Sintering Parameters Research Articles

Comparative study on manufacturing of EDM electrodes by laser sintering process

The abstract aims to investigate the comparative performance of Electrical Discharge Machining (EDM) and Selective Laser Sintering (SLS) with unconventional machining processes. Unconventional machining processes have gained significant attention due to their versatility and capability to fabricate intricate components with high precision. This study focuses on assessing the efficacy of EDM and SLS techniques in terms of data removal rate and relative wear volume. Electrical Discharge Machining (EDM) is a thermal erosion process that utilizes electrical discharges to remove material from a workpiece. In contrast, Selective Laser Sintering (SLS) is an additive manufacturing technique that employs a laser to selectively fuse powdered material, layer by layer, to build up a three-dimensional object. Both methods offer unique advantages in terms of precision, speed, and material compatibility. The performance evaluation of these techniques involves analyzing key parameters such as data removal rate, which measures the volume of material removed per unit time, and relative wear volume, which quantifies the wear on the tool or workpiece during the machining process. By comparing these metrics, insights into the efficiency and effectiveness of EDM and SLS can be gained, aiding manufacturers and researchers in selecting the most suitable method for specific applications. Through experimental investigations and data analysis, this study aims to provide valuable insights into the capabilities and limitations of EDM and SLS in unconventional machining processes. The findings will contribute to advancing the understanding of these techniques and optimizing their utilization in various industrial sectors, including aerospace, automotive, and biomedical engineering. The experimental analysis examines the impact of the Direct Metal Laser Sintering (DMLS) process parameter on sintering depth. The optimized parameters for AlSi10Mg alloy powder sintering were obtained using laser power at 162 W, scanning speed at 156 mm s−1, porosity at 20%, laser area size of 0.2 mm, and layer thickness of 1 mm.

Color Characteristics of High Yttrium Oxide–Doped Monochrome and Multilayer Partially Stabilized Zirconia upon Different Sintering Parameters

Abstract Objectives Sintering influences the optical properties of zirconia. This study examined the effect of altering sintering temperature and time of monochrome (Mo) and multilayer (Mu) 5 mol% yttria-partially stabilized zirconia (5Y-PSZ) on color characteristics. Materials and Methods Three hundred specimens (width × length × thickness = 10 × 20 × 2 mm) were prepared from Mo and Mu (with cervical [C], middle [M], and incisal [I] region) 5Y-PSZ and randomly sintered at decreasing (Td: 1,450°C), regular (Tr: 1,500°C), and increasing (TI: 1,550°C) sintering temperature, with extremely short (He: 10 minutes), ultrashort (Hu: 15 minutes), short (Hs: 30 minutes), and regular (Hr: 135 minutes) sintering time (n = 15/group). Color appearance (EW ), translucency parameter (TP), contrast ratio (CR), opalescence parameter (OP), and color appearance difference (∆E diff) were evaluated in the CIE L*a*b* system. Microstructures were evaluated by scanning electron microscope (SEM) and X-ray diffractometer (XRD). Statistical Analysis Analysis of variance (ANOVA) and Bonferroni comparisons were determined for significant differences (p < 0.05). Results Significant differences in color parameters upon zirconia type, sintering temperature, and sintering time, and their interactions were indicated (p < 0.05). Increasing sintering temperature and extended sintered time resulted in larger grain, reduced tetragonal-to-monoclinic phase transformation, and significantly increased the TP and OP, but decreased the CR and ∆E diff (p < 0.05). Decreasing sintering temperature and time led to clinically unacceptable color appearance. Conclusion Mo was found to be more translucent than Mu. To achieve the most favorable optical properties, increasing sintering temperature and extending sintering time are recommended. Decreasing sintering temperature is not suggested. However, shortened sintering time is feasible, but it needs sintering with increasing sintering temperature to achieve a promising color appearance.

