whereas that of the Ni nanoparticles pyrolyzed at 750 °C is fcc structure. The grain sizes of the hcp Ni nanoparticles calcined at 250 °C range from 5 to 20 nm in diameter, and that of the fcc Ni nanoparticles calcined at 750 °C range in 7–35 nm. The studies of magnetic properties of the hcp and fcc Ni nanoparticles show that both have quite different magnetic behaviors.     

Crystallization of Gels in the Apatite-Mullite System

Crystallization processes in gels of the apatite-mullite system were studied to obtain information for the synthesis of bioglass-ceramics and composite materials. SiO2-sol, Al(NO3)3·9H2O, Ca(NO3)2·4H2O, (NH4)3PO4·3H2O and CaF2 were used as precursors. CaF2 was added before and after gelation. Mixtures of mullite gel-glass and fluorapatite in the range 10 to 90 mol% were investigated for synthesis of composites. All the samples were heat treated at different temperatures in the range 950–1250°C and the structural changes were established using X-ray diffraction and IR-spectroscopy. When the gels were treated at 1050°C and at 1150°C, the main crystalline phases found were fluorapatite and mullite independent of the CaF2 content and the manner of its addition. At 1250°C the relative amounts of fluorapatite and mullite decrease and gehlenite appears. Composite materials containing fluorapatite and mullite as main crystalline phases can be obtained only when the content of mullite gel-glass in the initial mixture is more than 60 mol%.     

IR structural evidence of hydrotalcites derived oxidic forms

Ni–Al hydrotalcite-like compounds with the general formula [Ni_1−xAl_x(OH)₂](CO₃)_x/2⋅mH₂O, where 0.25≤x≤0.66, were synthesised using coprecipitation at a constant pH, and were treated hydrothermally. The structures of the oxidic forms obtained by calcination of the hydrotalcites at 450°C and 900°C, respectively, were investigated using X-ray diffraction and, mainly, IR and UV–VIS spectroscopy. A NiO phase was identified by XRD in all calcined samples; an additional oxidic phase — the nickel spinel, NiAl₂O₄ — developed at 900°C. IR spectroscopy results gave supplementary information about the incipient, local organisation of cations in the interstices of the oxygen atoms lattice. IR spectra were different, depending on the samples' composition. In case of the HT precursors calcined at 450°C a structure like a transition alumina (γ-Al₂O₃) was found as a main oxidic phase in samples with a high Al-content; IR spectra of the samples with a high Ni content evidenced NiO as the main oxidic phase; in case of these latter samples, the formation of an oxidic structure with a spinel-type local order was identified at this temperature. This structure developed to an inverse nickel spinel oxidic phase at 900°C, as shown by the IR absorption bands. The NiO structure in the samples with a high Ni content at 450°C was found also in the oxides obtained by calcination at 900°C. The spinel-type local order was also observed by UV–VIS spectroscopy in case of the HT precursors calcined at 450°C, by the presence of both absorption bands of the tetrahedral and octahedral Ni(II) ions in the Al₂O₃ lattice and of octahedral Ni(II) ions in the NiO lattice. The same absorption bands were found also in the samples calcined at 900°C, proving that the NiAl₂O₄ spinel identified has a partial inverse structure, with the Ni(II) ions both in tetrahedral and octahedral crystalline fields. Our found structural data were in accord with the models proposed in the literature.     

Novel non-hydrolytic sol-gel route to metal oxides

Monolithic alumina and aluminosilicate gels have been prepared using a novel sol-gel process based on the non-hydrolytic condensation reaction between a metal halide and a metal alkoxide. XRD indicated that the alumina gel remained amorphous at 750°C; solid state ²⁷Al NMR indicated the presence in the dried gel and in the amorphous calcined sample of a large amount of pentacoordinated aluminum atoms. A study of the sol formation using liquid state ²⁷Al NMR suggested that the gel structure was reminiscent of the oligomeric structure of the chloroisopropoxide precursors. Differential thermal analysis and XRD indicated that the aluminosilicate gels were converted to mullite below 1000°C, suggesting a high degree of homogeneity in these precursors.     

