Development of mullite and mullite/Al2O3 precursor sols for electrophoretic deposition of oxidation protection coatings

Mullite and mullite/Al₂O₃ precursor sols have been developed for the deposition of oxidation barrier coatings on carbon fibre reinforced composites using a combination of sol–gel synthesis and electrophoresis.The sols were synthesised by controlled hydrolysis and condensation of TEOS (tetraethoxysilane) and Al(OBu^s)₃ (aluminium tri-sec-butylate). The main objective was the definition of synthesis conditions which yield sols suitable for the electrophoretic deposition (EPD). Measurements of the Electrokinetic Sonic Amplitude were used to investigate the electrokinetic properties of the sols in the as-prepared state and depending on the later addition of H₂O. ²⁹Si CP/MAS NMR spectra of dried precursor samples were recorded to study the homogeneity of Al/Si mixture. The progress of crystallisation with increasing temperature of heat treatment was examined by XRD. Oxidation protection coatings on C/C–SiC composites were prepared by EPD.Whereas a low H₂O to TEOS ratio during the sol synthesis was advantageous for a low mullite formation temperature, a high H₂O to TEOS ratio was necessary to enable the EPD. The synthesis of a sol with a low H₂O to TEOS ratio in the first step and the later modification of this sol by the addition of water was a successful method to combine the required electrokinetic properties and mullitisation temperatures below 1200 °C.     

Determination of Particle Size and Shape during the Hydrolysis of Pb(Zr0.3Ti0.7)O3 Precursor Solutions

The formation and growth of polymeric particles during the hydrolysis and condensation of PbZr_0.3Ti_0.7 O₃ (PZT 30/70) sol-gel precursor solutions have been investigated by using photon correlation spectroscopy (PCS), small angle X-ray scattering (SAXS) and by measuring their rheological properties. The measurements showed that the growth of the particles in the transition of PZT sol to gel followed a simple polymerisation process. Solution A (containing by-products) and Solution B (by-products removed) displayed a similar plot of logarithmic viscosity against logarithmic time, indicating that the particles in both solutions have similar structures after hydrolysis. The changes in viscosity and particle size with time were described by single logarithmic growth models. However, the increasing rate of logarithmic particle size in Solution B is higher than that in Solution A. A model for the form of the aggregates is discussed which is applicable to PZT organometal-particle aggregation process in systems with acetic acid as a modifier.     

A Comparison of the Nanostructure of Lead Zirconate,Lead Titanate and Lead Zirconate Titanate Sols

Sol-gel processing has been widely used for the fabrication of lead zirconate titanate (PZT) thin films. To successfully and consistently make high quality thin films for different applications, we must develop a fundamental understanding of the structures of the sols. In this study, the characters of lead titanate (PT) and lead zirconate (PZ)sols were studied by measuring the rheological properties and particle sizes in them and comparing their behaviours. The average particle sizes in unhydrolysed PT, PZ and PZT sols are 11.5, 1.0, and 6.0 nm, respectively. PT sol has the highest rate of hydrolysis. It gels at about 24 h after hydrolysis. PZ and PZT sols have a quite similar feature in hydrolysis. The reasons for the differences in the hydrolysis behaviour of the different types of sol are discussed in terms of a model which indicates that the inhomogeneous sols consist of 5 to 6 nm PT particles surrounded by much smaller PZ particles, which tend to dominate the sol behaviour.     

Colloid chemical properties of hydrated tungsten trioxide hydrosols

Hydrosols of hydrated tungsten trioxide WO₃ ? nH₂O have been synthesized via peptization of a precipitate obtained by hydrolysis of potassium tungstate. It has been shown that the resulting sols are stable to aggregation in a pH range of 3.0–4.5. Hydrodynamic diameters and ζ potentials of WO₃ ? nH₂O particles have been determined as functions of dispersion medium pH. In addition, their density and degree of hydration have been found for the stable sols. The thickness of particle surface layers has been estimated.     

