Historical Heritage: A Study to Conservation

Considering ancient monuments and historical buildings, it seems that these mortars have proved to be durable and reliable materials. The restoration and maintenance of old renders is one of the key aspects of correct rehabilitation practice. The ideal course of action is to replace the damaged material by a material with compatible characteristics.The study in development presents the chemical, physical and morphologic analysis performed for ancient air lime mortars belonging to historical monuments: Santa Marta Fortress in the coast line Lisbon-Cascais dated from XVII century and Defense Wall of Lisbon dated from XI century, which layout could be associated to roman period. It is important to underline that the studied samples of ancient portuguese air lime mortars, have been submitted during centuries to very severe maritime environment that includes daily cycles of wet/dry, wind, friction and the constant presence of salts, generally aggressive. However, they show very good performance and conservation state, unlike most of the new air lime mortars, which are generally considered weak, not very durable, materials. This work is included in a study intending to determine key factors to the durability of these ancient materials in presence of water. Visible reaction rims around some aggregates suggests the occurrence of pozzolanic reactions between aggregates and the lime binder that creates neoformation products, such as calcium-silico-aluminates, which seems be, besides the pores filling, the responsible for the resistance and cohesion of these ancient mortars submitted to aggressive humid environments.

An SEM investigation of the pozzolanic activity of a waste catalyst oil refinery

The most active phase of the fluid catalytic cracking (FCC) catalyst, used in oil refinery, is zeolite-Y which is an aluminosilicate with a high internal and external surface area responsible for its high reactivity. Waste FCC catalyst is potentially able to be reused in cement-based materials - as an additive - undergoing a pozzolanic reaction with calcium hydroxide (Ca(OH)2) formed during cement hydration [1-3]. This reaction produces additional strength-providing reaction products i.e., calcium silicate hydrate (C-S-H) and hydrous calcium aluminates (C-A-H) which exact chemical formula and structure are still unknown. Partial replacement of cement by waste FCC catalyst has two key advantages: (1) lowering of cement production with the associated pollution reduction as this industry represents one of the largest sources of man-made CO2 emissions, and (2) improving the mechanical properties and durability of cement-based materials. Despite these advantages, there is a lack of fundamental knowledge on pozzolanic reaction mechanisms as well as spatial distribution of porosity and solid phases interactions at the microstructural level and consequently their relationship with macroscopical engineering properties of catalyst/cement blends. Within this scope, backscattered electron (BSE) images acquired in a scanning electron microscope (SEM) equipped with Energy-Dispersive Spectroscopy (EDS) and by X-ray diffraction were used to investigate chemical composition of hydration products and to analyse spatial information of the microstructure of waste FCC catalyst blended cement mortars. For this purpose mortars with different levels of cement substitution by waste catalyst as well as with different hydration ages, were prepared. The waste FCC catalyst used is produced by the Portuguese refinery company Petrogal S.A.

Lime mortars with brick dust and grounded particles for ancient masonry: development and evaluation

HMC08 - 1st Historical Mortars Conference: Characterization, Diagnosis, Conservation, Repair and Compatibilit, LNEC, Lisbon, 24-26 September 2008