Synthetic space bricks from lunar and Martian regolith via sintering

The prospect of establishing extra-terrestrial habitats using in situ resource utilization (ISRU) constitutes a long-term goal of multiple space agencies around the world. In this work, we investigate furnace sintering as a potential route for making building blocks—termed synthetic space bricks—using in situ regolith material. By systematically evaluating sintering parameters using a numerical lattice model, coupled with experimental observations and post-sintering characterization, we propose a process protocol for two lunar simulants (lunar highland simulant (LHS-1) and lunar mare dust simulant (LMS-1)) and one Martian simulant (mars global simulant, MGS-1). The resulting bricks demonstrate compressive strengths of up to 45 MPa under uniaxial loading, depending on the simulant used. These strengths are much greater than those typically mandated for structural applications under reduced gravity. Taking recourse to classical ceramic sintering studies, we infer particle-level sintering mechanisms indirectly by measuring temporal evolution exponents of sample dimensions. For all three simulants, volume diffusion appears to be the primary mechanism for particle coalescence. Our results clearly make a strong case for the use of sintering as a potentially scalable method for consolidating regolith into brick-like structures for construction and load-bearing applications in extra-terrestrial settings.

Densification of zirconia-based ceramics by non-conventional sintering processes and chemical pathways

The present work reports an overview of the main results we have obtained from non-conventional sintering approaches towards the densification of 3mol.% yttria stabilized zirconia (3YSZ), the lessons learned from these results, and open questions that still need to be addressed. A wide range of techniques have been developed in the field of ceramic sintering, both in high temperature regime with extreme heating rates (>10 000 °C/min), as well as in very low temperatures (<400 °C) regime involving chemical reactivity to activate sintering mechanisms. In this context, we have recently explored several of these methods in order to understand and control the different sintering parameters and their impact on microstructure, crystallinity, grain boundaries and defect chemistry. Due to its complex chemistry, 3YSZ is a playground for the exploration of sintering capabilities and their influence on ceramic properties. Our recent studies in this field are presented in the present work, highlighting the effect of high heating rates through Flash Spark Plasma Sintering ( Flash-SPS) and Ultra High temperature Sintering (UHS) on sintering, but also the combination of low temperature Cold Sintering Process (CSP) and the associated precursors chemistry, with Spark Plasma Sintering (SPS). It also shows the possible densification by reactive hydrothermal sintering, using hydroxide precursors, and the effect of High Pressure SPS (HP-SPS) on 3YSZ nanopowders. All of these results touch upon current trends in the field of sintering, and highlight the possibilities in terms of chemical reactivity of precursors and physical parameter control. In particular, they show the importance of defect chemistry, related to the sintering atmospheres and their impact on both microstructures and properties.

Development of red mud based sintered artificial aggregates with various industrial wastes

Red mud (RM) has drawn a lot of attention in the search for potential uses in the production of sintered artificial aggregate from industrial waste products. The main objective of the study is to produce an RM-based sintered artificial aggregate (SAA), with several blends (binary, ternary, and quaternary) using various industrial wastes. This study includes assessing the mechanical and physical properties of SAA as well as the sintering parameters in order to determine the appropriate material mix ratio. To achieve these objectives, a comprehensive experimental approach was adopted. A total of 35 different mixtures were formulated by incorporating various industrial wastes as binders and sintering additives. The green pellets were preheated at 105 °C for 24 h, and consecutively sintered at different temperatures, namely 700 °C, 900 °C, 1100 °C, and 1150 °C with a duration of 30 min. A compressive strength test was performed in order to find the mechanical property of SAA similarly water absorption and bulk density tests were conducted to find the physical properties of SAA. To characterize the SAA, scanning electron microscope analysis (SEM), X-ray diffraction (XRD) and energy dispersive x-ray analysis were conducted, and also data analysis was performed using Artificial Neural Network (ANN) tools, yielding accurate predictions. Successfully best compressive strength low water absorption SAA was produced. The best material weight mix ratio for the production of SAA was identified as (A18) RM: Fly Ash: Waste Glass Powder; 78:10:12. Out of all blends the ternary blend (A18) SAA exhibited impressive properties after 30 min of sintering at 1150 °C: high compressive strength of 22.92 MPa, water absorption of 4.26%, and bulk density of 1296.12 kg m−13. This was made possible by the high amount of Al2O3, SiO2, in the combination of fly ash, and waste glass powder with RM. SEM and XRD analysis also confirmed that the (A18) SAA achieved the best compressive strength, and low water absorption due to turning the surface and core area into a solid, reduced internal pores and formed quartz, and hematite phases. The findings of this study serve as a foundation for future work and pave the way for the development of sustainable construction materials.

