Ceramic Processing Research Articles

Spark plasma sintering of boron carbide (B4C): From characterisation to finite element modeling of sintering

Boron carbide (B4C), known for its unique properties, presents challenges in reaching its full density with sintering process due to low diffusion coefficients. This study explores the application of Spark Plasma Sintering (SPS) to overcome these challenges and enhance the understanding of its impact on pure B4C ceramics. The study outlines a comprehensive methodology for developing an SPS sintering model. Starting with a summary of conducted studies, powder oxidation analysis, characterization methods, and dilatometry curves processing, the article details the derivation of constitutive parameters based on the Skorohod-Olevsky theory. Isothermal profiles at different temperatures, variation in heating regimes, and a stepwise approach for SPS pressure application form the basis of the derivation methods. A grain growth model is developed for a comprehensive simulation of sintering, incorporating microstructural analysis and parameter derivation. Finally, the article addresses the integration of this mechanical sintering model with thermal and electrical considerations into a finite element method (FEM) software for a holistic SPS modeling. Thermo-electrical considerations, including the Peltier effect, are also computed, providing a well-rounded understanding of the SPS process for B4C ceramics. This study contributes valuable insights to optimizing the SPS parameters to achieve enhanced densification and microstructure control in B4C ceramics.

Pushing the grain size limit of pressureless-sintered alumina nanocrystalline ceramics by non-oxidizing atmospheres

Nanocrystalline ceramics are of interest due to their refined grains and expected ductility, yet their pressureless sintering is challenging considering the large coarsening driving force and the coupled densification-coarsening kinetics. Of special interest is the pressureless sintering of alumina nanocrystalline ceramics, with fundamental significance to ceramic processing science and technology. Previously reported efforts offered dense alumina nanocrystalline ceramics with average grain size Gavg down to 34 nm and with a coarsening ratio β (defined as the ratio of average grain size after and before sintering) of 7.2 from nanoparticles to dense alumina ceramics, by synergistically optimized α-Al2O3 nanoparticles and pressureless two-step sintering in air. Here we further pushed Gavg down to 29 nm and β down to 5.8, by changing air to non-oxidizing atmosphere (e.g., N2, Ar, and vacuum). We identified pronounced difference in sintering kinetics in air versus in N2, Ar, or vacuum, which is unexpected for wide-bandgap, redox-insensitive oxide materials of alumina. With smaller initial nanoparticles (e.g., <3.5 nm) and better optimized sintering conditions, it may be possible to pressureless-sinter dense alumina ceramics with Gavg below 20 nm.

Analisis Biaya dan Dampak Lingkungan dalam Proses Produksi Keramik: Studi Kasus UKM ABC

ABC Ceramic Factory conducted the process of producing ceramic floor tiles, distributing them to ceramic shops, and then selling them to consumers. Several processes or stages, from manufacturing to distribution, still leave abandoned waste. This research aims to determine what costs in making ceramics at the ABC Ceramic Factory can be reduced to save on company costs. The methods used are Green Quality Function Deployment and AHP Methods. Based on the data processing results, the ceramic manufacturing process is efficient, and the ceramic color is long-lasting because it has the expected satisfaction values of 0.661 and 0.538. Then, recycling waste is the highest technical response, with a value of 0.24. At the same time, the production process is the stage that produces the most waste, with a value of 0.29, and raw material costs are the costs that can be reduced the most, with the highest value of 4+2-. Therefore, the ABC Ceramic Factory must improve from the manufacturing process to the final product.

Investigation of sintering properties and behavior of sericite ceramifying powder under low temperature

AbstractPolymer–ceramic composites are widely used in refractory cables. The ceramic fillers provide high temperature and fire resistance, while the polymer matrix provides flexibility and improved electrical insulation. The properties of the polymer–ceramic composites are determined by the ceramization‐forming properties of the corresponding ceramifying powders. Properties such as shrinkage, density, and porosity were characterized to compare the effects of different contents of glass powder. The sintering activation energy was calculated using the logarithmic relationship between shrinkage and holding time. The microstructure, cross‐section, and crystalline phases were investigated by scanning electron microscopy (SEM) and X‐ray diffraction analysis (XRD) to explore the ceramization process of sericite ceramifying powder. The ceramization process of ceramifying powder is proposed. The results show that during low‐temperature sintering, the glass powder and muscovite phases melt and partially transform into α‐quartz and albite low during cooling down.

