The sol–gel transition of mullite spinning solution in relation to the formation of ceramic fibers

Continuous mullite ceramic fibers were fabricated by a sol–gel dry spinning technique. The sol was prepared from an aqueous solution of aluminum nitrate (AN), aluminum isopropoxide (AIP) and tetraethylorthosilicate (TEOS). The sol–gel transition was investigated by measuring the volume, the solid content, the viscosity and the rheological properties of the solution. Shear viscosity η of the mullite sol varied dynamically with concentrating time and temperature. Combine size analysis of sol particles and TEM analysis on this basis, the growth character of sol particles agglomeration and its structural evolution were discussed. By adjusting the temperature, the gelling degree could stabilize at a certain value and the sol–gel transition could be transferred to the spinning line. Continuous fibers were spun from such sols immediately before gelling in a laboratory dry spinning apparatus. The spinneret contained thirty circular holes, each having a diameter of 0.2 mm. The temperature inside the spinning channel was 100–120 °C, the winding speed was 100–300 m/min. Sintering of the precursor fibers at 1,100 °C yields crack-free mullite ceramic fibers.     

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.     

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.     

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.     

Formation of sol-gel nanostructured mullite by additions of fluoride ion

Summary The subject of this study was to investigate the effect of fluoride ions addition on the temperature of sol gel mullite formation based on the hypotheses that the presence of fluoride ions can decrease the temperature of mullite formation (in respect to common 980°C, in sol-gel processing). Polymeric sols were prepared by mixing TEOS and aluminum nitrate nanohydrate and by adding fluoride ions (from 2 to 5 mass%). DTA, TG, XRD and SEM were used for characterisation of mullite gel and crystalline mullite. The experimental results confirmed that the addition of fluoride ions decrease the temperature of mullite formation up to 890°C for the fluorine concentration of 3.5 mass%. Experimental results showed that the temperature of mullite formation is not a simple function of the fluoride ion content. The mechanism of fluorine effect was discussed in terms of the gelling process, gel structure and the phase separation before the mullite formation.     

Spinel-Mullite Composites with Optical Properties

The aim of this paper was to study the synthesis and characterization of spinel-containing mullite based materials, using sol-gel techniques. Several gels were prepared, with nominal compositions 3(Al_2−2xM_x Ti_xO₃)·2SiO₂ and 3(Al_2−xM_xO₃)·2SiO₂, with M=Ni⁺² or Co⁺² and 0.0≤x≤0.2, by hydrolysis and condensation of mixtures of aluminum, silicon and titanium alkoxides and nickel chloride. Dried gels were homogeneous and displayed a glass transition at around 750°C, which indicated that the system could be described as an amorphous silicoaluminate network. Crystallization pathway of gels were followed using differential thermal analysis and X-ray diffraction patterns of samples thermal treated at temperatures in the range between 800 and 1400°C. A two-phase aluminate spinel-mullite arrangement was detected at temperatures around 1200°C. The microstructure of the final product was interesting, because the minor secondary phase was homogeneously dispersed in the mullite matrix. Chemical and thermal resistance of diphasic materials were tested and the results indicate that these materials can be used as high temperature ceramic pigments.     

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.     

Preparation of unsupported alumina membrane by sol-gel techniques

Unsupported alumina membranes were prepared by sol-gel technique using aluminum isoproxide. The influence of the hydrolysis conditions, the type and concentration of peptizant acid on the boehmite sols has been studied. The suitable hydrolysis temperature for the aluminum isoproxide was above 50°C. Crack-free unsupported alumina membranes were obtained by rapid gelation processing of sols. The boehmite gel membrane and γ-Al₂O₃ membrane formed exhibited (020) and (440) preferred orientation.     

Structural development and kinetic analysis of PbTiO3 powders processed at low-temperature via new sol-gel approach

The synthesis of crystalline lead titanate powder by a generic low-temperature sol-gel approach is developed. Acetoin was added as ligand, instead of the commonly used alkanolamines, to ensure total dissolution of the precursor compounds. The feasibility of the acetoin-Ti isopropoxide complex as a new precursor of PbTiO₃ perovskite particles via sol-gel method has been demonstrated. No excess lead has been introduced. Nanometric PbTiO₃ crystallites have been formed at 400 °C under atmospheric pressure from titanium isopropoxide and lead acetate in alcoholic solution by remarkably low activation energy of crystallization process of 90 kJ mol⁻¹. The powders show tetragonal lattice and dendritic morphology. In addition to the effect of heat-treatment temperature, time, and atmosphere, the sol chemistry particularly influenced the phase composition, particle size, and particle morphology. The use of different ligands significantly modified powder morphology. The extent of the crystallization was quantitatively evaluated by differential thermal analysis and analyzed by Johnson-Mehl-Avrami approach. The crystallization followed two rate regimes depending on the interval of the crystallized fraction.     