Effect of the sintering parameters on the structure and mechanical properties of zirconia-based ceramics

The paper presents the results of an investigations of the sintered zirconia ceramics that have been stabilized with Y2O3 and CeO2. The initial powders were synthesized via decomposition of the fluoride salts, which determined morphological features and dimensions of the particles. The specific electroconsolidation process, performed using the modified spark plasma sintering device, allowed for the retention of the nanoscale grain sizes and related properties of the sintered ceramic composites. It was found that the as-obtained materials with cerium oxide exhibited high bending strength of 609 MPa, by ca. 33 % higher than that of yttria-stabilized ones (410 MPa). In turn, the best combination of hardness and fracture toughness, K1С = 5.8 МPа·m1/2 аnd Нv = 14.8 GPа, respectively, exhibited ZrO2+3 wt% Y2O3. This result can be attributed to the chemical composition and morphology of the powders, which in turn is influenced by the synthesis conditions and calcination time and temperatures, as well as to the sintering parameters. In particular, yttria-stabilized zirconia showed higher sensitivity to the variations of the sintering temperatures and holding times.

Impact of the sintering parameters on the grain size, crystal phases, translucency, biaxial flexural strength, and fracture load of zirconia materials

ObjectivesTo investigate the influence of the zirconia and sintering parameters on the optical and mechanical properties. MethodsThree zirconia materials (3/4Y-TZP, 4Y-TZP, 3Y-TZP) were high-speed (HSS), speed (SS) or conventionally (CS) sintered. Disc-shaped specimens nested in 4 vertical layers of the blank were examined for grain size (GS), crystal phases (c/t’/t/m-phase), translucency (T), and biaxial flexural strength. Fracture load (FL) of three-unit fixed dental prostheses was determined initially and after thermomechanical aging. Fracture types were classified, and data statistically analyzed. Results4Y-TZP showed a higher amount of c + t’-phase and lower amount of t-phase, and higher optical and lower mechanical properties than 3Y-TZP. In all materials, T declined from Layer 1 to 4. 3/4Y-TZP showed the highest FL, followed by 3Y-TZP, while 4Y-TZP showed the lowest. In 4Y-TZP, the sintering parameters exercised a direct impact on GS and T, while mechanical properties were largely unaffected. The sintering parameters showed a varying influence on 3Y-TZP. Thermomechanical aging resulted in comparable or higher FL. Conclusion3/4Y-TZP presenting the highest FL underscores the principle of using strength-gradient multi-layer blanks to profit from high optical properties in the incisal area, while ensuring high mechanical properties in the lower areas subject to tensile forces. With all groups exceeding maximum bite forces, the examined three-unit FDPs showed promising long-term mechanical properties.