Quality Control of Ceramic Wall Products Six Sigma Method with Dmaic Tools and Failure Mode and Effect Analysis (FMEA)

Considering the importance of increasingly rapid industrial development, business people must be aware of the orientation towards product quality. The manufacturing industry has an important role in industrial development. It is hoped that it will be able to grow and have advantages in industrial development, therefore it is necessary to improve and increase product quality. The company continues to strive to maintain and improve product quality and increase productivity so that customers are satisfied with the products produced. One way that needs to be done is to reduce the number of defective products in the production process. This effort is one way of continuous improvement carried out by PT. ABC and companies operating in the same field. The ceramic wall production process has relatively high demand but still has a high level of defects. Based on information on production data and data on the number of defects for the period January – September 2023, wall ceramic production has a defect rate of 3.86%. Companies must reduce the number of defects to achieve company targets. This research aims to improve the production process of wall ceramics by minimizing the number of defective products. This research uses the six sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) tool assisted by the FMEA (Failure Mode and Analysis) method. Corrective action to reduce defects based on the 5 Why analysis is to find out what the problem is and ask "why" and "what is the root of the problem". The research results show that there are 4 types of defects which have a large number of defects, namely Rupture Defects, Application Defects, Peeling Defects and Hole Defects. From the research results, solutions were obtained for the emergence of several types of defects in the wall ceramic production process, namely by providing planning suggestions and corrective actions which are discussed this time. At the defect calculation stage, Broken produces a DPMO value of 29.362 with a sigma level of 3.39 with a sigma level of 3.48, Defect Peeled produces a DPMO value of 28.044 with a sigma level of 3.38, and holes are defective. resulting in a DPMO value of 26,020 with a sigma value of 3.45 from the data calculation results, it is still not enough to meet the company's target at the sigma level, therefore the company must make quality improvements to achieve the main target at the sigma level.

Towards a debinding-free additive manufacturing of ceramics: A development perspective of water-based LSD and LIS technologies

Ceramic additive manufacturing (AM) requires a complex process chain with various post-processing steps that require expensive machines and special expertise. The key to further market penetration is AM that makes it possible to integrate into an already established ceramic process chain. Most successful AM technologies for ceramics are, however, based on processes that initially have been developed for polymeric materials. For ceramics AM, polymers or precursors are loaded with ceramic particles. This strategy facilitates the entry into AM, however the introduction of organic additives into the ceramic process chain represents a considerable technological challenge to ultimately obtain a ceramic component after additive shaping. In the present communication, two technologies based on ceramic suspensions will be introduced, the “layerwise slurry deposition” (LSD) and “laser induced slip casting” (LIS) technology. Both technologies take advantage of the high packing densities reached by conventional slip casting and moreover enable the processing of fines, even nanoparticles.

Evaluation of influence of thermoplastic slurry flow conditions on heat transfer coefficient during beryllium ceramic formation

The article presents the results of calculation of the influence of thermoplastic slurry flow conditions on the total heat transfer coefficient when forming ceramic products. Methods of detailed description of casting processes and thermal calculations have been developed to ensure reliable correspondence of calculated data and experimental results implemented on the basis of calculational experiment. The modeling of physical processes occurring during the formation of products allows you to discover new opportunities for improving the quality of castings by allowing you to more closely track the change in the temperature-phase fields of the process and clearly present the solidification kinetics depending on the casting modes. The speed of heat removal from the casting during the solidification period determines the rate of movement of the slurry, along with the temperature field on which the width of the transition region depends. These factors have a direct influence on the formation of the structure of beryllium ceramics. The study of the heat exchange process in the formation of ceramic products depending on temperature, heat at phase transition is the main task, since they largely determine the technological and operational characteristics of beryllium ceramics. The design data allows to determine the optimal conditions of the ceramic casting process and to obtain a solidified product with a uniform structure at the outlet.

