Addition Of Cenosphere Research Articles

Effect of cenospheres on the proprieties of plain concrete exposed to elevated temperature

AbstractThe main objective of the study was to determine the effect of the use of cenospheres for C30/37 class concretes used in construction and road construction. As part of the research, four concrete mixtures were designed: three with the addition of cenospheres and one reference mixture, without the additive. In the three modified mixtures, 20, 40 and 60% of fine aggregate were replaced by cenospheres, respectively. Selected features of the mixtures were determined—consistency and density, as well as the strength properties of concrete. Strength tests were carried out after 28 and 56 days of maturation. Experimental tests of concrete after initial thermal treatment were also carried out at three selected temperatures: 300, 500 and 700 °C, with loading times ranging from 60 to 180 min. These times were selected in such a way that the samples could be heated in their entire volume. A separate group of experimental studies was microstructure studies, the aim of which was to assess the changes occurring in concrete under the influence of high temperatures and to try to justify why CS-I concrete containing cenospheres in the amount of 20% of concrete subjected to annealing at 300 °C has a higher compressive strength than the corresponding reference concrete. The negative influence of cenospheres on the strength of concrete after initial thermal treatment was unequivocally demonstrated. An increase in the amount of cenospheres causes a decrease in compressive strength. A similar negative relationship was also demonstrated in the case of non-heat-treated samples. Graphical Abstract

On low velocity impact response of Sandwich composite with jute/epoxy facesheet and cenosphere reinforced functionally graded Core: Experimental and finite element approach

AbstractThe assessment of energy absorption behavior has a vital role in determining suitability of lightweight composites for impact protection applications. This study focuses on evaluating the energy absorption characteristics of cenosphere reinforced epoxy syntactic foam core and jute epoxy facesheet sandwich composite subjected to low velocity impact. The syntactic foam is composed of lightweight cenospheres embedded within an epoxy matrix, resulting in a high‐strength and lightweight composite material. Low velocity impact tests were conducted using a drop tower apparatus to simulate realistic impact conditions. The impact force, energy absorption and damage mitigation of the syntactic foam specimens with varied weight percentage of Cenosphere (0%, 10%, 20% and 30%) were measured and analyzed to assess the energy absorption behavior. The gradation revealed that the weight of top layer when compared to bottom layer is 50.49%, 70.23% and 95.74% less in syntactic foam core with 10, 20 and 30 wt% Cenosphere respectively, indicating gradation. The study demonstrates that the addition of Cenosphere up to 20 wt% enhances the energy absorption capacity of the sandwich composites by 59.37%–93.44% compared to sandwich without Cenosphere reinforced core. However, beyond this threshold, a decline in energy absorption is observed when subjected to low‐velocity impact (LVI). Fractography analysis demonstrates that the incorporation of Cenosphere induces a rough fracture surface with deep river‐like topography, indicative of greater energy absorption during impact loading. This substantiates the conclusion that Cenosphere‐reinforced syntactic foams exhibit enhanced impact resistance, making them promising materials for structures subjected to low‐velocity impact events.Highlights Development of functionally graded core sandwich composite for low velocity impact applications. Assessing the performance of developed composites under low velocity impact loading. Determining the optimal weight percentage of cenospshere in functionally graded core. Studying the fractography of developed sandwich composites. Corelation between experimental and finite element studies.

Towards sustainable construction: Performance evaluation of slag-cenosphere geopolymers under different NaOH concentrations