Experimental study and characterisation of 316L stainless steel parts fabricated with metal fused filament fabrication

The 3D printing process of Fused Deposition Modelling (FDM) can be used for fabricating metal parts without the need of mold. Metal Material Extrusion uses metal-polymer composite filament in the 3D printer to extrude the green part, then a de-binding process for removing the polymer binder, and eventually, the sintering process under high temperatures for making a metallic part. A comprehensive research is conducted in which sintering parameters including heating rate, dwell time, and sintering atmospheres are varied for metal parts mechanical characteristics including tensile strength, ductility, and density. Moreover, sintering atmospheres including vacuum and argon are taken into consideration in this research study. The metal part is known as silver part which has exhibited a high mechanical strength of 540 MPa, a considerable density of 7.57 g/cm3, and a high hardness of 220 HV under a vacuum sintering atmosphere. Whereas the metal parts produced under argon atmosphere have shown comparatively low mechanical strength 424 MPa, density 7.1 g/cm3 and 177 HV. The results are compared with an industrial benchmark process where catalytic de-binding and sintering are used to achieve 500 MPa tensile strength, density 7.83 g/cm3, and 175 HV. Scanning Electron Microscopy reveals that grains are coarsened in a vacuum, and grains appear peeled off along with small pores in the boundaries. The industrial benchmark part has uniform and finer grains.

Preparation of coal gangue based foamed ceramics with SiC as blowing agent and study on its thermal insulation performance

The main objective of this study was to utilize coal gangue as the primary raw material and SiC as the foaming agent to successfully prepare foamed ceramics using the high-temperature foaming method. The study investigated the composition and crystal phases of the foamed ceramics formulation, the influence of sintering parameters on the microstructure and physical properties of the samples, as well as the reaction mechanisms during the foaming process. The experimental results showed that when the SiC addition amount was 2.5 wt%, the sintering temperature was 1230°C, and the sintering time was 60 min, the bulk density of the foamed ceramics reached as low as 0.414 g/cm3, with a compressive strength of 1.64 MPa and a closed porosity as high as 74.86%. Additionally, the water absorption and thermal conductivity were simultaneously reduced to 1.48% and 0.1968 W/(m·K), respectively. Besides maximizing the utilization of coal gangue, foamed ceramics also demonstrated excellent porous structure and physical properties, making them suitable for use as thermal insulation materials.

The effect of degree of sintering on the structural and mechanical properties of Si3N4–SiO2 glass ceramics

Silica-based glass ceramics have been extensively used in biomedical applications due to their superior biocompatibility and controllable properties. However, their low mechanical strength limits their application. This could be addressed by optimizing the crystalline phase which determines their final properties. Silicon nitride has attracted attention due to its combination of good mechanical and biological properties. Therefore, to combine the advantage of silica-based glass and silicon nitride ceramic, this study developed a silicon nitride-silicon dioxide (Si3N4–SiO2) glass ceramics. The effects of spark plasma sintering parameters on the structural and mechanical properties of Si3N4–SiO2 glass ceramics were investigated. Full densification was reached at a sintering temperature of 1300 °C, a holding time of 10 min and an applied pressure of 80 MPa (relative density = 99.19 %). No silicon oxynitride (Si2N2O) crystalline phase was formed in the sintered glass ceramics, as confirmed by XRD. The interface between the β-Si3N4 crystalline and amorphous SiO2 was investigated by HRTEM, and the results indicated that an amorphous interfacial oxide was formed at the interface. The mechanical properties increased with increasing sintering temperature, as a result of the increased density. The Si3N4–SiO2 glass ceramics sintered at 1500 °C exhibited the highest value of toughness and flexural strength, at 4.6 ± 0.28 MPa m1/2 and 360 ± 27 MPa. The indentation cracks observed by SEM showed that the large β-Si3N4 grains promoted crack deflection, while the equiaxed Si3N4 grains with a lower aspect ratio led to transgranular fracture. The mechanical properties of these Si3N4–SiO2 glass ceramics are comparable to commercial glass ceramics, indicating their promising aspects in biomedical applications.