27Al NMR Study of Al-Speciation in Aqueous Alumina-Sols

A new method of preparing concentrated alumo-sols, the hydrolysis of Al-tri-sec-butylate in acidic aqueous media at 85°C, was studied in detail by varying the H₂O/Al- and NO₃ ⁻/Al-ratios in wide ranges. The components of the sols were characterized by ²⁷Al NMR spectroscopy. The pH-value depends on both the chosen H₂O/Al- and NO₃ ⁻/Al-ratio and on the aging time of the sols and reflects the composition of the sols. Al₁₃ polycations were detected in sols with a pH-value between 3.0 and 3.7. As a new result its presence was shown by NMR below 3.4. The Al₁₃ content of the sols increased with pH and the maximum fraction of Al₁₃ polycations was detected in the sol with the highest pH (3.7). Nearly 65% of the entire aluminium content of this solution is bound in the Al₁₃ polycations. Hence, a new synthetic method for the preparation of Al₁₃ ions containing sols was developed. Aging studies of the sols showed, that the Al₁₃ polycations were more stable in solutions with higher pH-value. Al₁₃ polycations were detected after an aging time of four months only in sols with a pH-value of 3.7. Tempering the aged sols at 40° to 80°C caused formation of Al₁₃ and also of Al₃₀ polycations.     

Formation of TiO2 Sols,Gels and Nanopowders from Hydrolysis of Ti(OiPr)4 in AOT Reverse Micelles

Titania sols, gels and nanopowders have been produced by the controlled hydrolysis of tetraisopropyltitanate (TPT) in sodium bis(2-ethylhexyl)sulfosuccinate (AOT) reverse micelles. Particle formation and aggregation have been investigated by photon correlation spectroscopy, the crystal phases by FT-Raman spectroscopy, and the crystallite dimensions of the precipitates by transmission electron microscopy. Nanoparticles could be produced at relatively high Ti(IV) concentrations (up to 0.05 mol dm^–3). These nanoparticles aggregated into sols, with colloid sizes of 20–300 nm, eventually forming gelatinous precipitates. The kinetics of particle formation and aggregation were controlled by varying the primary process parameters [TPT], [H₂O]/[AOT] (w₀), and [H₂O]/[Ti(IV)] (R), yielding a range of products including stable, transparent sols, precipitates and monolithic gels. The aggregation kinetics and physical properties of the sols depended strongly on w₀. Different titania phases were produced, depending on w₀; w₀ 6 yielded amorphous particles, while w₀ 10 produced anatase. The dimensions of the crystallites were comparable to those of the parent reverse micelles. A model was developed to interpret the effect of the primary process parameters on colloidal stability: (1) nucleation to form primary crystallites occurs by rapid hydrolysis and condensation reactions within the reverse micelle and (2) subsequent colloidal growth by aggregation occurs by reverse micellar exchange, where the rate of growth is governed by electrostatic and steric stability factors which increase as [AOT]/[TPT] (S) and residual [H₂O]/[AOT] (w_r) increase.     

The interaction of dibutyltin dilaureate with tetraethyl orthosilicate in sol-gel systems

Sols composed of dibutyltin dilaureate (DTL) and tetraethyl orthosilicate (TEOS) were prepared using a mixture of methyl ethyl ketone (MEK) and acetone as the solvent in order to study the interaction between the oligomeric Sn and Si species. The hydrolysis molar ratio r (r=nH₂O/nM (M: Si, Sn or Si+Sn) was 2. The use of an acid or basic catalyst was avoided, as the sols are intended to be used in the formulation of potential stone consolidants. The sols were studied by several spectroscopic techniques including Small Angle X-ray Scattering (SAXS), ²⁹Si and ¹¹⁹Sn NMR, Fourier Transform Infrared (FTIR) spectroscopy and X-ray diffraction (XRD). According to the spectroscopic results the lauric acid produced by the hydrolysis of DTL modifies the condensation path of the Si species, leading to the formation of two types of oligomeric chains: linear swollen and multiparticle diffusion-limited aggregates, depending on the molar ratio Sn/Si. The ²⁹Si NMR results indicated that the hydrolysis of DTL catalizes the condensation of the Si species, giving as a result higher condensation extents of the Si species in the Sn-Si sols compared to a pure Si sol. Based on the Radial Distribution functions (RDF) and the FTIR results, heterocondensation occurred.     