Optimization of Soil Stabilization with Class C Fly Ash, January 1987

Previous Iowa DOT sponsored research has shown that some Class C fly ashes are ementitious (because calcium is combined as calcium aluminates) while other Class C ashes containing similar amounts of elemental calcium are not (1). Fly ashes from modern power plants in Iowa contain significant amounts of calcium in their glassy phases, regardless of their cementitious properties. The present research was based on these findings and on the hyphothesis that: attack of the amorphous phase of high calcium fly ash could be initiated with trace additives, thus making calcium available for formation of useful calcium-silicate cements. Phase I research was devoted to finding potential additives through a screening process; the likely chemicals were tested with fly ashes representative of the cementitious and non-cementitious ashes available in the state. Ammonium phosphate, a fertilizer, was found to produce 3,600 psi cement with cementitious Neal #4 fly ash; this strength is roughly equivalent to that of portland cement, but at about one-third the cost. Neal #2 fly ash, a slightly cementitious Class C, was found to respond best with ammonium nitrate; through the additive, a near-zero strength material was transformed into a 1,200 psi cement. The second research phase was directed to optimimizing trace additive concentrations, defining the behavior of the resulting cements, evaluating more comprehensively the fly ashes available in Iowa, and explaining the cement formation mechanisms of the most promising trace additives. X-ray diffraction data demonstrate that both amorphous and crystalline hydrates of chemically enhanced fly ash differ from those of unaltered fly ash hydrates. Calciumaluminum- silicate hydrates were formed, rather than the expected (and hypothesized) calcium-silicate hydrates. These new reaction products explain the observed strength enhancement. The final phase concentrated on laboratory application of the chemically-enhanced fly ash cements to road base stabilization. Emphasis was placed on use of marginal aggregates, such as limestone crusher fines and unprocessed blow sand. The nature of the chemically modified fly ash cements led to an evaluation of fine grained soil stabilization where a wide range of materials, defined by plasticity index, could be stabilized. Parameters used for evaluation included strength, compaction requirements, set time, and frost resistance.

Preparação e caracterização de pós cerâmicos de aluminatos de lítio

The preparation of gamma-LiAlO2 by coprecipitation and sol-gel synthesis was investigated. Ceramic powders obtained by coprecipitation synthesis were prepared from aqueous solutions of aluminum and lithium nitrates using sodium hydroxide as precipitant agent. By sol-gel synthesis, the ceramic powders were prepared from hydrolysis of aluminum isopropoxide. The materials obtained by two routes of synthesis were dried at 80ºC and calcined at 550, 750, 950 and 1150ºC. The characterization was done by X-ray diffraction, infrared spectroscopy, emission and absorption atomic spectrometry, helium picnometry, specific surface area (BET method) and scanning electronic microscopy. Mixtures of crystalline phases were obtained by coprecipitation synthesis: 80ºC- LiAl2(OH)7.2H2O + Al(OH)3; 550 and 750ºC- alpha-LiAlO2 + eta-Al2O3; 950 and 1150ºC- gamma-LiAlO2 + LiAl5O8. Chemical analysis showed molar ration Al/Li @ 3. Crystalline single-phases were obtained by sol-gel synthesis above 550ºC: 550ºC-alpha-LiAlO2; 750, 950 and 1150ºC-gamma-LiAlO2. These powders presented molar ration Al/Li @ 1. Thus, gamma-LiAlO2 crystalline phase was obtained at 750ºC by sol-gel synthesis while by coprecipitation synthesis, a mixture of crystalline phases was obtained. These results showed the superiority of the sol-gel synthesis for the preparation of pure gamma-LiAlO2.

Polarizabilidades e primeira hiperpolarizabilidades elétricas dipolares de ésteres E-4-amino-trans-1,3-butadienil-(1',2'-di-hidroxibenzeno) de boro, alumínio e gálio

Static electric dipole polarizabilities and first hyperpolarizabilites have been calculated for the title molecules and their 3' and 4'-nitro derivatives at ab-initio Hartree- Fock/6-31G(d, p) level. The influence of the pivotal p vacant 3A elements (B, Al or Ga) substitution on the electrical properties of these molecules is detailed. The axial vector components of the first hyperpolarizabilities β(0) of the push-pull 4'-nitro derivatives, -18.2×10-32 esu (B), -21.1×10-32 esu (Al) and -20.8×10-32 esu (Ga) are calculated to be as much as fourfold larger then that calculated for the p-nitroaniline, a reference organic molecule for comparison for this type of molecular property.

Synthèse totale du méthyl ester de la zincophorine et étude DFT du transfert d’hydrogène diastéréosélectif impliquant des intermédiaires radicalaires vicinaux à un ester