Enhancing Transparency in Non-Cubic Calcium Phosphate Ceramics: Effect of Starting Powder, LiF Doping, and Spark Plasma Sintering Parameters

Our objective is to achieve a new good-quality and mechanically durable high-transparency material that, when activated by rare earth ions, can be used as laser sources, scintillators, or phosphors. The best functional transparent ceramics are formed from high-symmetry systems, mainly cubic. Considering hexagonal hydroxyapatite, which shows anisotropy, the particle size of the initial powder is extremely important and should be of the order of several tens of nanometers. In this work, transparent micro-crystalline ceramics of non-cubic Ca10(PO4)6(OH)2 calcium phosphate were fabricated via Spark Plasma Sintering (SPS) from two types of nanopowders i.e., commercially available (COM. HA) and laboratory-made (LAB. HA) via the hydrothermal (HT) protocol. Our study centered on examining how the quality of sintered bodies is affected by the following parameters: the addition of LiF sintering agent, the temperature during the SPS process, and the quality of the starting nanopowders. The phase purity, microstructure, and optical transmittance of the ceramics were investigated to determine suitable sintering conditions. The best optical ceramics were obtained from LAB. HA nanopowder with the addition of 0.25 wt.% of LiF sintered at 1000 °C and 1050 °C.

Research on the Preparation of Zirconia Coating on Titanium Alloy Surface and Its Tribological Properties

Titanium alloys have been widely used in aerospace and other fields due to their excellent properties such as light weight and high strength. However, the extremely poor tribological properties of titanium alloys limit their applications in certain special working conditions. In order to improve the tribological properties of titanium alloys, the zirconia coatings were prepared on the surface of a TC4 titanium alloy using the discharge plasma sintering method in this article. The influence of sintering parameters on properties such as density, adhesion, hardness, and phase composition, as well as tribological properties (friction coefficient, wear rate) were investigated, and the influence mechanism of the coating structure on its mechanical and frictional properties was analyzed. The results showed that, with the increase in sintering temperature, the density, bonding strength, and hardness of the zirconia coating were significantly improved. The zirconia coating prepared at a sintering temperature of 1500 °C and a sintering time of 20 min had the lowest friction coefficient and wear rate, which are 0.33 and 6.2 × 10−8 cm3·N−1·m−1, respectively. Numerical analysis showed that the increase in temperature and the extension of time contributed to the extension of the diffusion distance between zirconia and titanium, thereby improving the interfacial adhesion. The influence mechanism of different sintering temperatures and sintering times on the wear performance of zirconia coatings was explained through Hertz contact theory.

Modeling and characterization of sintered YSZ/NiO porous electrode structural properties using coarse-graining molecular dynamics method

In solid oxide fuel cell (SOFC), sintering of YSZ and NiO powders into porous anode plays a crucial role in determining its overall performance. In this study, a coarse-graining (CG) molecular dynamics (MD) model is developed to capture sintered half-cell composed of porous functional layer with NiO/YSZ particles and dense YSZ ceramic electrolyte layer with applied in anode-supported SOFC. The sintering process is simulated in two stages, i.e., heating process followed by temperature-holding process. This study also explores effects of sintering parameters (e.g., temperature, powder size and material compositions) on structural characteristics, including distribution of sintered triple-phase boundary (TPB) length, porosity, and pore size. It is found that structural properties vary mainly during the heating stage of sintering, while a higher sintering temperature leads to a larger TPB length and a lower porosity, while increasing in diameter ratio of the NiO powders to YSZ powders is advantageous for increasing TPB length, porosity and size pores for promoting electrode electrochemical activity. This work provides a bottom-up approach for potential optimization of SOFC fabrication condition and parameters.

Fabrication of High Thermal Conductivity Aluminum Nitride Ceramics via Digital Light Processing 3D Printing.