Influence of powder preparation process on piezoelectric properties of PZT sol-gel composite thick films

In this work, piezoelectric PbZr_0.52Ti_0.48O₃ (PZT) thick films were deposited onto silicon and alumina substrates using sol-gel composite slurry. Thick films prepared with rough and attrited powders are compared. A time stable polymeric PZT sol was first synthesised as the binder. It was then used as a precursor for PZT powder fabrication. Powder attrition ball milling was optimised to reduce the particles size to 200 nm. Composite slurries were obtained by mixing PZT sol with attrited or rough powders and thick films were deposited by dip-coating. The film thickness, roughness and microstructure were studied as a function of powder content, particle size, sol concentration and slurry ageing. Electromechanical measurements were performed. By strictly controlling each step of the thick film fabrication, high coupling factor (thickness mode, k_t) can be obtained using both types of powder. Nevertheless, with attrited powder, better and more reproducible effective coupling coefficients in thickness mode (k_t up to 46%) were reported on silicon and alumina substrates.     

Sol–gel based synthesis of ultrafine tetragonal BaTiO3

Ultrafine tetragonal BaTiO₃ nanocrystals have been prepared by a sol–gel based method. By adjusting the volume ratio of H₂O/DEG (diethylene glycol) in the solutions, hydrolysis rate of tetra-n-butyl titanate was strongly inhibited and the particle size could be controlled as small as 4–8 nm. The powder X-ray diffraction and transmission electron microscopy characterizations exhibit that the nanocrystals are spherical and well crystallized. The Raman spectrum shows the products are composed of the orthorhombic phase and tetragonal phase. The Fourier transform infrared spectrum revealed that a surface modification layer was formed around the BaTiO₃ nanocrystals, which can prevent them from aggregation and help to form a stable, high solid content sol.     

Preparation of highly stable TiO<Subscript>2</Subscript> sols and nanocrystalline TiO<Subscript>2</Subscript> films via a low temperature sol–gel route

Highly stable TiO₂ sols were prepared by adjusting the water-to-titanium molar ratio to ~4 in the process of hydrolysis and condensation of titanium isopropoxide in ethanol with HNO₃. Particularly, long-term stable TiO₂ sols were prepared without adding any chemical additives. Anatase TiO₂ nanocrystallites with sizes of 3–5 nm in diameter were uniformly dispersed in the stable sol. Crystallized TiO₂ films were successfully deposited on Si (100) using the stable sol via a dip-coating process with low temperature curing at as low as 100 °C. The synthesized TiO₂ sols and films are promising for use in flexible or dye-sensitized solar cells.     

Preparation and Structure of Microporous Silica Membranes

Silica sols have been prepared in an alcoholic solution by hydrolysis and condensation of TEOS (tetra-ethyl-ortho-silicate) molecules as a function of water and nitric acid concentration. The polymers are intended as precursors for ceramic, gas separation membranes. These molecules show fractal behavior as determined by SAXS (Small Angle X-ray Scattering). Microporosity of dried and calcined silica polymers is determined by N₂-adsorption at 77 K. Fractal dimension and porosity increase with increasing acid concentration. Both the sol structure and the drying kinetics determine the porosity values. N₂-adsorption isotherms are not very suitable for the determination of pore size distributions of microporous silica.     

Size Distribution Evolution of NiO x H y and Au: NiO x H y Sols

The present work reports on the preparation of nickel oxi/hydroxide and gold composite nanoparticulate sols. The precursor was prepared as an alcoholic suspension of nickel oxi/hydroxide. Controlled amounts of 2,4-pentanedione (AcAc) were added to the nickel salt suspension and lead to the formation of a nickel complex. The dependence of the particle size with AcAc titration was followed by Small Angle X-Ray Scattering (SAXS). The results showed that the particle size distribution shifts towards low values with the increase in the AcAc concentration. The complex, obtained by adding an excess of the AcAc ligand, [Ni(AcAc)₂]·2H₂O, was identified by FTIR spectroscopy and X-ray diffraction. An AcAc specific volume was chosen in order to obtain a homogeneous sol of nickel oxi/hydroxide to which gold was added. The size distribution of the Au particles in this sol was followed by SAXS.     