The incorporation of industrial wastes into construction materials, such as geopolymers, is highly desirable to improve their environmental impact. The choice of source materials, such as slag and cenosphere, and the amount of activator used significantly impact the properties of geopolymers. For instance, including high-reactivity precursors and optimizing activator composition may enhance mechanical strength and durability. However, no studies have evaluated the effect of cenosphere addition on the properties of geopolymer composites. This research study aims to unveil the synthesis of a binary geopolymer material by integrating slag and cenosphere as precursors, activated by sodium silicate (Na2SiO3) and sodium hydroxide (NaOH). Geopolymer composites were prepared to assess the impact of cenosphere addition (by substituting the slag with cenosphere in different percentages of 25, 50, and 75 %) and NaOH concentration (specifically 6 M, 9 M, and 12 M) on the material's properties. Additionally, one conventional mortar with a water-to-cement ratio of 0.5 was also prepared. Compressive strength, ultrasonic pulse velocity (UPV), electrical resistivity, water absorption, density, and thermogravimetric analysis were conducted. Results showed that increasing the cenosphere percentage increased the water absorption and decreased the compressive strength, UPV, electrical resistivity, and density compared to the geopolymer mixture with 100 % slag content. However, up to 50 % substitution of cenosphere, the geopolymer mix performed better than conventional mortar. Notably, results suggest a potential increase in CO2 uptake due to the addition of cenosphere, further enhancing the environmental performance of geopolymer composites. The findings of this study suggest the potential use of slag-cenosphere geopolymer as an alternative and sustainable construction material.

Development of silica - cenosphere aerogel composites for thermal insulation applications

Novel aerogel composites were prepared by sol-gel process and dried by adding 5 to 15 weight percentage of cenosphere to silica aerogel prepared by subcritical drying process. Silica-cenosphere aerogels were calcined at 1200ºC, as α-cristobalite phase was formed in silica aerogel at 1200°C. At temperatures less than 1200°C only amorphous silica was found in silica aerogel. Microstructural analysis showed spherical shape in different sizes with micro pores in surface of cenosphere and popcorn-like structure in silica-cenosphere aerogels. Effect of cenosphere addition in silica aerogel was studied by FT-IR. The particle size and distribution of prepared aerogels and cenosphere were analysed by particle size distribution analyser. The average particle size of silica aerogel was found to reduce by increased addition of cenosphere. The nitrogen adsorption studies of cenosphere and silicacenosphere aerogels indicated type II isotherm which represents macroporous/nonporous unrestricted monolayer – multilayer adsorption. The powder flow behaviour of the cenosphere and prepared aerogels were found to be strongly dependent on the particle size and distribution. The compressive strength and thermal conductivity of all the samples were found to be dependent on the porosity and bulk density. Among all the samples, lower density and higher porosity was observed in SC15. The silica aerogel recorded the highest strength value and was reduced by the addition of cenosphere except for SC5. The thermal conductivity was also found to be lowered for silica-cenosphere aerogels than pure silica aerogel and was found suitable for thermal insulation application that do not require strength.

Evaluation of Mechanical and Wear Assessment of Al-1.2Si-0.75Fe/Mullite MMCs for Industrial Applications

The outline idea is based on saddling the high quality and wear capacities of eminent engineered fortifications, for example with the lightweight and minimal effort of preparing or squandering fiery remains. There is almost no writing which has considered the outline of Aluminium Matrix Composites (AMCs) with the utilization of fortifications of agro squander slag. The Scanning Electron Microscope (SEM) images of gleaming samples, the subsequent were examined. The distribution of strengthening flecks (Mullite (Al2O3 -SiO2 )) is recovered to be steady. Mullite specks are not confined to the grain frontiers. From the wear studies of Al4006 alloy, it was observed that there was more wear out of the surface when compared to Al4006/ Al2O3 -SiO2 composites. Wear tracks of Al4006 alloy show a tough face with extra grooves and ridges associated with wear tracks of Al4006/Al2O3 -SiO2 composites dispersion and binding of the Al2O3 -SiO2 in the composite could indeed be explained by the reduced wear rate. Also, the addition of cenospheres acts as a load-bearing material which protects the matrix from more wear out. Wear track investigation described more wear out and deep abrasive trenches in as-cast contrasted to that of composites which may be due to the lack of load-bearing reinforcing material (mullite) which worsens the material strength leading to more tear or wear out. Overall, from the current studies, it can observed that as the mullite particle reinforcement increases the matrix hardness, strength, and density increase. This study highlights the essential characteristics of the technique of liquid metallurgy and its application to Al4006 MMCs reinforced with mullite.