Effect of lattice defects on crystal structure and microwave properties of Ba(Ga1/2Ta1/2)O3 doped Ba(Zn1/3Nb2/3)O3 ceramics

Traditionally, B-site cation ordering structure in Ba(B′1/3B″2/3)O3 based ceramics with complex perovskite structure is considered to be the dominant factor in determining the dielectric loss. The crystal structure of BZN-BGT ceramics changes to the B-site disordering from B-site 1:2 ordering accompanying with remarkably reduced dielectric loss. Ba(Ga1/2Ta1/2)O3 doping also inhibits the formation of Nb-rich secondary phases induced by Zn volatilization on the surface of BZN-BGT ceramics as well. The conductive activation energy Ea, an energy required for electrons to escape from the traps, increases to 0.55 eV from 0.40 eV, indicating the decrease of lattice defects concentration. As Ba(Ga1/2Ta1/2)O3 doping concentration increases, the dielectric thermal relaxation process of BZN-BGT ceramics weakens and the electrical conductivity decreases. These results indicate that the dielectric loss of BZN-BGT ceramics containing volatile Zn could be controlled by the lattice defects and secondary phases rather than B-site 1:2 ordering structure.

Microstructure and mechanical properties of a porous ceramic composite with needle‐like mullite and zirconia

AbstractPorous mullite ceramics have good properties for high‐temperature applications, but porosity gives place to ceramics with low mechanical strength, which restricts the service life in their potential applications. Therefore, performing modifications at the microscale to increase the mechanical strength has become a current challenge to expand its application fields. This work describes the properties of a porous mullite–zirconia composite produced by ceramic processing, using industrial kaolin and stabilized zirconia as raw materials. The growth of mullite needle‐like grains to reinforce the ceramic was promoted by the addition of a molybdenum oxide precursor. The effect of zirconia on the composite was analyzed through an experimental multi‐technique approach and considering a pure mullite sample, identically processed, as a reference. The novel composite has a porosity of about 50%, and presents a homogeneous microstructure, with interlocked mullite needle‐like grains and dispersed rounded zirconia grains. This morphology restricts the mullite tendency to shrink during sintering, giving the material a higher stiffness. In particular, the presence of zirconia in the composite improves both the flexural strength and the apparent Young modulus of the material (about 20% and up to 600%, respectively). These results encourage further investigations to establish this composite for different technological applications.

Degradation of sulfamethazine in coastal aquaculture tailwater by Na2S2O4@iron-electrode electrooxidation combined with ceramic membrane process

Offshore aquaculture's explosive growth improves the public food chain while also unavoidably adding new pollutants to the environment. Consequently, the protection of coastal marine eco-systems depends on the efficient treatment of wastewater from marine aquaculture. For the sulfamethazine (SMZ) of representative sulfonamides and total organic pollutants removal utilizing in-situ high salinity, this work has established an inventive and systematic treatment process coupled with iron-electrode electrochemical and ultrafiltration. Additionally, the activated dithionite (DTN) was being used in the electrochemical and ultrafiltration processes with electricity/varivalent iron (FeII/FeIII) and ceramic membrane (CM), respectively, indicated by the notations DTN@iron-electrode/EO-CM. Quenching experiments and ESR detection have identified plenty of reactive species including SO4·-, ·OH, 1O2, and O2·-, for the advanced treatment. In addition, the mass spectrometry (MS) and the Gaussian simulation calculation for these primary reaction sites revealed the dominate SMZ degradation mechanisms, including cleavage of S–N bond, hydroxylation, and Smile-type rearrangement in DTN@iron-electrode/EO process. The DTN@iron-electrode/EO effluent also demonstrated superior membrane fouling mitigation in terms of the CM process, owing to its higher specific flux. XPS and SEM confirmed the reducing membrane fouling, which showed the formation of a loose and porous cake layer. This work clarified diverse reactive species formation and detoxification with DTN@iron-electrode/EO system and offers a sustainable and efficient process for treating tailwater from coastal aquaculture.