Mullite-Alumina Composites Prepared by Sol-Gel

Ceramic composite gels in the mullite-alumina system (with mullite phase contents ranging from 20 to 100 wt%) were prepared by sol-gel in acid media and using a water/alkoxide molar ratio of 4. Powders were uniaxially pressed to obtain discs.The effect of heat treatment on the materials was followed by thermal analysis and X-ray diffraction (XRD). The crystalline phases formed from the gels were dependent upon the sample composition and the heat treatment temperature. For samples with composition close to the stoichiometric mullite composition the crystallization of mullite was observed after heat treatment at temperatures 900°C, and corundum appeared at higher temperatures. For samples with higher alumina contents mullite formation together with the spinel phase was observed at the lower heat treatment temperatures, while mullite, silimanite, corundum, and other transient phases of alumina were also detected at higher temperatures. The densities and microstructures of materials sintered at 1400°C were studied. Densification of the samples was low due to the agglomeration of the powders, as confirmed by scanning electron microscopy.     

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.     

Synthesis of Cristobalite Containing Ordered Interstitial Mesopores using Crystallization of Silica Colloidal Crystals

Cristobalite with ordered interstitial dual-sized mesopores was synthesized through the crystallization of silica colloidal crystals composed of monodispersed amorphous silica nanoparticles. An aqueous solution containing both a flux (Na₂O) and a carbon precursor (an aqueous low-molecular weight phenolic resin) was infiltrated into the interstices of silica colloidal crystals. The organic fraction in the nanocomposite was further polymerized and subsequently carbonized in an Ar flow at 750 °C to reinforce the colloidal crystal structure. The thermal treatment resulted in the crystallization of the colloidal crystals into cristobalite while retaining the porous structure. The cristobalite-carbon nanocomposite was calcined in air to remove the carbon and create interstitial ordered mesopores in the cristobalite. The surfaces of crystalline mesoporous silica are quite different from those of various ordered mesoporous silica with amorphous frameworks; thus, the present findings will be useful for a precise understanding and control of the interfaces between the mesopores and silica networks.     

Influence of Ti addition on boehmite-derived aluminum silicate aerogels: structure and properties

Aluminosilicate aerogels offer potential for extremely low thermal conductivities at temperatures greater than 900?°C, beyond where silica aerogels reach their upper temperature use limits. Aerogels have been synthesized at two Al:Si ratios, a 3Al:1Si mullite composition, and an 8Al:1Si alumina rich composition. Boehmite (AlOOH) is used as the Al source, and tetraethoxysilane as the Si precursor. The influence of Ti as a ternary constituent, introduced through the addition of titanium isopropoxide in the sol?Cgel synthesis, on aerogel morphology and thermal properties is evaluated. Four different boehmite precursor powders are evaluated. Morphology, surface area and pore size, and thermal transformation vary with the crystallite size of the starting boehmite powder, as does incorporation of titanium and evolution of Ti-containing crystalline phases. The addition of Ti influences sol viscosity, gelation time, surface area and pore size distribution, as well as phase formation on heat treatment.     

Sol–gel derived mesoporous and microporous alumina membranes

Stable polymeric and colloidal boehmite sols were prepared by sol–gel process through controlled hydrolysis/condensation reactions. The particle sizes of the colloidal sols were in the 12–25 nm range depending on the process parameters and about 2 nm for polymeric sols. The presence of a significant increase in the microporosity content of the heat treated polymeric membranes relative to the mesoporous colloidal membranes might make the design of thermally stable microporous alumina membranes with controlled pore structures possible. The phase structure evolution in the 600–800 °C range had shown that the crystallization of the gamma alumina in the amorphous matrix starts at about 800 °C. This indicated that the pore structure stability may be enhanced through processing up to this relatively high temperature in polymeric alumina derived unsupported membranes. The permeance values of the two and three layered colloidal alumina membranes were observed to be independent of pressure which implies that the dominant gas transport mechanism is Knudsen diffusion in these structures. This was also supported by the 2.8 nm BJH pore sizes of the colloidal membranes. The Knudsen diffusion equation derived permeances of the polymeric alumina membranes with thicknesses of about 300 nm were determined to be very close to the experimentally determined permeance values.     

Sol–gel preparation of mesoporous Al2O3–SiO2 glasses: structural evolution monitored by solid state NMR