Development of 3D printable cenosphere‐reinforced polyethylene terephthalate glycol (PETG) filaments for lightweight structural applications

AbstractPresent research evaluates the feasibility of producing polyethylene terephthalate glycol (PETG) filaments reinforced with cenosphere (CS), which have great potential to develop syntactic foam composites (SFC) for several applications, that is, from automotive to aerospace. A melt flow extrusion technique was used to reinforce PETG with different weight fractions (i.e., 0, 10, 20, 30, and 40 wt%) cenosphere, and further, the thermal, mechanical, and physical properties of the prepared feedstocks were investigated in detail. Results indicated that Young's modulus, load‐bearing capacity, and ultimate tensile strength of PETG filament with 40 wt% CS were 1652.1 5 MPa, 76.91 1 N, and 31.97 1 MPa, respectively, which is similar to virgin PETG filament. In addition, the porosity of the CS‐reinforced PETG filaments decreased with increasing concentration of the CS in the PETG matrix. Such cenosphere‐filled filaments possess attractive thermo‐mechanical and physical properties to develop high‐quality SFC through additive manufacturing (AM) routine.Highlights PETG/cenosphere based 3D printing filaments were developed. The modulus and strength significantly improved by adding 40% cenosphere. The porosity decreased with increasing cenosphere weight fraction. Addition of cenosphere affected water absorption characteristics of filaments.

Synthesis of Cenospheres from Ash and Their Application

The possibility of improving the strength properties of concrete materials based on ash/slag waste from thermal power plants of Almaty (Kazakhstan) by adjusting their chemical composition is considered. An X-ray phase analysis, scanning electron microscopic (SEM) analysis, infrared analysis (IR), and elemental determination analysis (EDAX) of ash and slag wastes were carried out, and additives to correct their chemical composition were selected. The analysis of the conducted studies shows that the addition of polypropylene fiber leads to an increase in the compressive crack resistance compared to the composition of the mixture in which ash is present. The highest compressive strength in which cenospheres increase in strength characteristics is observed on samples modified with 7% cenospheres. It was found that the strength of the concrete with the addition of cenospheres increased by more than two times in comparison with a sample without additives.

Study on the characteristics of alkali-activated fly ash-slag improved by cenosphere: Hydration and drying shrinkage

Cenosphere is coal-based solid waste material, which has similar chemical compositions to fly ash. In this paper, the effect of the cenosphere on hydration kinetics and drying shrinkage characteristics of AAFS pastes were explored, and the action mechanism of the cenosphere was deeply revealed. The results showed that the hydration induction period was prolonged, the hydration exothermic rate was reduced or the peak value was delayed during the acceleration period, and the 72 h hydration degree of the sample was increased when mixed with the cenosphere. The incorporation of more than 20% cenosphere significantly reduced the drying shrinkage of AAFS pastes. Comparing the results of compressive strength, drying shrinkage, and pore structure, the most suitable content of the cenosphere is 20%. To significantly improve the drying shrinkage of alkali-activated materials, the content can also be increased. The action mechanisms of the cenosphere are shown as the filling effect, pozzolanic activity, and surface effect. The addition of cenosphere reduces the amount of C-S-H, C-A-S-H and N-A-S-H gel phases, but increases the formation of silicates (calcium hydrosilitates and calcium hydroaluminates).

Self-healing properties of lightweight high-toughness cementitious composites under dry-wetting cycles

Lightweight high-toughness cementitious composites (LHTCC) were induced to produce pre-cracks through bending and tensile loads, which were self-healed under dry-wetting cycles. Cementitious composites used silica sand as fine aggregate and without aggregate were used as the reference group to explore the influence of cenospheres as lightweight fine aggregate on the self-healing properties. The self-healing properties were evaluated with bending properties, tensile properties and capillary water absorption. The composition of healing products was tested by X-ray diffraction and thermo-gravimetric analysis. The results indicated that cenospheres effectively improved the self-healing ability of LHTCC compared with silica sand as fine aggregate. The flexural strength and ultimate deflection of the self-healed specimens were increased by 32.2% and 118.5%, respectively, compared with the original specimens. The self-healing products filled the cracks and pores of the specimens, thus significantly decreasing the sorptivity coefficient. The addition of cenospheres promoted the consumption of calcium hydroxide to generate calcium silicate hydrate and calcium carbonate crystals with a dense microstructure, thereby increasing the flexural strength and toughness of LHTCC after self-healing. Therefore, LHTCC integrate the advantages of lightweight, high toughness and self-healing ability, and it is expected to be an ideal choice for concrete structures.