Laser-Induced Graphene/h-BN Laminated Structure to Enhance the Self-Lubricating Property of Si3N4 Composite Ceramic

Incorporating graphene as ceramic additives can significantly enhance both the toughness and self-lubricating characteristics of ceramic matrices. However, due to the difficult dispersion and easy agglomeration of graphene, the preparation process of composite ceramics still faces many problems. In this study, a laminated laser-induced reduced graphene oxide/hexagonal boron nitride (L-rGO/h-BN) was introduced as an additive into a silicon nitride matrix, then a silicon nitride/reduced graphene oxide/hexagonal boron nitride (Si3N4/L-rGO/h-BN) ceramic composite was successfully synthesized using Spark Plasma Sintering technology. This approach led to enhancements in both the mechanical and self-lubricating properties of silicon nitride ceramics. This is due to the good monodispersity of the incorporating graphene in the silicon nitride matrix. The flexural strength and fracture toughness of the ceramic composite experienced notable increases of 30.4% and 34.4%, respectively. Tribological experiments demonstrate a significant enhancement in the self-lubricating performance of ceramic composites upon the incorporation of L-rGO/h-BN. The coefficient of friction and wear spot diameter experienced reductions of 26.6% and 21%, respectively. These improvements extend the potential industrial applications of Si3N4/L-rGO/h-BN ceramic composites. Throughout the friction process, the evenly exposed rGO and h-BN demonstrate an effective self-lubricating effect on the wear surface. This research paves the way for a novel approach to fabricating high-performance self-lubricating structural ceramics.

Production of ceramic alumina scaffolds via ceramic stereolithography with potential application in bone tissue regeneration

Scaffolds are devices that mimic the characteristics of the extracellular matrix; they are highly porous, with well-distributed and interconnected pores. Tissue engineering proposes scaffolds as an alternative treatment for different diseases and injuries affecting bone tissue. Triply periodic minimal surfaces (TPMS) are geometric structures whose characteristics fit well with the scaffold’s requirements. Ceramic stereolithography enables the production of these complex geometries with high precision using ceramic materials. Alumina (Al2O3) is a well-known ceramic material appreciated for its chemical and mechanical stability properties. The biomedical use of alumina as an alternative to replace metallic parts in bone components has been increasing. In this work, a suspension of alumina particles in a photopolymerizable resin is developed in order to be implemented in the printing of ceramic scaffolds with TPMS-type geometries by ceramic stereolithography for potential biomedical applications. The resin used was characterized in a different work by TGA and FTIR (Duque et al., 2023) and is acrylic in nature, also the alumina particles were characterized by DTP and XRD, these are micrometer sized and a showed an α-alumina phase with a high degree of crystallinity. The rheological behavior of the suspension was studied with ceramic load percentages of 35, 40, and 50 vol% in order to choose the most favorable conditions for piece printing. The three suspensions presented low viscosities, being the 50 vol% sample the one that presented the highest viscosity, with an average value of 0.77 Pa s. These viscosities were suitable for the ceramic stereolithography printing process. The 50 vol% suspension was characterized by TGA and DSC and did not show any difference compared to the resin without particles. Scaffolds with TPMS Gyroid and Schwartz P geometry were obtained by ceramic stereolithography and characterized morphologically and mechanically before and after sintering. The thermal treatment was successful. The polymer-ceramic scaffolds before sintering exhibited better compression resistance than the sintered ones. Fully ceramic scaffolds with gyroid geometry showed compressive strength values of 0.4 MPa, which is comparable to human trabecular bone. The best compression resistance was for the samples with the gyroid geometry. Since the 50 vol% sintered scaffolds with gyroid geometry showed better mechanical results, they were impregnated with propolis extracts from the Arauca region of Colombia in order to evaluate their antimicrobial activity against the standard strains Staphylococcus aureus (ATCC 29212) and Escherichia coli (ATCC 25922). The evaluated scaffolds exhibited better antibacterial activity against the S. aureus strain. After sintering, the 50Al scaffolds were submitted to a degradation test in phosphate-buffered saline (PBS) to assess the chemical stability of the alumina. The results indicated that the samples maintained their initial weight throughout the testing period, with measurements taken on days 1, 5, 8, and 12 showing no significant changes in weight loss percentage. This stability suggests that the alumina scaffolds possess robust chemical resistance under the tested conditions.

Rheology and Printability of a Porcelain Clay Paste for DIW 3D Printing of Ceramics with Complex Geometric Structures.