The sintering of high-performance ceramics with complex shapes at low temperatures has a significant impact on the future application of ceramics. A joint process of digital light processing (DLP) 3D printing technology and a nitrogen-gas pressure-assisted sintering method were proposed to fabricate AlN ceramics in the present work. Printing parameters, including exposure energy and time, were optimized for the shaping of green bodies. The effects of sintering temperature, as well as nitrogen pressure, on the microstructure, density, and thermal conductivity of AlN ceramics were systematically discussed. A high thermal conductivity of 168 W·m-1·K-1 was achieved by sintering and holding at a significantly reduced temperature of 1720 °C with the assistance of a 0.6 MPa nitrogen-gas pressure. Further, a large-sized AlN ceramic plate and a heat sink with an internal mini-channel structure were designed and successfully fabricated by using the optimized printing and sintering parameters proposed in this study. The heat transfer performance of the ceramic heat sink was evaluated by infrared thermal imaging, showing excellent cooling abilities, which provides new opportunities for the development of ceramic heat dissipation modules with complex geometries and superior thermal management properties.

Optimization of extrusion-based additive manufacturing of bronze metal parts using a CuSn10/Polylactic acid composite

As additive manufacturing gains widespread adoption across various industries, its application to traditional materials such as bronze remains relatively underexplored. Through a comprehensive assessment, this research investigates the extrusion-based additive manufacturing of bronze, utilizing a CuSn10/Polylactic Acid (PLA) composite filament for printing bronze green parts, followed by thermal debinding and sintering processes to produce metal parts. By systematically varying 3D printing, debinding, and sintering parameters, optimized conditions for manufacturing bronze metal parts are identified. The study evaluates key material properties including density, ultimate tensile strength, surface morphology, and electrical conductivity of the produced metal parts. Additionally, the influence of printing parameters on dimensional deviation and shrinkage for both bronze green and metal parts is analyzed. Overall, this research highlights the potential of additive manufacturing to revolutionize bronze production, offering valuable insights into optimized process parameters and the enhancement of bronze component properties for a wide range of industrial applications.

The effects of sintering temperature on the microstructural evolution and mechanical properties of yttrium hydride monoliths via spark plasma sintering

In recent years, yttrium hydride has garnered significant attention due to its remarkable thermal stability and potential for high hydrogen density. It is regarded as one of the most promising metal hydrides for use as a neutron moderator in microreactors. In this study, yttrium hydride monoliths were synthesized using yttrium hydride powder obtained through direct hydrogenation, facilitated by Spark Plasma Sintering (SPS) at temperatures ranging from 800 to 1200 ℃. The effects of SPS temperatures on the phase composition, microstructure, density, and mechanical properties of yttrium hydride monoliths were studied. The results show that the sintering temperature markedly impacts the hardness, pore evolution, grain size and precipitation of α-Y and Y2O3 phase. Notably, the hardness of the samples escalates significantly with an increase in sintering temperature below 1000 ℃, influenced by a reduction in both the number and size of pores. The occurrence of twin crystals, distribution of grain size and the phase-transformed particles of α-Y within the sintered sample may contribute to an increase in hardness. The procedures described herein affect developing important microstructure-property relationships, as well as correlations in the sintering parameters and mechanical properties.

Formation of HfCxNy by carbothermal reduction nitridation and their laser ablation behavior

Hafnium carbonitride (HfCxNy) powders have been successfully prepared by heating a mixture of fine-grained HfO2 and nano-carbon powders during 1873 K-2273 K in nitrogen. The carbothermal reduction nitrdation (CTRN) process is composed of two steps: (1) the formation of microporous HfC and (2) catalytic nitridation of microporous HfC. The results demonstrate that the as-prepared HfCxNy powder consists of a single phase and various nitrogen content through different sintering parameters. The mechanism consists of three stages: (1) Formation of cubic mixed crystal HfCxOy, (2) Transformation into microporous hafnium carbide, and (3) Crucially, microporous hafnium carbide catalyzes the activation and dissociation of nitrogen molecules, leading to the formation of HfCxNy. Additionally, we introduce a laser etching method to confirm the ultra-high-temperature melting behavior of HfCxNy. This study enhances our understanding of HfCxNy powders synthesis and their laser ablation performance, offering valuable insights for future material applications.