Phase Transformation During the Heat Treatment of Sol-Gel Mullite

The mechanism of mullite formation depends upon the method of combining the silica and alumina-containing reactants. In this work, the effects of the processing variables (dilution, pH, gelling temperature and water content) on mullite formation were investigated. Monophasic gel was synthesized from aluminium nitrate nanohydrate dissolved in an absolute ethyl alcohol and silica sol mixture. The gelling was performed at room temperature and at 60°C. It was found experimentally that the temperature of mullite formation depends on the microstructure of the gel. The lowest temperature of mullite formation (970°C) was observed when the mullite gel was prepared at low pH (pH=1), low water content and high gelling temperature. This revised version was published online in July 2006 with corrections to the Cover Date.     

Effect of the nature of anions of aluminum salts used to synthesize a precursor of the Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-ZrO<Subscript>2</Subscript> ceramics on the stabilization of the tetragonal modification of zirconium dioxide

Samples of a precursor for an aluminum oxide ceramics reinforced with zirconium oxide were synthesized by hydrolysis of various aluminum salts in the presence of a ZrO₂ sol under conditions of urea decomposition at 90°C and pH < 4 maintained, with hydrolysis products deposited onto the surface of ZrO₂ sol particles. It was found that the nature of a salt anion affects the interaction of hydrolysis products of the aluminum cation with the surface of ZrO₂ sol particles. The structure of products formed in thermal treatment of samples of a precursor for Al₂O₃-ZrO₂ (T = 1250°C) was characterized by X-ray phase analysis and scanning electron microscopy. The phase transition temperatures of the oxides Al₂O₃ and ZrO₂ contained in the precursor were estimated using the results of thermal analysis of the samples in the temperature range 20–1300°C.     

Sol–gel combustion synthesis of BNBT powders

Ba-modified bismuth sodium titanate with composition 0.94[(Bi_0.5Na_0.5)TiO₃]-0.06BaTiO₃ (BNBT) was prepared by a citrate nitrate sol–gel combustion method. The sol was obtained using barium acetate, bismuth nitrate, sodium nitrate and a peroxo-citrate complex of titanium isopropoxide as starting precursors. Various molar ratios of citrate/nitrate (C/N) were considered for the sol production. The corresponding gels were fired at different temperatures (300, 400, 500 °C) in order to evaluate the conditions necessary to obtain the decomposition of the precursors and the formation of the pure BNBT perovskitic phase in a single step. The best conditions to obtain the desired phase are: (C/N) = 0.2, and combustion temperature of 500 °C. Ball milled powders were densified at a temperature 100 °C lower than the one generally used for powder produced with the conventional mixed oxide route. The electrical properties are comparable to those reported for conventionally prepared materials.     

Synthesis and mechanism research of an ethylene glycol-based sol-gel method for preparing PZT nanopowders

Lead zirconate titanate nanopowders Pb(Zr_0.52Ti_0.48)O₃ (PZT) were prepared by modified sol-gel process in ethylene glycol system with zirconium nitrate as the zirconium source. The research showed that it was critical to add lead acetate after the reaction of zirconium nitrate and tetrabutyl titanate in ethylene glycol system for preparing PZT of exact titanium content. The reaction mechanisms of the sol synthesis, preparation of xerogel and agglutinating process were characterized through using FT-IR, NMR, TG-FTIR, and GC-MS. The experiment proved that ethylene glycol system did not rely on hydrolysis and condensation reactions in the process of the sol formation, but on the formation of chain or network large molecules from complexation of ethylene glycol and all Ti and minor Pd, Zr. In the preparation of xerogel, the complexation reaction was so completed that it formed large molecules network composed of metal and dioxyethyl. Bulk weight loss happened before 350°C in the process of sintering xerogel to prepare PZT nanopowders. Volatile matters and vapor phase decomposition resultants were primarily oxy-compounds including ethylene glycol, aldehyde-ketone compounds, carbon dioxide and nitrate radical conversion matters. After 350°C, primary vapor phase decomposition resultants were carbon dioxide and minor carbonyl compound.     