Time-resolved small angle X-ray scattering study of sol-gel precursor solutions of lead zirconate titanate and zirconia

The evolution of nanostructure in sol-gel derived lead zirconate titanate (PZT) and zirconia precursor sols at different hydrolysis ratios was investigated by small angle X-ray scattering (SAXS). The shape of the clusters in the zirconia sol could be described by the length-polydisperse cylindrical form factor. The zirconia-based clusters were characterized by a cross-sectional radius, r(0), of 0.28 nm and a practically monodisperse length of ca. 1.85 nm. These clusters were probably constructed of zirconia-related tetrameric building blocks. Similar cylindrical structural motifs were observed in PZT precursor sols with [H(2)O]/[Zr+Ti]=9.26 and 27.6, but the polydispersity in length was much higher. Clear scattering contributions from Ti and Pb centers were not detected, which was interpreted in terms of a homogeneous distribution of unbound lead ions in solution and the relatively low scattering intensity from any Ti-based clusters or oligomers that may have been present in the sols.     

Synthesis of hydrated tungsten(VI) oxide sols by peptization

A method has been developed for the synthesis of hydrated tungsten oxide hydrosols, with this method being based on potassium tungstate hydrolysis followed by peptization of the formed precipitate. The influence of the conditions of precipitation, aging, and washing of the precipitate on the particle phase composition and shape and the degree of precipitate peptization has been studied. Hydrosol-particle sizes have been determined by different methods. It has been found that the dispersed phase of the hydrosols consists mainly of platelike particles of hydrated tungsten oxide WO₃ · 2H₂O with a number-average size of 52 nm. The sols are stable to aggregation in a pH range of 3.0–4.5. The zeta potential of the particles ranges from–33 to–38 mV.     

Development of nanoscale inhomogeneities during drying of sol-gel derived amorphous lead zirconate titanate precursor thin films

The structural evolution of sol-gel derived lead zirconate titanate (PZT) precursor films during and after physical drying was investigated by transmission electron microscopy (TEM), electron energy loss spectroscopy (EELS), selected area electron diffraction (SAED), and time-resolved X-ray diffraction (XRD). Films were deposited from initial 0.3 mol/dm(3) precursor sols with varying hydrolysis ratios. Zr-rich grains of 1-10 nm size, embedded in a Pb-, Zr-, and Ti-containing amorphous matrix were found in as-dried films. The Zr-rich regions were crystalline at hydrolysis ratios [H(2)O]/[PZT] < 27.6, and amorphous at ratios > 100. X-ray diffraction analysis of PZT and zirconia sols revealed that the crystalline nanoparticles in both sols are identical and are probably composed of nanosized zirconium oxoacetate-like clusters. This study demonstrates that time-resolved X-ray diffraction combined with electron energy loss spectroscopy mapping is a powerful tool to monitor the nanoscale structural evolution of sol-gel derived thin films.     

Kinetic study on photochromism of WO3 aqueous sol and its enhancement accompanying spectral changes by the addition of TiO2 aqueous sol

Photochromism of a WO₃ aqueous sol has been investigated in a nitrogen atmosphere under controlled temperature. Effects of ageing of the WO₃ sols, concentrations of WO₃ sols or Cl⁻ ion and temperature on the coloring rate were examined. The coloring rate was the first-order with respect of the WO₃ concentration. The coloring process was accelerated by an addition of TiO₂ aqueous sols. Spectral changes were measured using the mixing sol with various molar ratios (γ) of WO₃ and TiO₂. The absorption spectra changed from those having the single peak at 775 nm to those with two peaks at 640 and 980 nm. Such spectral transformation was ascribed to the structural change of the WO₃ nanoclusters, depending on the γ value and the concentration of Cl⁻ ion.     

Effects of aging time on V2O5 sol-gel coatings

Vanadium pentoxide (V₂O₅) sols have been used in conductive coatings and related applications [1, 2, 3]; however, the changes which may occur in the properties of these coatings with sols of different ages have not been carefully shown. Properties which may be dependent on the age of the sol (sol viscosity, film morphology and conductance) were measured in this work. The coating sols were prepared by ion-exchange of sodium metavanadate solutions.It was found that the coating thickness, sol viscosity, and surface morphology of the coatings were directly related to the age of the sol used. The dried coating thickness increased from 3 microns to 20 microns over a 30 day period. The sol viscosity increased from 1 centipoise to near 2 centipoise. The surface morphology of the coatings changed from that of a featureless surface at day 1 to a continual coverage of micron-sized fibers as the coating sols aged. The conductivity of the coatings, though, was unaffected by the age of the sol. The coating properties were correlated to the amount of polymerization of dissolved precursors in solution.     