Cet ouvrage traite d’une méthodologie pour l’induction de centres stéréogènes au sein des motifs propionates par la chimie des radicaux et de son application à la synthèse totale du méthyl ester de la zincophorine. Cet ionophore, aux propriétés biologiques intéressantes, présente plusieurs défis synthétiques dont une séquence de type polypropionate anti, anti, anti, anti difficilement accessible ainsi qu’un tétrahydropyrane trans trisubstitué. Récemment, l’intérêt renouvelé pour ces composés polyéthers, en tant qu’agents anticancéreux, accentue l’importance de stratégies versatiles permettant l’accès à ces structures ainsi qu’à leurs analogues. Depuis quelques années, notre groupe s’intéresse à la synthèse d’unités propionates acycliques par une séquence réactionnelle contrôlée uniquement par le substrat. La première étape découle d’une aldolisation de Mukaiyama entre un aldéhyde alpha-chiral et un énoxysilane tétrasubstitué portant une liaison carbone-halogène, et où l’issue stéréochimique dépend de la nature monodentate ou bidentate de l’acide de Lewis employé. La seconde réaction-clé implique la formation d’un radical tertiaire, vicinal à un ester, pouvant être réduit diastéréosélectivement en présence d’hydrure d’étain. La première section décrit l’élaboration de motifs tétrahydropyranes trisubstitués et l’induction des centres stéréogènes vicinaux par une réduction radicalaire. Nous avons révélé que l’issue diastéréosélective de la réaction de cyclisation par une iodoéthérification était dictée par le groupement gamma-méthyle des esters alpha,beta-insaturés de départ. Nous avons ensuite démontré que les produits de la réaction radicalaire anti et syn pouvaient être obtenus sélectivement à partir d’un intermédiaire commun, respectivement en prenant appui sur l’effet exocyclique ou endocyclique lors de la réduction. Par une stratégie complémentaire, nous avons révélé que le précurseur radicalaire pouvait également être obtenu par une réaction de cycloéthérification en présence d’un énoxysilane tétrasubstitué. Une étude systématique des substituants du cycle a révélé que certaines relations stéréochimiques conduisaient à une perte de sélectivité au détriment du produit anti. La seconde section concerne l’étude DFT au niveau BHandHLYP/TZVP des intermédiaires radicalaires impliqués lors du transfert d’hydrogène. Par une étude de décomposition de l’énergie d’activation, nous avons été en mesure de rationaliser l’issue diastéréosélective de la réaction sur la base des énergies de distorsion (∆Ed‡) et d’interaction (∆Eint‡) requises pour accéder à la paire d’états de transition pro-anti et pro-syn. De plus, nous avons démontré qu’une analyse NBO permettait de relativiser l’impact des interactions stéréoélectroniques. Par la suite, l’évaluation des intermédiaires radicalaires borinates et aluminates nous a permis de révéler que l’encombrement stérique de la chaîne propionate était la cause principale de la formation sélective des produits anti ou syn lors d’une réduction en présence d’un acide de Lewis. La dernière section décrit l’élaboration de la séquence polypropionate de la zincophorine, et de ses isomères, à partir du fragment tétrahydropyrane substitué. Au cours de notre étude, nous avons identifié que le nombre de sites de chélation potentiels devait être limité à trois lors de l’aldolisation en condition Cram-chélate. De plus, nous avons démontré que les différents motifs acétates sont accessibles sélectivement par l’utilisation d’un énoxysilane encombré. Par ailleurs, nous avons révélé qu’une même séquence réactionnelle pouvait être employée pour la synthèse du fragment C17–C25 de son analogue naturel CP-78,545, et avons complété la plus récente synthèse totale du méthyl ester de la zincophorine.

Studies on the Effect of High Energy Ball Milling On the Structural, Electrical and Magnetic Properties of Some Normal Spinets in the Ultrafine Regime

The present work is an attempt to understand the characteristics of high energy ball milling on the structural, electrical and magnetic properties of some normal spinets in the ultra fine regime, Magnetism and magnetic materials have been a fascinating subject for the mankind ever since the discovery of lodestone. Since then, man has been applying this principle of magnetism to build devices for various applications. Magnetism can be classified broadly into five categories. They are diamagnetic, paramagnetic, ferromagnetic antiferromagnetic and ferrimagnetic. Of these, ferro and ferri magnetic materials assume great commercial importance due to their unique properties like appropriate magnetic characteristics, high resistivity and low eddy current losses. The emergence of nanoscience and nanotechnology during the last decade had its impact in the field of magnetism and magnetic materials too. Now, it is common knowledge that materials synthesized in the nanoregime exhibit novel and superlative properties with respect to their coarser sized counterparts in the micron regime. These studies reveal that dielectric properties can be varied appreciably by high-energy ball milling in nanosized zinc ferrites produced by coprecipitation method. A semi conducting behaviour was observed in these materials with the Oxygen vacancies acting as the main charge carrier for conduction, which was produced at the time of coprecipitation and milling. Thus through this study, it was possible to successfully investigate the finite size effects on the structural, electrical and magnetic properties of normal spinels in the ultra fine regime

