Matérias-primas da plataforma do Mondego para cerâmica

O presente trabalho divulga os resultados dos estudos levados a efeito nas matérias-primas argilosas que se integram tipologicamente na argila comum, ocorrentes na designada Plataforma do Mondego, Centro de Portugal, na região entre Miranda do Corvo, a SW, e Tábua, a NE. Para tal realizou-se a cartografia superficial dos sedimentos continentais do Cretácico e do Terciário, aí preservados, estabeleceram-se as colunas sedimentares, a nível regional e a nível local, nas áreas de maior potencial reconhecido e, caracterizaram-se as matérias-primas argilosas amostradas, em termos de composição, textura e aptidão cerâmica, objectivando a definição das zonas das jazidas com maior interesse industrial. A informação obtida e compilada, relativa ao caulino e ao feldspato é também apresentada, com vista a uma percepção da potencialidade destas matériasprimas cerâmicas ocorrentes na área. O estudo de caracterização dos materiais argilosos investigados teve como base 53 amostras obtidas em seis regiões da Plataforma do Mondego aqui definidas por motivo de organização do trabalho, segundo os critérios geográfico e geotectónico. As formações de Côja e de Campelo, do Terciário, constituem as unidades onde ocorrem litótipos produtivos, em termos de matéria-prima para a Cerâmica de Barro Vermelho ou Cerâmica de Construção. Relativamente às características texturais e composicionais, em síntese, apresentam-se os factos relevantes seguintes: A matéria-prima argilosa existente na área estudada materializa, granulometricamente, na maioria das amostras, silte, caindo os níveis amostrados com maior percentagem de argila, no domínio do silte argiloso. O défice em fracção argila implica limitações quanto à possibilidade de diversificação de produtos cerâmicos fabricados com estas matérias-primas tal-qual. Os diferentes métodos analíticos utilizados na caracterização mineralógica dos materiais amostrados confirmaram uma composição em termos dos minerais argilosos, consistindo de ilite/mica (em geral, o mais abundante), caulinite e esmectite, interestratificados e clorite. Os minerais não argilosos são quartzo (predominante), feldspato (sobretudo potássico) e hematite, com uma representação baixa. A mineralogia da fracção inferior a 2μm das amostras, não difere das amostras totais, salvo no teor mais elevado dos minerais argilosos e acentuada redução dos minerais não argilosos. Os resultados da análise química por fluorescência de raios X das amostras integrais correlacionam-se com as características mineralógicas observadas através das técnicas analíticas utilizadas. No respeitante às propriedades e comportamento cerâmico verifica-se: Os parâmetros relacionados com a plasticidade indicam que parte das pastas elaboradas com estes materiais argilosos têm uma trabalhabilidade aceitável, mas existem problemas de conformação e acentuada retracção num número significativo de amostras, devido à elevada plasticidade da maioria das amostras. A extrusão é satisfatória a óptima. A RMF e a retracção em seco assumem valores, respectivamente, moderados a baixos e moderados, embora seja necessário ter em conta o procedimento de extrusão dos provetes, sem dispositivo de vácuo. Todas as amostras foram sujeitas a cozedura a 900ºC, e um conjunto seleccionado foi cozido a 1000ºC e a 1100ºC. As fases mineralógicas ocorrentes após cozeduras a 900ºC e 1100ºC foram identificadas num conjunto de amostras, tendo-se evidenciado a coerência dessas fases, com a mineralogia das amostras em seco. Após cozedura a 900ºC, os valores de RMF das amostras satisfazem geralmente os valores mínimos, exigidos para o fabrico de tijolo, abobadilha e, com alguma frequência, de telha, como já se verificava com os valores daquela propriedade em seco. Os valores de retracção seco-cozido são em geral, modestos. A capacidade de absorção de água é maioritariamente elevada. A formação de vidro, sobretudo, condiciona o comportamento destas propriedades por cozedura dos provetes a 1000ºC e a 1100ºC. A coloração predominante em cru das matérias-primas argilosas amostradas é amarelo acastanhado