Glasses along the composition line 0.5Al₂O₃–xSiO₂ (1 ≤ x ≤ 6) were prepared via a novel sol–gel route using tetraethylorthosilicate and aluminum lactate as precursors. The structural evolution from solution to gel to glass is monitored by standard ²⁷Al and ²⁹Si nuclear magnetic resonance (NMR) spectroscopies, revealing important insights about molecular level mechanisms occurring at the various stages of glass formation. Under the experimental conditions reported, silica and alumina precursors undergo homoatomic condensation processes when the gel is heat treated at about 100 and 300 °C, respectively, and only little heteroatomic co-condensation occurs in this temperature range. The latter is promoted only upon elimination of the residual lactate and water ligands upon annealing the gels above 300 °C. Following calcination at 650 °C, mesoporous glasses are obtained, having average pore diameter of about 3 nm and a surface areas near 500 m²/g. Si–O–Al connectivities are detected by ²⁹Si magic angle spinning (MAS)-NMR. ²⁷Al MAS-NMR spectra reveal aluminum in four-, five- and six-coordination. The spectra differ significantly from those of other sol–gel derived Al₂O₃–SiO₂ materials prepared from different precursor routes, suggesting that the lactate route results in a higher degree of compositional homogeneity.     

Improving functional properties of ZnO nanostructures by transition-metal doping: role of aspect ratio

Localized surface plasmon resonance (LSPR) of gold nanoparticles (AuNPs) has been used for biosensing and chemical sensing applications because the LSPR peak wavelength depends on the dispersion state and local refractive index of the surrounding medium. In this study, AuNP-loaded silica gels were prepared as sensing chips with high transparency and solution holding capability. The silica gels were prepared at various sintering temperatures from 500 to 900 °C, and the AuNPs precipitated in the gels by using a subsequent thermal reduction process. At sintering temperatures of 700, 800, and 900 °C, transparent and crack-free AuNP-loaded silica gels were obtained. Transmission electron microscopy observation revealed the AuNP size to be approximately 20 nm, and they were highly dispersed in all the silica gel samples. However, the sintering temperature of the silica gels strongly affected the LSPR property of the AuNPs and the porous property of the silica gel. The samples sintered at higher temperature exhibited a lower LSPR sensing ability against the refractive index of immersing solvents. The low sensing ability was considered as a result of a decrease in the contact area between the AuNPs and immersing solvent caused by an increase in the silica gel density with sintering temperature.     

Nano-alumina by gel combustion, its thermal characterization and slurry-based coating on stainless steel surface

Gel combustion method was used to prepare nano-alumina from aluminum nitrate and stoichiometric amount of glycine as fuel. The TG–DTA pattern of the as-prepared powder (combustion product) exhibited exotherms with peaks around 500 and 900 °C accompanied with loss of weight of 25 and 5 % attributed to burning away of carbon left behind and decomposition of residual reaction intermediates left behind, respectively. Even though mass stability is attained above 900 °C, the DTA exhibited an exotherm around 1,150 °C attributed to transformation of gamma to alpha form of alumina. The XRD studies revealed that the powder heated to 900 °C was chemically pure nano-crystalline alumina while that heated above 1,150 °C was crystalline alpha form. As nano-crystalline powders are sinter-active, the nano-crystalline alumina formed by calcination at 900 °C was used to form the coating. A morphological feature of the agglomerates of nano-alumina powders were evaluated using SEM. The powder was de-agglomerated by wet grinding method. The dispersion conditions to form slurry using 900 °C calcined powder for slurry-based coating was optimized using zeta-potential studies, and it was found to exhibit a maximum value of ?45 mV at a pH of 9. After 8 h of grinding, the median agglomerate size reduced to 2 μm. Rheological studies exhibited desired pseudoplastic behavior in the range of 10–20 vol.% of solid while the slurry with 15 vol.% only form crack free, dense, and adherent coating after heat treatment at 1,150 °C. The morphology of the coating was found to be uniform and dense.     

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.     

Thermal evolution of TEOS-Al(secBuO)3-etac mullite gels

Mullite gels have been prepared using tetraethyl orthosilicate and aluminium tri-sec-butoxide chemically modified by ethylacetoacetate as precursors. The hydrolysis conditions are shown to have a very noticeable influence on the evolution of both phase and microstructure of the resulting xerogels. The optimization of thermal treatment allows well crystallized mullite samples with a density more than 90% of the theoretical value after sintering at 1200°C for 4 hours to be obtained.     

Mullite fibers prepared from an inorganic sol–gel precursor

Mullite fibers were prepared by sol–gel process using alumina sol and silica sol. Alumina sol was synthesised from dissolution of aluminum powder in aluminum chloride hexahydrate solution. The optimal spinning alumina sol could be obtain in the composition range of Al/AlCl₃·6H₂O molar ratio 3.4–3.8. The Al and Si components were mixed at the molecular level and linear molecules were formed in the mullite precursor sol. The dried mullite precursor gel fibers completely transformed to mullite fibers at 1,000 °C with a smooth surface and uniform diameter.