Synthesis and properties of high alumina cement-based porous composites in the ZrO2-CaO-Al2O3 system

IF 5.6 2区材料科学 Q1 MATERIALS SCIENCE, CERAMICS

Ceramics International Pub Date : 2025-09-01 DOI:10.1016/j.ceramint.2025.06.214

Yesica L. Bruni , María F. Hernández , Susana Conconi , Gustavo Suárez

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Abstract

Previous research showed that ZrO₂–CaO–Al₂O₃ (Z-C-A) composites presented high chemical stability, making them suitable as refractory materials. This work obtained porous composites based on CA₂–CZ and CA–CA₂–CZ phases using commercial high-alumina cement (HAC) and pure ZrO₂ powders with CaCO₃ and Al(OH)₃. The powder mixtures were dry-uniaxially pressed and sintered at 1300 and 1400 °C. The reaction was studied using thermal analysis techniques (TG-DTA). CaAl₄O₇ (CA₂), CaAl₂O₄ (CA), and CaZrO₃ (CZ) were the main phases formed in the ceramics, with c-ZrO₂ as a secondary phase. The sintering at 1400 °C promoted the in situ reactions, leading to the formation of the CA₂ and CZ phases and producing the reduction of the CA and c-ZrO₂ phase content. The high porosity determined in these composites (44–63 %) could be attributed to the thermal decomposition of gibbsite (Al(OH)₃) during calcination. In the ceramics with a high content of the CA₂ phase (66.7 and 76.7 wt% determined by Rietveld), the thermal expansion coefficient (CTE) reached a minimum value of ∼5.8 × 10⁻⁶ °C⁻¹, comparable to that of the mullite. The composite based on CA₂-CZ phases (sintered at 1400 °C) presented the highest flexural strength (37 MPa), attributed to its lower porosity and more homogeneous microstructure.

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ZrO2-CaO-Al2O3体系高铝水泥基多孔复合材料的合成与性能

前人的研究表明，ZrO2-CaO-Al2O3 （Z-C-A）复合材料具有较高的化学稳定性，适合作为耐火材料。本研究以商用高铝水泥（HAC）和纯ZrO2粉末（含CaCO3和Al(OH)3）制备了基于CA2-CZ和CA-CA2-CZ相的多孔复合材料。将粉末混合物在1300和1400℃下进行干式单轴压制和烧结。用热分析技术（TG-DTA）对反应进行了研究。CaAl4O7 （CA2）、CaAl2O4 （CA）和CaZrO3 （CZ）是陶瓷中形成的主要相，c-ZrO2是次要相。在1400℃下烧结促进了原位反应，导致CA2和CZ相的形成，CA和C - zro2相含量降低。这些复合材料的高孔隙率（44 - 63%）可归因于在煅烧过程中三水铝石（Al(OH)3）的热分解。在CA2相含量高（Rietveld测定为66.7 wt%和76.7 wt%）的陶瓷中，热膨胀系数（CTE）达到最小值~ 5.8 × 10−6°C−1，与莫来石相当。基于CA2-CZ相的复合材料（1400℃烧结）具有较低的孔隙率和较均匀的组织，具有最高的抗折强度（37 MPa）。

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来源期刊

Ceramics International 工程技术-材料科学：硅酸盐

CiteScore

9.40

自引率

15.40%

发文量

4558

审稿时长

25 days

期刊介绍： Ceramics International covers the science of advanced ceramic materials. The journal encourages contributions that demonstrate how an understanding of the basic chemical and physical phenomena may direct materials design and stimulate ideas for new or improved processing techniques, in order to obtain materials with desired structural features and properties. Ceramics International covers oxide and non-oxide ceramics, functional glasses, glass ceramics, amorphous inorganic non-metallic materials (and their combinations with metal and organic materials), in the form of particulates, dense or porous bodies, thin/thick films and laminated, graded and composite structures. Process related topics such as ceramic-ceramic joints or joining ceramics with dissimilar materials, as well as surface finishing and conditioning are also covered. Besides traditional processing techniques, manufacturing routes of interest include innovative procedures benefiting from externally applied stresses, electromagnetic fields and energetic beams, as well as top-down and self-assembly nanotechnology approaches. In addition, the journal welcomes submissions on bio-inspired and bio-enabled materials designs, experimentally validated multi scale modelling and simulation for materials design, and the use of the most advanced chemical and physical characterization techniques of structure, properties and behaviour. Technologically relevant low-dimensional systems are a particular focus of Ceramics International. These include 0, 1 and 2-D nanomaterials (also covering CNTs, graphene and related materials, and diamond-like carbons), their nanocomposites, as well as nano-hybrids and hierarchical multifunctional nanostructures that might integrate molecular, biological and electronic components.