Effect of cenosphere and specimen crack lengths on the fracture toughness of Al6061-SiC composites

Main aim of this work is to investigate the influences of the addition of cenosphere and specimen crack length on the fracture toughness of Al6061-SiC composites. The experimental analysis was carried out for 3, 6 and 9 wt% proportions of cenosphere with the 3 wt% of SiC as reinforcements in the aluminum 6061 matrix for various crack lengths. The fracture toughness of Al6061-SiC-Cenosphere hybrid composites was estimated using compact tension (CT) specimen for the said compositions. The CT specimens were prepared, according ASTM E399 standard, for different crack length to width (a/W=0.3-0.6) ratios. From the experimental outcomes, it is identified that the fracture toughness of the hybrid composite increases upto the 6wt% of cenosphere and further increment in the cenosphere causes the decrement in the values. It is also found that the load bearing capacity and fracture toughness of the hybrid composite decreases with increment in the a/W ratios of the CT specimen.

Influence of Filler Content on Tribological Behavior of Cenopshere Flyash Filled Bamboo Fiber Reinforced Composites

ABSTRACT Present work incorporates the fabrication of short bamboo fiber reinforced polymer composites with Cenosphere fly ash as a filler. Alkali treatment was given to the short bamboo fibers and the composite samples were fabricated using both the untreated and alkali treated fibers. Erosion wear behavior has been studied for both groups of composites. Air jet type test rig has been used for the erosion study following the design of experiments approach using Taguchi’s orthogonal arrays. Optimal parameter settings have been identified using the Taguchi approach to minimize the erosion rate. Influence of the input parameters (Impact angle, Impact velocity, Filler Content) has been investigated on the erosion resistance of composites and the variance has been studied using ANOVA. Surface morphology has also been studied to see the impact of erosion. Results have indicated that the wear rate of both category of composites is significantly affected by the size of erodent, impact velocity, impingement angle as well as the filler content. A major improvement in the erosion behavior of the samples have been reported with the addition of Cenosphere.

Review on strength and durability performance of cenosphere and flyash in light weight concrete

Nowadays, Lightweight concrete plays a major part in the construction industry. Lightweight concrete is preferred for many reasons because it improves sound insulation, it has good thermal properties, and it has low density. Cenosphere is a slight weight by -product from thermal power plants mainly composed of silica and alumina. The cenosphere is the lightest of cloth with lesser particular density and fly ash- based absolutely substances, so it can be synthesized into powder of immoderate fineness. This finely grinded cenosphere is currently applied in construction companies, manufacture of ceramic and slight weight composite, substances. Many researchers have already studied about the mechanical properties of cenosphere on concrete and distinct building substances. Even though there are various studies on addition of cenosphere to cement; it should be said that there was no software program studied on cenosphere on its effect on immoderate usual overall performance. This review article has been done to generate particular experimental data on the ability to use steady variation of fly ash and varying cenosphere as a cement alternative in elements in immoderate usual overall performance slight weight concrete. A by-product Fly Ash is formed from coal and made up of silicon dioxide and calcium oxide. Fly Ash is used in concrete to surge the performance, strength and stability of concrete. The use of flyash is one of the cost effective. The amount of Portland cement is reduced by using fly ash. It is used in the Portland cement has a lot of benefits and also improves the performance in fresh and hardened concrete state. Fly ash in cement mortar improves the workability and durability significantly. The purpose of the project is to use recycled industrial waste like fly ash to attain the strength and durability in lightweight concrete.