The modeling of ceramics with complex geometric structures currently depends on the handcrafted mode, with long cycles, high costs, and low efficiency; additive manufacturing (AM) technology can solve this problem well. Herein, the porcelain clay paste was successfully prepared for the direct ink writing (DIW) 3D printing process of ceramics with complex geometric structures, and the effects of sodium citrate (SC) content on the rheological properties and DIW 3D printability of the porcelain clay paste were investigated in detail. The SC has a vital role in the rheological behavior of porcelain clay paste. Adding SC increases the absolute zeta potential and decreases the viscosity of the paste, while a high SC content will lead to a low storage modulus of the paste. The porcelain clay paste with an SC content of 0.05% and a paste solid content of 75% possesses suitable rheological properties and a storage modulus for DIW 3D printing. The as-prepared porcelain clay paste has high DIW 3D printability at a pressure of 0.5 MPa, and a 3D-printed green body with a well-densified structure can be achieved. After being sintered, the 3D-printed ceramic exhibits high densification and mechanical properties. A green body with complex geometric structures is quickly and precisely modeled by the DIW 3D printing process with the resultant porcelain clay paste as the raw material. This work provides a practical approach to rapidly fabricating ceramics with complex geometrical structures.

Phase equilibria study and thermodynamic assessment of CaO–MgO–P2O5 system

The phase diagram of the CaO–MgO–P2O5 system was established by both experimental investigation and thermodynamic assessment. The presence of the contentious binary compound Ca4P6O19 in the CaO–P2O5 system was confirmed. The phase relationships in the CaO–MgO–P2O5 system at temperature 1150 °C and 1200 °C were studied via high-temperature quenching experiments in conjunction with X-ray diffraction (XRD) and electron probe micro-analyzer (EPMA) techniques. The CaO–MgO–P2O5 system was critically evaluated and optimized by means of the CALPHAD (CALculation of PHAse Diagrams) methodology. The ionic two-sublattice model (Ca+2, Mg+2)P (O−2,PO3−1,PO4−3,PO7/2−2,PO5/2)Q is used to describe the liquid phase in the CaO–MgO–P2O5 system due to the ionic nature of oxide melts and the presence of ions with different charges. A set of self-consistent thermodynamic parameters were obtained, showing good agreement between the experimental data and the calculated results. This study holds significant implications for guiding the manufacturing processes of phosphate ceramics.

Effect of solution temperature on the microstructure and properties of ceramic coating on the surface of 2024 aluminum alloy

This study investigates the influence of the 2024 aluminum alloy was treated with solution before ceramic treatment on the microstructure and characteristics of ceramic coatings applied to 2024 aluminum alloy substrates. The microhardness, corrosion resistance, and microstructural properties of these ceramic coatings were assessed using a microhardness tester, an electrochemical workstation, and a scanning electron microscope. The findings indicate that pre-treatment involving solution treatment significantly enhances the hardness and corrosion resistance of 2024 aluminum alloy ceramic coatings. Notably, when the solution temperature was maintained at 460 °C, the most rapid decrease in current density was observed during the ceramization process, resulting in the attainment of the lowest final stable current density. This particular condition yielded ceramic coatings with optimal hardness and corrosion resistance, with hardness exhibiting a remarkable increase of 48.9 HV, self-corrosion potential rising by 0.207 V, and polarization resistance surging by 5310.7 Ω. Moreover, the surface of the ceramic coating displayed remarkable smoothness and was devoid of discernible defects such as cracks or looseness. In light of these findings, it can be concluded that the optimum solution temperature for achieving these desirable properties is 460 °C. This conclusion is derived from a comprehensive analysis encompassing both the morphology and corrosion resistance of ceramic coatings.

Effect of crystalline phase formed by compound flame retardant on the flame retardancy and ceramization of polyethylene composites