Microstructural evolution during densification process of neodymium-doped indium zinc oxide ceramic targets and application for high mobility films

Oxide targets are crucial materials for transparent conducting oxide (TCO) thin films used in optoelectronic devices. In this study, neodymium-doped indium zinc oxide (NdIZO) ceramic targets were prepared using an advanced pressureless oxygen atmosphere sintering process. By optimizing the experimental conditions, the best sintering parameters were obtained, resulting in dense, fine-grained, and uniformly microstructured NdIZO targets. The influence mechanism of different Nd doping concentrations on the phase composition, microstructure evolution, and electrical properties of the targets during the process of oxide composite powder, green body shaping, and sintering densification was analyzed in detail. The results showed that the pretreatment of the composite powder improved its dispersibility, and sintering activity. The NdIZO-2 target with an atomic ratio of Nd:In:Zn = 0.02:1:1, fabricated under optimal conditions, exhibited high density of 99.8 %, low resistivity of 5.2 mΩ cm, and an average grain size of about 3.9 μm, thereby demonstrating the best comprehensive performance. Moreover, the sputtered films prepared using NdIZO-2 targets also showed excellent properties with transmittance (T) of 88.1 %, electron mobility (μe) of 31.5 cm2/Vs, and resistivity (ρ) of 7.5 × 10−3 Ω cm. This work provides theoretical support for the preparation of high-quality indium zinc oxide (IZO) ceramic targets and their application in high-performance optoelectronic thin film devices.

Fabrication of micro-ultrasonic phased array electrode via electric field-driven printing method

The electrode is an important part of a micro-ultrasonic phased array, commonly fabricated by magnetron sputtering technology. However, with the expansion of the application field, the structures of the phased arrays are becoming more complex, making the traditional magnetron sputtering method no longer applicable, and the realization of micro-scale phased array electrodes by direct printing technology still faces great challenges. Herein, an electric field-driven direct printing method was proposed to fabricate micro-ultrasonic phased array electrodes. The influence of sintering parameters on the resistivity and the effect of printing parameters on the geometric size and surface morphology of the electrode were comprehensively explored, and the mathematical model between the electrode line width and the printing parameters was established. The final printed electrodes exhibit superior properties with a resistivity of 2.4 × 10−7 Ω⋅m , a surface roughness range of 460–550 nm, and a line width range of 125–480 µm. Additionally, a micro-scale electrode was printed on the piezoelectric ceramic with PZT-5 as the material, and after polarization treatment, the piezoelectric coefficient can reach 405 pC N−1, which proves that this method can be applied in the field of fabricating phased array electrodes.

Contrasting effects of various factors upon the properties of foam ceramics and the mechanisms of crystalline phase reconstruction and microstructure regulation

The application prospects of foam ceramics are closely linked to their properties; however, the influence mechanism of the raw material composition and sintering parameters on the properties of foam ceramics remains obscure. In this study, the properties of SiO2–Al2O3–Na2O–K2O-based foam ceramics at various sintering temperatures and sintering times, and with different SiC contents, ratios of Al2O3 to SiO2, and fluxing agent contents were determined. Significant discrepancies in the variation trends and strengths of different influencing factors were observed. To interpret these phenomena, the crystalline phases and microstructure of the foam ceramics were analyzed, and the results indicated that their compressive strength was jointly controlled by their crystal phases and microstructure; however, other properties depended only on the microstructure. Furthermore, analysis of the phase diagram and sintering process revealed that the chemical reactions between the basic materials varied, as the ratio of Al2O3 to SiO2 and the fluxing agent contents were varied, resulting in differences in the phase transition temperature, liquid phase content, and crystalline phases. Moreover, the sintering temperature, sintering time, and SiC content affected the microstructure of the foam ceramics by changing the liquid viscosity, reaction time, and foaming amount, respectively. Overall, our findings provide a theoretical basis for preparing foam ceramics with excellent properties.