Experimental investigation of mechanical sustainability and acoustic performance of fly ash cenosphere/epoxy polymer composites

Hollow spherical fly ash cenosphere is a by-product of the coal firing process in thermal power plants and nowadays has become a substitute for the other organic fillers in the composite industry. The present study investigates the mechanical and acoustic performance of cenosphere/epoxy-based polymer composites. Void content, Shore Hardness, Tensile, Flexural, Impact, and Acoustic studies were conducted on epoxy specimens containing 0, 3, 5, and 7% of cenosphere by weight. Surface morphology and failure pattern of the tensile failure samples were investigated using the scanning electron microscope technique. Incorporation of cenosphere into epoxy reduced the void content from 4.27 to 2.54 % and increased the Shore hardness from 80.8 ± 1.44 to 85.8 ± 1.78 when the filler content was increased from 3 to 5%. Impact strength, Tensile and Flexural modulus showed an incremental trend with the increase in the weight percentage of the cenosphere. Examination of the tensile failure surface showed the presence of twist hackles and better interlocking of cenosphere with epoxy matrix. The density of the specimens played vital role in sound absorption characteristics. The addition of the cenosphere in epoxy deteriorates the sound absorption behaviour of the material as compared to neat epoxy.

Novel Pb alloys based composite foams containing hybrid pores produced by liquid metallurgy for lightweight batteries

High-quality novel Pb alloys based composite foams reinforced with fly ash cenospheres of different diameters in a variety of volume fractions were successfully synthesized by stir casting. Several crucial parameters such as wetting between the cenospheres and molten Pb alloy, volume fraction and size of the cenospheres, melt temperature, rate of cenosphere addition, stirring time and speed, foaming agent amount, foaming temperature and foaming time were optimized to produce high-quality composite foams. The microstructure of the composite foams revealed uniform cell distribution and size with mostly closed cell structure. The cells were measured to be of the size range of 290–430 μm. Microscopy and spectroscopy of the composite foams indicated that limited or no interfacial reaction products are formed between fly ash cenospheres and Pb alloys. The specific discharge electrical capacity of the composite foams was higher than those of the Pb alloys used in conventional Pb-acid batteries. Moreover, the weights of the composite foam electrodes were much lower than those of the conventional lead alloys, providing benefits in transportation applications. The cyclic voltammetric and galvanostatic polarization results indicated that the rates of oxidation of Pb into PbSO4 in the composite foam were much lower than those in Pb-grids and the oxidation of the Pb in the positive and negative grids occurred at much lower voltage than that in composite foams.

High-Temperature Solid-Particle Erosion Behaviour of Plasma-Sprayed Fe17Cr2Ni0.18C/Cenosphere-Based Composite Coating

The present investigation deals to improve the solid-particle erosion resistance of boiler steel material. FeCrNiC and FeCrNiC with 5, 10 and 15wt.% cenosphere composite coatings were deposited on A387 Grade 22 steel using plasma spray technique. Powder and as-sprayed coatings are characterized using Scanning Electron Microscope (SEM), X-ray diffraction to study the surface morphology and cross section to study the nature of coatings deposited. Microhardness and adhesion strength of the coatings are evaluated. High-temperature solid-particle erosion behavior of these coating is evaluated at 300 oC and 600 oC at different impact angles. FeCrNiC + 15%Cenosphere designates higher hardness and adhesion strength. Convention weight change method cannot be used to validate the erosion performance due to undesirable variation. Optical profiler is used to determine erosion volume loss. The FeCrNiC coatings with the addition of cenospheres showed better erosion resistance than as-sprayed FeCrNiC and substrate. FeCrNiC + 10%Cenosphere coating shows the highest erosion resistance as compared to other coatings and substrate. Further increase in cenosphere percentage leads to reduction in erosion resistance due to predominant brittle fracture. High-temperature erosion is a concurrent erosion–oxidation process which shows combination of ductile and brittle erosion mechanism.

Effect of Cenosphere Addition on Mechanical Properties of Bamboo and E-Glass Fiber Reinforced Epoxy Hybrid Composites

Cenosphere is a ceramic-rich industrial waste produced during burning of coal in the thermal power plants. This study deals with the effect of cenosphere as particulate filler on mechanical behaviour of woven bamboo-glass hybrid composites. The hybrid composite consists of bamboo and E-glass fiber as reinforcement and epoxy as matrix. Cenosphere of different weight percentage (0.5, 1, 1.5 and 2 %) was added to the hybrid composite. The samples were tested as per ASTM standards for their mechanical properties to establish the effect of filler content. It is found that the mechanical properties are significantly influenced by addition of waste ceramic filler cenosphere up to 2 wt.% and increases the tensile, flexural and inter-laminar shear strength in comparison to unfilled composite. Finite element analysis is also done using Midas NFX and the simulation results are compared with experimental results. From the results, it has been found that the experimental values obtained from tensile testing and flexure testing nearly matches with finite element values.