AbstractCeramic polyolefin composites have the capability to transform into hard ceramics when exposed to fire conditions. During the ceramization process, the formation of new crystalline phase plays a crucial role in enhancing flame‐retardant and ceramifiable properties. Consequently, ceramic polyolefin composites show great potential for the applications in fire‐resistant wires and cables. In this article, the incorporation of the compound flame retardant consisting of ammonium polyphosphate/melamine cyanurate/zinc borate (APP/MCA/ZB) was found to enhance the flame retardancy and ceramization of polyethylene/wollastonite fiber/phosphate glass frits (PE/WF/PGF) composites. The results indicated that ceramifiable flame‐retarding PE composites with compound flame retardant exhibited superior flame retardancy compared to pure PE and PE composites with a single flame retardant. Specifically, the limiting oxygen index (LOI) was significantly increased to 26.8%, and the vertical combustion test rating in UL‐94 (test for flammability of plastic materials for parts in devices and appliances) reached V‐0. During the heating process, ZB thermally decomposed to produce 2ZnO ⋅ 3B2O3, which reacted with CaSiO3 to form a silicate glass intermediate phase (CaO ⋅ SiO2 ⋅ 2ZnO ⋅ 3B2O3). APP thermally decomposed to produce (HPO3)n, which reacted with 2ZnO ⋅ 3B2O3 to form a phosphate glass intermediate phase (nP2O5 ⋅ 2ZnO ⋅ 3B2O3). These two glass phases experienced a eutectic reaction with WF, ultimately producing the formation of a new crystalline phase of calcium zinc phosphate (CZP, Ca19Zn2(PO4)14). This newly formed CZP phase made sintered ceramics more compact and had higher flexural strength. The flexural strength of ceramic residues after sintering was 11.68 MPa, meeting the requirements for practical applications.

Bi compensation and poling process to enhance piezoelectric properties of BiFeO3-BaTiO3 lead-free piezoceramics

BiFeO3-BaTiO3 (BF-BT) ceramics are an excellent choice for high-temperature lead-free piezoelectric ceramic due to their high Curie temperature and good piezoelectric properties, but the volatilization of Bi leads to the formation of A-site cationic vacancies and oxygen vacancies, culminating in heightened leakage currents and detrimental effects on piezoelectric properties. In this study, a chemical composition of 0.70Bi(1+x)Fe0·97Al0·03O3-0.30BaTiO3 ceramics, abbreviated as B1+xFA-BT, where 0 ≤ x ≤ 0.05, were synthesized, with special attention on the effects of Bi compensation and poling process on their insulation and piezoelectric properties. Due to the coexistence of R-PC phases and low leakage current, B1+xFA-BT ceramics exhibit excellent piezoelectric properties and high Curie temperature, among which the B1.02FA-BT ceramic boasts optimal overall properties: d33 = 196 pC N−1, TC = 480 °C, kp = 34%, θmax = 49.5° and Qm = 32, under optimal poling parameters Ep = 50 kV cm−1 and Tp = 100 °C. The poling process is directly linked to the reorientation of domains, the redistribution of positive/negative space charge and the aggregation or injection of holes, which is achieved by tuning the poling field and temperature in a ceramic with optimal integrated piezoelectric properties. The poling process of BF-BT ceramics is significantly influenced by their leakage characteristics, which can have a significant impact on their overall performance. Optimizing electrical poling conditions and minimizing leakage current is crucial to achieving favorable piezoelectric properties in BF-BT ceramics with R-PC coexisting structures.

How to Improve the Curing Ability during the Vat Photopolymerization 3D Printing of Non-Oxide Ceramics: A Review.

Vat photopolymerization (VP), as an additive manufacturing process, has experienced significant growth due to its high manufacturing precision and excellent surface quality. This method enables the fabrication of intricate shapes and structures while mitigating the machining challenges associated with non-oxide ceramics, which are known for their high hardness and brittleness. Consequently, the VP process of non-oxide ceramics has emerged as a focal point in additive manufacturing research areas. However, the absorption, refraction, and reflection of ultraviolet light by non-oxide ceramic particles can impede light penetration, leading to reduced curing thickness and posing challenges to the VP process. To enhance the efficiency and success rate of this process, researchers have explored various aspects, including the parameters of VP equipment, the composition of non-oxide VP slurries, and the surface modification of non-oxide particles. Silicon carbide and silicon nitride are examples of non-oxide ceramic particles that have been successfully employed in VP process. Nonetheless, there remains a lack of systematic induction regarding the curing mechanisms and key influencing factors of the VP process in non-oxide ceramics. This review firstly describes the curing mechanism of the non-oxide ceramic VP process, which contains the chain initiation, chain polymerization, and chain termination processes of the photosensitive resin. After that, the impact of key factors on the curing process, such as the wavelength and power of incident light, particle size, volume fraction of ceramic particles, refractive indices of photosensitive resin and ceramic particles, incident light intensity, critical light intensity, and the reactivity of photosensitive resins, are systematically discussed. Finally, this review discusses future prospects and challenges in the non-oxide ceramic VP process. Its objective is to offer valuable insights and references for further research into non-oxide ceramic VP processes.