Effect of calcination temperature on the microstructure of porous TiO<Subscript>2</Subscript> film

To obtain porous TiO₂ film, the precursor sol was prepared by hydrolysis of Ti isopropoxide and then complexed with trehalose dihydrate. The porous TiO₂ film was fabricated by the dip-coating technique on glass substrates using this solution. The TiO₂ film was calcined at 500 °C. The maximum thickness of the film from one-run dip-coating was ca. 740 nm. The film was composed of nanosized particle and pores. The porosity of the TiO₂ film was increased by addition of trehalose dihydrate to the sol. The porous TiO₂ films were calcined at different temperatures. The effects of calcination temperature on the microstructure of the porous TiO₂ film were investigated. The porous film prepared from sol containing trehalose still kept the porous structure after calcination at 950 °C. The phase transition temperature of the film from anatase to rutile was shifted from 650 to 700 °C by addition of trehalose to the sol.     

Preparation of nanostructured porous SiO2-Al2O3 oxycarbonitride materials obtained by a new chemical precursor method

Nanostructured hybrid materials containing Al₂O₃ were synthesized via a sol-gel method through hydrolysis and co-condensation reactions using trimethylsilyl isocyanate (TMSI) as a new silica source in the presence of tetramethoxysilane (TMOS) and three different quantities (10, 20 and 30 wt.%) of aluminum sec-butoxide (Al(OBu^sec)₃ as a modifying agent. The xerogel nanostructured materials are pyrolyzed in nitrogen atmosphere in the temperature range from 400°C to 1100°C. The transformation of the xerogel hybrid networks into Al-Si oxycarbonitride materials has been investigated by XRD, FTIR, SEM, AFM, and ²⁹Si MAS-NMR. To the best of our knowledge, the work reported here is the first synthesis of porous di-urethanesils modified with aluminum and one of the few examples of alumosilica oxycarbonitride materials      

Epoxide assisted sol-gel synthesis of rutile NixTi1-3xSb2xO2 solid solution nanoparticles

Rutile Ni _x Ti_1-3x Sb_2x O₂ solid solution nanoparticles were synthesized by a sol-gel route using propylene oxide as a gelation agent. Titanium oxide nanopowder and 12% TiCl₃ solution were used as the source for titanium to investigate the influence of the titanium precursors on the formation of the target materials. It was found that the nanoparticles prepared using 12% TiCl₃ solution showed a much lower phase formation temperature (700°C) as compared to those prepared from TiO₂ nanoparticles (1000°C). This lower phase formation temperature allowed a substantial reduction of the aggregation of the particles during calcination leading to the formation of nearly mono-dispersed nanoparticles of about 20 nm. The results of this work show that the epoxide assisted sol-gel method is capable to produce titanium-based ternary oxide solid solution nanoparticles, owing to the formation of a highly homogeneous precursor gel intermediate.     

Alkylation of phenol by myrtenol

Alkylation of phenol by myrtenol in the presence of aluminum phenoxide and aluminum isopropoxide was studied in the temperature range 120–160°C. The reaction occurred with the formation of an array of alkylated phenols. Isomerization of the terpene substituent as a result of rearrangements of the bicyclic myrtenol structure was observed. The side reaction of myrtenol reduction occurred during the alkylation in the presence of aluminum isopropoxide. A significant number of compounds with two aromatic moieties was formed in the presence of aluminum phenoxide.     

Formation of spinel from metal organic compounds

A magnesium-aluminum product, which can be used to form spinel, is prepared by the simultaneous hydrolysis of magnesium acetylacetonate and aluminum isopropoxide. Infrared spectrum and X-ray diffraction analyses show that the product is a magnesium substituted γ-alumina-like amorphous material. Spinel is formed slowly at ≈700–1250°C at a heating rate of 1O°C min⁻¹. A marked increase in crystallite size occurs between 1100 and 1200°C. Spinel powders consist of aggregates of plate-like particles. The kinetics of crystallization of spinel have been studied by X-ray measurements. The initial stage at each temperature proceeds rapidly in a short time. The final stage can be described in terms of the contracting square equation 1 − (1 − f)^1/2 = kt, the activation energy being 164 kJ mol⁻¹.     

Effect of nature of templates on formation mechanism of aluminum oxide mesoporous structure

Mesoporous aluminum oxide is produced by the sol-gel method from aluminum isopropoxide using molecular structures of a cationic polyelectrolyte (polyethylenimine) and dodecylamine micelles as nanotemplates. The mechanism for the formation of mesophases of hybrid materials in colloidal systems upon template synthesis is discussed.     

High temperature solid state transformations in Jammu bauxite

Thermal reactions of Jammu bauxite heated to different temperatures from 950°–1900°C were studied by X-ray powder diffraction method. The formation of mullite by the aluminasilica reaction at temperature 1200°–1400°C and then the transformation of mullite to a glassy phase around 1900°C has also been discussed in detail.