a castanho avermelhado. Após cozedura a 900ºC, há um acentuado escurecimento e incremento no grau de vermelho. As cozeduras a 1000ºC e 1100ºC promovem escurecimento gradual, com ligeira influência na cor. O comportamento dos provetes após as cozeduras cerâmicas revelou-se homogéneo a cada uma das respectivas temperaturas, não se registando também defeitos significativos, nem eflorescências. A análise das amostras em termos composicionais e tecnológicos permitiu destacar as principais características e aspectos distintivos das matériasprimas, nas diferentes regiões definidas objectivando as diferentes potencialidades cerâmicas. Nesta abordagem comparativa foram consideradas só as amostras dos campos silte e silte arenoso, por serem aquelas com maior interesse para a Cerâmica de Construção. Nas colunas sedimentares das regiões de Tábua e Santa Quitéria constata-se a ocorrência de dois ritmos de sedimentação, que embora assumam características específicas em cada região, têm aspectos composicionais e tecnológicos em comum, traduzindo melhor aptidão cerâmica os ritmos inferiores. A conjugação da cartografia realizada com os estudos laboratoriais permite concluir que as regiões de Tábua e de Santa Quitéria serão as que têm maior potencial por explorar, em matéria-prima para Cerâmica de Construção, apesar da primeira já ser intensamente explorada. Na região de Tábua, as amostras têm como fases mineralógicas principais ilite e quartzo na mesma proporção média (35%) e caulinite (média=19%) que regista enriquecimento significativo na fracção argila (média=38%). As argilas desta região registam a cor em cru mais vermelha e pH mais ácido observados. O ritmo de sedimentação inferior, com esmectite e interestratificados e ligeiramente menos quartzoso, apresenta melhores propriedades cerâmicas. A composição mineralógica média das amostras da região de Santa Quitéria é próxima daquela da região de Tábua, mas menos caulinítica, em especial na sequência inferior, na qual o teor médio de caulinite na fracção argila (7%) é o mais baixo observado. Na região de Côja – Arganil, a actividade extractiva é significativa na bacia de Côja. Aqui, a exploração de novas áreas potenciais é condicionada pela cobertura conglomerática e por estruturas tectónicas e não tectónicas relacionadas com comportamento plástico. Na restante área desta região, os recursos argilosos são penalizados por material areno-conglomerático. As amostras desta região distinguem-se das restantes a nível textural pela maior fracção areia e mineralogicamente pela presença de clorite, teor reduzido de caulinite e elevado de feldspato. As potencialidades em barro vermelho na região de Sanguinheda não serão significativas, pois a Formação de Côja é predominantemente arcósica e a Formação de Campelo pouco espessa e conglomerática. As argilas com melhor aptidão cerâmica foram amostradas na região de Miranda do Corvo – Lousã. Na composição, estas amostras são as que contêm maior fracção de argila, maior teor de ilite e caulinite e menor de argilas expansivas. Registam os melhores valores nas características tecnológicas, nomeadamente a RMF e absorção de água. A consistência dos grupos amostrais e ritmos definidos em termos composicionais e tecnológicos é corroborada pelas técnicas de análise estatística multivariada aplicadas, que os identificam. As condições de amostragem na região de Tábua, permitiram a elaboração de uma coluna tipológica, na qual, a partir de uma caracterização expedita de amostras é possível identificar a sua afinidade com os ritmos argilosos definidos e, consequentemente, a sua situação na coluna sedimentar regional e aptidão cerâmica. A cartografia dos recursos argilosos potenciais, elaborada à escala 1:25.000, constitui um dos objectivos principais deste trabalho e nela constam unidades litológicas, nas quais são diferenciadas unidades argilosas tendo também em consideração a tipologia e guias mineralógicos resultantes da caracterização das amostras. As características composicionais destas unidades denotam diferente aptidão cerâmica e, portanto, permitem salientar as zonas com maior interesse económico.