Preparation of Polycrystalline Antimonic Acid Films by Electrophoretic Deposition

Cubic antimonic acid (Sb₂O₅·nH₂O) films were successfully prepared on stainless steel and Si(100) substrates by electrophoretic deposition (EPD) using two types of sols. The sols were prepared by reacting an H₂O₂ aqueous solution with Sb(O-i-C₃H₇)₃ or metallic Sb powder. The resulting films were found to consist of fine particles of cubic Sb₂O₅·nH₂O single crystals with uniform particle sizes of 30 nm and 150 nm. The weight of the Sb₂O₅·nH₂O deposit on the anode Si(100) substrate by EPD increased linearly with the current density in the range of 0–0.67 mA cm^–2, when the sol pH was over 7. The proton conductivity of the polycrystalline Sb₂O₅·nH₂O discs, formed from the two types of sols, was evaluated by an ac impedance method at room temperature under controlled levels of relative humidity.     

Hydrolysis and Condensation Processes of Titanium iso-Propoxide Modified with Catechol: An NMR Study

The hydrolysis and condensation processes of titanium iso-propoxide modified with catechol (C₆H₄(OH)₂; H₂cat) have been investigated by ¹H, ¹³C and ¹⁷O nuclear magnetic resonance spectroscopy. The hydrolysis reactions of the modified titanium iso-propoxide in the system with Ti:tetrahydrofuran (THF):H₂O = 1:20:x (x = 1, 2 and 5 in a molar ratio) are essentially completed in the initial stage (<1 h), and the condensation reactions also proceed significantly during this stage. Upon hydrolysis with H₂O/Ti = 1, the iso-propoxy groups are selectively hydrolyzed and the catecholate groups remain bound to titanium. With H₂O/Ti = 2 and 5, both the iso-propoxy and catecholate groups are hydrolyzed, and the hydrolysis of the iso-propoxy groups is relatively preferential. Approximately half the catecholate groups are stably bound to titanium, even after hydrolysis with H₂O/Ti = 5.     

Synthesis of high surface area nanocrystalline anatase-TiO2 powders derived from particulate sol-gel route by tailoring processing parameters

Stabilised titania sols were prepared using an additive free particulate sol-gel route, via electrostatic stabilisation mechanism, with various processing parameters. Peptisation temperature, 50°C and 70°C, and TiO₂ concentration, 0.1, 0.2 and 0.4 molar, were chosen as processing parameters during sol preparation. Results from TiO₂ particle size and zeta potential of sols revealed that the smallest titania hydrodynamic diameter (13 nm) and the highest zeta potential (47.7 mV) were obtained for the sol produced at the lower peptisation temperature of 50°C and lower TiO₂ concentration of 0.1 M. On the other hand, between the sols prepared at 70°C, smaller titania particles (20 nm) and higher zeta potential (46.3 mV) were achieved with increasing TiO₂ concentration up to 0.4 M. X-ray diffraction (XRD) and Brunauer-Emmett-Teller (BET) results of produced powders annealed at different temperatures showed that the 300°C annealed powder made from 0.1 M sol prepared at 50°C was a mixture of anatase and brookite, corresponding to a major phase of anatase (∼95% estimated), with the smallest average crystallite size of 1.3 nm and the highest specific surface area (SSA) of 193 m²/g. Furthermore, increasing TiO₂ concentration up to 0.4 molar for the sols prepared at 70°C resulted in decreasing the average crystallite size (1.9 nm at 300°C) and increasing SSA (116 m²/g at 300°C) of the powders annealed at different temperatures. Anatase-to-rutile phase transformation temperature was increased with decreasing peptisation temperature down to 50°C, whereas TiO₂ concentration had no effect on this transition. Anatase percentage increased with decreasing both peptisation temperature and TiO₂ concentration. Such prepared powders can be used in many applications in areas from photo catalysts to gas sensors.