Dynamic mechanical analysis of 3D printed eco-friendly lightweight composite

Abstract Dynamic mechanical analysis (DMA) is conducted on 3D printed eco-friendly environmentally pollutant fly ash cenosphere/HDPE lightweight composite. Cenospheres with varying volume % are mixed with HDPE, filament extruded and fed to FDM based 3D printer. Higher crystallinity % is observed in prints compared to respective filaments owing to differential cooling rates in extrusion and printing. Crystallinity drops with cenosphere addition owing to pseudo lubricating effect. The crystallinity of prints is higher than their respective filaments. Storage (E′), loss modulus (E″), and damping (Tan δ) increase with increasing cenosphere content in printed lightweight composite. HDPE with 60 by volume % of cenospheres registered higher values, implying the potential of eco-friendly 3D printed lightweight composite to be utilized for weight-sensitive structures.

In vivo analysis of bone-tissue interface in medical grade titanium and porous titanium with and without cenosphere as space holder

The present study aims at understanding the in vivo behavior of titanium (Ti) foam (with and without addition of cenosphere as space holder) developed by powder metallurgy route which follows compaction at an applied pressure of 100 MPa and sintering at 1100 °C for 4 h. Cenosphere with the particle size 150–212 µm was used as spaceholder and its content was 20 wt%. The porosity content of the titanium foam developed in the present study with and without addition of cenosphere was 40% and 27%, respectively. However, they possess reduced yield strength in compression as compared to medical grade titanium. In vivo study was carried out by implanting the samples in bone defect of rabbit femur. All the titanium based samples were well-integrated within the host bone tissue which is revealed in radiography and micro-CT (µ-CT) images of the implants after three months of insertion. Fluorochrome labeling using oxytetracycline marker showed better and comparable new osseous tissue formation in medical grade Ti and porous Ti with cenosphere as space holder after three months as compared to porous Ti. The scanning electron microscopic image of the bone sample interface showed strong bonding with the signature of marginal bone in-growth inside the tissue. Finally, the in vivo behavior was correlated with initial microstructure and composition of the material. The performance of the titanium foam was evaluated by the detailed analysis of the physicochemical properties and in vivo behavior.

Fretting Wear Resistance of Titanium Foam Developed by Powder Metallurgy Route

Titanium foam is a promising material for bio-implant application because of its capability of minimizing the stress shielding effect at the interface between implant and host bone, in addition to its higher strength and weight ratio and shock absorbing capacity as compared to solid titanium and its alloys. In the present study, titanium foam has been developed by powder metallurgy route under optimum processing conditions with and without addition of cenosphere as space holder. Followed by the development of titanium foam (with and without addition of cenosphere), characterization and fretting wear behavior (kinetics and mechanism) has been studied using tungsten carbide as counter body. A detailed study of wear behavior shows that there is a significant decrease in wear rate due to fretting wear in porous titanium with 20 wt% cenosphere addition as compared to as received Ti6Al4V, porous titanium with 10 wt% cenosphere and without cenosphere. Coefficient of friction was also found to be reduced in porous titanium with cenosphere addition and 10 wt% cenosphere added titanium showed a maximum reduction in coefficient of friction. The mechanism of wear was found to vary with cenosphere content in the matrix.

Effect of Adding Cenospheres on Heat-Resistant Lightweight Concrete Properties

Results are provided for a study of the effect of adding cenospheres (coal combustion waste) on hydration of alumina cement and exothermic reaction parameters. It is established that an increase in addition of cenospheres retards cement hydration, and reduces specimen density after firing at 1200°C up to 40%, strength up to 60% and shrinkage up to 95% compared with control specimens. With respect to parameters for the relationship of strength and density an amount of 5 – 10% of cenospheres is the optimum.