Electromechanical properties of engineered lead free potassium sodium niobate based materials

K0.5Na0.5NbO3 (KNN), is the most promising lead free material for substituting lead zirconate titanate (PZT) which is still the market leader used for sensors and actuators. To make KNN a real competitor, it is necessary to understand and to improve its properties. This goal is pursued in the present work via different approaches aiming to study KNN intrinsic properties and then to identify appropriate strategies like doping and texturing for designing better KNN materials for an intended application. Hence, polycrystalline KNN ceramics (undoped, non-stoichiometric; NST and doped), high-quality KNN single crystals and textured KNN based ceramics were successfully synthesized and characterized in this work. Polycrystalline undoped, non-stoichiometric (NST) and Mn doped KNN ceramics were prepared by conventional ceramic processing. Structure, microstructure and electrical properties were measured. It was observed that the window for mono-phasic compositions was very narrow for both NST ceramics and Mn doped ceramics. For NST ceramics the variation of A/B ratio influenced the polarization (P-E) hysteresis loop and better piezoelectric and dielectric responses could be found for small stoichiometry deviations (A/B = 0.97). Regarding Mn doping, as compared to undoped KNN which showed leaky polarization (P-E) hysteresis loops, B-site Mn doped ceramics showed a well saturated, less-leaky hysteresis loop and a significant properties improvement. Impedance spectroscopy was used to assess the role of Mn and a relation between charge transport – defects and ferroelectric response in K0.5Na0.5NbO3 (KNN) and Mn doped KNN ceramics could be established. At room temperature the conduction in KNN which is associated with holes transport is suppressed by Mn doping. Hence Mn addition increases the resistivity of the ceramic, which proved to be very helpful for improving the saturation of the P-E loop. At high temperatures the conduction is dominated by the motion of ionized oxygen vacancies whose concentration increases with Mn doping. Single crystals of potassium sodium niobate (KNN) were grown by a modified high temperature flux method. A boron-modified flux was used to obtain the crystals at a relatively low temperature. XRD, EDS and ICP analysis proved the chemical and crystallographic quality of the crystals. The grown KNN crystals exhibit higher dielectric permittivity (29,100) at the tetragonal-to-cubic phase transition temperature, higher remnant polarization (19.4 μC/cm2) and piezoelectric coefficient (160 pC/N) when compared with the standard KNN ceramics. KNN single crystals domain structure was characterized for the first time by piezoforce response microscopy. It could be observed that <001> - oriented potassium sodium niobate (KNN) single crystals reveal a long range ordered domain pattern of parallel 180° domains with zig-zag 90° domains. From the comparison of KNN Single crystals to ceramics, It is argued that the presence in KNN single crystal (and absence in KNN ceramics) of such a long range order specific domain pattern that is its fingerprint accounts for the improved properties of single crystals. These results have broad implications for the expanded use of KNN materials, by establishing a relation between the domain patterns and the dielectric and ferroelectric response of single crystals and ceramics and by indicating ways of achieving maximised properties in KNN materials. Polarized Raman analysis of ferroelectric potassium sodium niobate (K0.5Na0.5)NbO3 (KNN) single crystals was performed. For the first time, an evidence is provided that supports the assignment of KNN single crystals structure to the monoclinic symmetry at room temperature. Intensities of A′, A″ and mixed A′+A″ phonons have been theoretically calculated and compared with the experimental data in dependence of crystal rotation, which allowed the precise determination of the Raman tensor coefficients for (non-leaking) modes in monoclinic KNN. In relation to the previous literature, this study clarifies that assigning monoclinic phase is more suitable than the orthorhombic one. In addition, this study is the basis for non-destructive assessments of domain distribution by Raman spectroscopy in KNN-based lead-free ferroelectrics with complex structures. Searching a deeper understanding of the electrical behaviour of both KNN single crystal and polycrystalline materials for the