Manufacturing and Processing of Advanced Ceramic Materials: Processing of Carbides, Borides, and Nitrides
Program Organizers: Bai Cui, University of Nebraska Lincoln; James Hemrick, Oak Ridge National Laboratory; Mike Alexander, Allied Mineral Products; Eric Faierson, Iowa State University; Keith DeCarlo, Blasch Precision Ceramics
Wednesday 2:00 PM
October 12, 2022
Room: 410
Location: David L. Lawrence Convention Center
Session Chair: Dongsheng Li, Advanced Manufacturing LLC; Zilong Hua, Idaho National Laboratory
2:00 PM Invited
Current Progress in Synthesis and Design of Ternary Phases: Surojit Gupta1; 1University of North Dakota
MAX and MAB phases have attracted a lot of attention due to their unique properties like damage tolerance, oxidation resistance, electrical/thermal conductivity, hardness and other attributes. In this invited presentation, I will present some of the recent developments from my research group on greening of manufacturing of these phases. Detailed microstructural characterization and phase analysis will be presented as a part of this presentation.
2:30 PM
Ultra-fast Densification of UHTC ZrB2: Santanu Mondal1; Juan Shiraishi1; Sreenivasulu Gollapudi1; Carolina Galdeano1; Jie-Fang Li1; Dwight Viehland1; 1Virginia Polytechnic Institute
Ultra-fast sintering (UFS) is a joule heating technique, by which an extremely high heating rate is achieved. We have utilized UFS to sinter ZrB2 in seconds in an energy-efficient way. ZrB2 is an ultra-high temperature ceramic (UHTC) And due to high melting temperature, hardness, strength, thermal conductivity, and oxidation resistance, ZrB2 is a potential candidate for high temperature structural components for various commercial and strategic applications. In this work, commercial ZrB2 powder was rapidly sintered via UFS to 93% relative density within 60 second in vacuum without pressure. The UFS ZrB2 was characterized by XRD, SEM, and EDS techniques. The effect of time, voltage and intensity on densification and microstructural evolution was studied. Key samples were further characterized by indentation and oxidation to evaluate the resulting microstructures. Results show that this sintering technique has the potential to produce UHTC with similar attributes to the current-state-of-art.
2:50 PM
Investigation of Lamination Approaches for SiC-filled Thermoplastic Polymer Blends: Olivia Brandt1; Rodrigo Orta1; Rodney Trice1; Jeffrey Youngblood1; 1Purdue University
Ceramic co-extrusion is a ceramic forming technique where a feedrod of a ceramic/polymer mixture is heated and extruded through a reduced cross-section, reducing the size but retaining the symmetry of the original feedrod. The co-extrusion process often involves a rebundling of ceramic/polymer extrudates or a “lamination” step via warm pressing to form the final component. Lamination is critical to the overall strength as any delaminations between adjacent exudates will manifest as cracks in the final sintered body. The aim of this presentation is to describe the mechanisms that cause delamination between warm-pressed ceramic-filled thermoplastic extrudates and to present approaches to mitigate this delamination. The approaches studied varied the thermoplastic blend compositions, the surface topography (e.g. surface roughening prior to warm pressing), and the binder burnout process. Mechanical tests and crack investigations were used to gain insight those variables that most contributed to successful lamination, and ultimately, crack-free sintered bodies.
3:10 PM
The Optimization of Field Assisted Sintering Technology and Processing for Ultrahigh Temperature Ceramics for Extreme Environments: Patrick Albert1; Erik Furton; Petr Kolonin2; Robert Slapikas1; Allison Beese1; Douglas Wolfe1; 1The Pennsylvania State University; 2The Applied Research Laboratory at Penn State
Development of next generation ultrahigh temperature (UHT) materials are required for disruptive advancements in several application spaces such as hypersonics and nuclear reactor technology. However, traditional material processing techniques, such as hot isostatic pressing, have challenges densifying components with optimized microstructures. These simplistic manufacturing techniques reduce processing flexibility associated with optimizing material design to tailor properties and performance. This study investigates field assisted sintering technology (FAST) to rapidly sinter binderless HfC, TaC, and (Hf,Ta)C, and evaluates the effect processing parameters (pressure, temperature, and time) have on structure-property-performance relationships for UHT materials in hypersonic environments. Fabricated FAST samples were characterized to examine microstructure, composition, phase, mechanical properties, oxidation kinetics, and high heat flux tolerance as a function of sample homogeneity. Three-point bend tests, Vickers, and nanoindentation have demonstrated that binderless high density carbides possess superior mechanical performance. The results show FAST is an optimal technique to manufacture next generation UHT materials.
3:30 PM Break
3:50 PM
Development of Textured UHTC Borides Using Extremely Low Magnetic Fields: Juan Diego Shiraishi Lombard1; Ben Dillinger1; Carolina Tallon1; 1Virginia Tech
Textured Ultra-High Temperature Ceramics have the potential for enhanced mechanical and thermal performance in extreme environments. Our previous analytical calculations predicted texture formation in UHTC borides using weak magnetic fields, which we validated experimentally by applying magnetic field as low as 0.55 T to various UHTC suspensions during slip casting to realize strong c-axis texture. In this work, we investigated the role of colloidal processing parameters, including solid content, dispersant concentration, and magnetic exposure, in texture development of ZrB2 and TiB2. We dicuss the interplay of interparticle, capillary, and magnetic forces through comparative study of casting and sedimentation by characterizing green bodies and supernatant and sediments. We also conducted initial thermal and mechanical characterization. The results give us new insight into the relationship between colloidal processing parameters and our analytical model of magnetically assisted slip casting, and the potential application to develop new microstructures and architectures with enhanced thermomechanical response.
4:10 PM
Densification and Phase Analysis of Zirconium Carbide Ceramics with Different Carbon Contents: Yue Zhou1; Jeremy Watts1; William Fahrenholtz1; Greg Hilmas1; 1Missouri University of Science and Technology
Zirconium carbide (ZrCx) ceramics with different carbon contents were fabricated by reaction hot pressing. Nominal stoichiometry ranged from x = 0.6 to x = 0.98 with 0.05 intervals. The final ceramics were characterized to determine relative densities using Archimedes method, carbon content employing thermal gravimetric analysis, oxygen content using inert gas-fusion, and microstructure by scanning electron microscopy. The phases in each ceramic were determined by x-ray diffraction, selected area electron diffraction, and neutron powder diffraction. The effects of the carbon content and heat treatment on carbon vacancy ordering were determined.