STUDY OF THE PERFORMANCE OF PLUNGER PUMP VALVES OPERATED IN AGGRESSIVE ENVIRONMENTS

Reciprocating plunger pumps are crucial for various industrial sectors, including chemical processing, well cementing, oil and gas production, and wastewater management. These pumps play a vital role in handling a range of fluids, making them indispensable for maintaining efficient and reliable operations in these demanding applications. These environments often involve handling aggressive fluids that can cause significant wear and corrosion to pump components, particularly the valves. Selection the right materials for valve manufacturing is essential to maintain the reliability, performance, and durability of plunger pumps operating in harsh environments. This ensures that the pumps can withstand extreme conditions while maintaining their efficiency over time. This research offers an in-depth review of the materials typically used for manufacturing plunger pump valves, with a focus on their performance in demanding environments. The research highlights the importance of material properties such as wear resistance, corrosion resistance, hardness, and mechanical strength. It evaluates various materials, including cast polyurethane, industrial ceramics such as silicon nitride and silicon carbide, and advanced coating techniques with nickel, chromium, and ceramic layers, to determine their effectiveness in harsh environments. Cast polyurethane is recognized as an optimal material due to its superior physical and mechanical properties, minimal shrinkage, and excellent chemical resistance. It excels in managing abrasive media and high-viscosity fluids, making it highly suitable for diverse industrial applications. Industrial ceramics, such as silicon nitride and silicon carbide, are distinguished by their ability to withstand high temperatures, resist corrosion, and offer low friction coefficients. Materials like silicon nitride and silicon carbide demonstrate exceptional performance in conditions where traditional metals and polymers fail. Moreover, applying advanced coatings, such as nickel-chromium-ceramic layers, to steel components significantly improves the durability and corrosion resistance of plunger rods and other critical parts. Keywords: plunger pump valves, aggressive environments, operational efficiency, material selection.

Applying Blockchain, Causal Loop Diagrams, and the Analytical Hierarchy Process to Enhance Fifth-Generation Ceramic Antenna Manufacturing: A Technology–Organization–Environment Framework Approach

This study used a technology–organization–environment (TOE) framework as the primary analytical tool to explore the burgeoning capabilities of blockchain technology in the area of 5G ceramic antenna development. A causal loop diagram (CLD) analysis is used to further clarify the complex dynamics and feedback mechanisms, and the impact of blockchain on the design, production, and deployment phases of ceramic antennas, which play a pivotal role in the development of 5G communications, is studied. We found that blockchain’s unique features, including its immutable ledger and decentralized architecture, have the potential to significantly improve the transparency, security, and efficiency of the ceramic antenna manufacturing process. Technology (T), organization (O), and environment (E) were used as the top factors, and the subfactors of TOE were selected and analyzed using the Analytic Hierarchy Process (AHP) by CLD. The AHP analysis was used to evaluate the relative importance of various internal and external factors affecting the adoption of blockchain technology. The integration of the TOE framework with AHP and CLD provides a comprehensive analytical tool that enhances the understanding of the complex dynamics in the 5G ceramic antenna manufacturing process. This methodological approach not only clarifies the interactions between technological, organizational, and environmental factors but also facilitates strategic decision-making through a structured evaluation of these factors. The AHP analysis showed that technical factors are the most important in the TOE analysis of 5G ceramic antenna manufacturing, with a weight of 0.427, which indicates the important role of technical factors in the development of ceramic antenna production. In addition, environmental and organizational factors were given weights of 0.302 and 0.271, respectively, confirming the importance of technological innovation and internal process optimization. In the subfactor of Technology (T), ‘Blockchain Technology’ has the highest ranking among the subfactors, with a global weight value of 0.129, emphasizing the importance of blockchain technology. This study explored the technical and organizational complexities of introducing blockchain technology into the 5G ceramic antenna manufacturing industry and, through an in-depth investigation of the potential benefits of such integration, it aims to propose new approaches to improve quality control and manufacturing efficiency. The research findings aim to contribute to the sustainable growth of the telecommunications industry by providing strategic recommendations for the application of blockchain technology in the production of 5G ceramic antennas.