sake of designing optimized KNN materials, a comparative study at the level of charge transport and point defects was carried out by impedance spectroscopy. KNN single crystals showed lower conductivity than polycrystals from room temperature up to 200 ºC, but above this temperature polycrystalline KNN displays lower conductivity. The low temperature (T < 200 ºC) behaviour reflects the different processing conditions of both ceramics and single crystals, which account for less defects prone to charge transport in the case of single crystals. As temperature increases (T > 200 ºC) single crystals become more conductive than polycrystalline samples, in which grain boundaries act as barriers to charge transport. For even higher temperatures the conductivity difference between both is increased due to the contribution of ionic conduction in single crystals. Indeed the values of activation energy calculated to the high temperature range (T > 300 ºC) were 1.60 and 0.97 eV, confirming the charge transport due to ionic conduction and ionized oxygen vacancies in single crystals and polycrystalline KNN, respectively. It is suggested that single crystals with low defects content and improved electromechanical properties could be a better choice for room temperature applications, though at high temperatures less conductive ceramics may be the choice, depending on the targeted use. Aiming at engineering the properties of KNN polycrystals towards the performance of single crystals, the preparation and properties study of (001) – oriented (K0.5Na0.5)0.98Li0.02NbO3 (KNNL) ceramics obtained by templated grain growth (TGG) using KNN single crystals as templates was undertaken. The choice of KNN single crystals templates is related with their better properties and to their unique domain structure which were envisaged as a tool for templating better properties in KNN ceramics too. X-ray diffraction analysis revealed for the templated ceramics a monoclinic structure at room temperature and a Lotgering factor (f) of 40% which confirmed texture development. These textured ceramics exhibit a long range ordered domain pattern consisting of 90º and 180º domains, similar to the one observed in the single crystals. Enhanced dielectric (13017 at TC), ferroelectric (2Pr = 42.8 μC/cm2) and piezoelectric (d33 = 280 pC/N) properties are observed for textured KNNL ceramics as compared to the randomly oriented ones. This behaviour is suggested to be due to the long range ordered domain patterns observed in the textured ceramics. The obtained results as compared with the data previously reported on texture KNN based ceramics confirm that superior properties were found due to ordered repeated domain pattern. This study provides an useful approach towards properties improvement of KNN-based piezoelectric ceramics. Overall, the present results bring a significant contribution to the pool of knowledge on the properties of sodium potassium niobate materials: a relation between the domain patterns and di-, ferro-, and piezo-electric response of single crystals and ceramics was demonstrated and ways of engineering maximised properties in KNN materials, for example by texturing were established. This contribution is envisaged to have broad implications for the expanded use of KNN over the alternative lead-based materials.

Alkaline-earth aluminosilicate-based glass and glass-ceramic sealants for functional applications

The planar design of solid oxide fuel cell (SOFC) is the most promising one due to its easier fabrication, improved performance and relatively high power density. In planar SOFCs and other solid-electrolyte devices, gas-tight seals must be formed along the edges of each cell and between the stack and gas manifolds. Glass and glass-ceramic (GC), in particular alkaline-earth alumino silicate based glasses and GCs, are becoming the most promising materials for gas-tight sealing applications in SOFCs. Besides the development of new glass-based materials, new additional concepts are required to overcome the challenges being faced by the currently existing sealant technology. The present work deals with the development of glasses- and GCs-based materials to be used as a sealants for SOFCs and other electrochemical functional applications. In this pursuit, various glasses and GCs in the field of diopside crystalline materials have been synthesized and characterized by a wide array of techniques. All the glasses were prepared by melt-quenching technique while GCs were produced by sintering of glass powder compacts at the temperature ranges from 800−900 ºC for 1−1000 h. Furthermore, the influence of various ionic substitutions, especially SrO for CaO, and Ln2O3 (Ln=La, Nd, Gd, and Yb), for MgO + SiO2 in Al-containing diopside on the structure, sintering and crystallization behaviour of glasses and properties of resultant GCs has been investigated, in relevance with final application as sealants in SOFC. From the results obtained in the study of diopside-based glasses, a bilayered concept of GC sealant is proposed to overcome the challenges being faced by (SOFCs). The systems designated as Gd−0.3 (in mol%: 20.62MgO−18.05CaO−7.74SrO−46.40SiO2−1.29Al2O3 − 2.04 B2O3−3.87Gd2O3) and Sr−0.3 (in mol%: 24.54 MgO−14.73 CaO−7.36 SrO−0.55 BaO−47.73 SiO2−1.23 Al2O3−1.23 La2O3−1.79 B2O3−0.84 NiO) have been utilized to realize the bi-layer concept. Both GCs exhibit similar thermal properties, while differing in their amorphous fractions, revealed excellent thermal stability along a period of 1,000 h. They also bonded well to the metallic interconnect (Crofer22APU) and 8 mol% yttrium stabilized zirconium (8YSZ) ceramic electrolyte without forming undesirable interfacial layers at the joints of SOFC components and GC. Two separated layers composed of glasses (Gd−0.3 and Sr−0.3) were prepared and deposited onto interconnect materials using a tape casting approach. The bi-layered GC showed good wetting and bonding ability to Crofer22APU plate, suitable thermal expansion coefficient (9.7–11.1 × 10–6 K−1), mechanical reliability, high electrical resistivity, and strong adhesion to the SOFC componets. All these features confirm the good suitability of the investigated bi-layered sealant system for SOFC applications.

Electrolytes for ceramic oxide fuel cells

The main objective of this dissertation is the development and processing of novel ionic conducting ceramic materials for use as electrolytes in proton or oxide-ion conducting solid oxide fuel cells. The research aims to develop new processing routes and/or materials offering superior electrochemical behavior, based on nanometric ceramic oxide powders prepared by mechanochemical processes. Protonic ceramic fuel cells (PCFCs) require electrolyte materials with high proton conductivity at intermediate temperatures, 500-700ºC, such as reported for perovskite zirconate oxides containing alkaline earth metal cations. In the current work, BaZrO3 containing 15 mol% of Y (BZY) was chosen as the base material for further study. Despite offering high bulk proton conductivity the widespread application of this material is limited by its poor sinterability and grain growth. Thus, minor additions of oxides of zinc, phosphorous and boron were studied as possible sintering additives. The introduction of ZnO can produce substantially enhanced densification, compared to the un-doped material, lowering the sintering temperature from 1600ºC to 1300ºC. Thus, the current work discusses the best solid solution mechanism to accommodate this sintering additive. Maximum proton conductivity was shown to be obtained in materials where the Zn additive is intentionally adopted into the base perovskite composition. P2O5 additions were shown to be less effective as a sintering additive. The presence of P2O5 was shown to impair grain growth, despite improving densification of BZY for intermediate concentrations in the range 4 – 8 mol%. Interreaction of BZY with P was also shown to have a highly detrimental effect on its electrical transport properties, decreasing both bulk and grain boundary conductivities. The densification behavior of H3BO3 added BaZrO3 (BZO) shows boron to be a very effective sintering aid. Nonetheless, in the yttrium containing analogue, BaZr0.85Y0.15O3- (BZY) the densification behavior with boron additives was shown to be less successful, yielding impaired levels of densification compared to the plain BZY. This phenomenon was shown to be related to the undesirable formation of barium borate compositions of high melting temperatures. In the last section of the work, the emerging oxide-ion conducting materials, (Ba,Sr)GeO3 doped with K, were studied. Work assessed if these materials could be formed by mechanochemical process and the role of the ionic radius of the alkaline earth metal cation on the crystallographic structure, compositional homogeneity and ionic transport. An abrupt jump in oxide-ion conductivity was shown on increasing operation temperature in both the Sr and Ba analogues.