Thermoluminescence and synchrotron radiation studies on the persistent luminescence of BaAl(2)O(4)/Eu(2+),Dy(3+)

The persistent luminescence materials, barium aluminates doped with Eu(2+) and Dy(3+) (BaAl(2)O(4): Eu(2+),Dy(3+)), were prepared with the combustion synthesis at temperatures between 400 and 600 degrees C as well as with the solid state reaction at 1500 degrees C. The concentrations of Eu(2+)/Dy(3+) (in mol% of the Ba amount) ranged from 0.1/0.1 to 1.0/3.0. The electronic and defect energy level structures were studied with thermoluminescence (TL) and synchrotron radiation (SR) spectroscopies: UV-VUV excitation and emission, as well as with X-ray absorption near-edge structure (XANES) methods. Theoretical calculations using the density functional theory (DFT) were carried out in order to compare with the experimental data. (C) 2010 Elsevier Inc. All rights reserved.

A study of slag corrosion of oxides and oxide-carbon refractories during steel refining

The use of ceramic material as refractories in the manufacturing industry is a common practice worldwide. During usage, for example in the production of steel, these materials do experience severe working conditions including high temperatures, low pressures and corrosive environments. This results in lowered service lives and high consumptions of these materials. This, in turn, affects the productivity of the whole steel plant and thereby the cost. In order to investigate how the service life can be improved, studies have been carried out for refractories used in the inner lining of the steel ladles. More specifically, from the slag zone, where the corrosion is most severe. By combining thermodynamic simulations, plant trails and post-mortem studies of the refractories after service, vital information about the behaviour of the slagline refractories during steel refining and the causes of the accelerated wear in this ladle area has been achieved. The results from these studies show that the wear of the slagline refractories of the ladle is initiated at the preheating station, through reduction-oxidation reactions. The degree of the decarburization process is mostly dependent on the preheating fuel or the environment. For refractories without antioxidants, refractory decarburization is slower when coal gas is used in ladle preheating than when a mixture of oil and air is used. In addition, ladle preheating of the refractories without antioxidants leads to direct wear of the slagline refractories. This is due to the total loss of the matrix strength, which results in a sand-like product. Thermal chemical changes that take place in the slagline refractories are due to the MgO-C reaction as well as the formation of liquid phases from impurity oxides. In addition, the decrease in the system pressure during steel refining makes the MgO-C reaction take place at the steel refining temperatures. This reduces the refractory’s resistance to corrosion. This is a serious problem for both the magnesia-carbon and dolomite-carbon refractories. The studies of the reactions between the slagline refractories and the different slag compositions showed that slags rich in iron oxide lead mostly to the oxidation of carbon/graphite in the carbon-containing refractories. This leads to an increased porosity and wettability and therefore an enhanced penetration of slag into the refractory structure. If the slag contains high contents of alumina and or silica (such as the steel refining slag), reactions between the slag components and the dolomite-carbon refractory are promoted. This leads to the formation of low-temperature melting phases such as calcium-aluminates and silicates. The state of these reaction products during steel refining leads to an accelerated wear of the dolomite-carbon refractory. The main products of the reactions between the magnesia-carbon refractory and the steel refining slag are MgAl2O4 spinels, and calcium-aluminates, and silicates. Due to the good refractory properties of MgAl2O4 spinels, the slag corrosion resistance of the magnesiacarbon refractory is promoted.

An Experimental Study of Submerged Entry Nozzles (SEN) Focusing on Decarburization and Clogging

The submerged entry nozzle (SEN) is used to transport the molten steel from a tundish to a mould. The main purpose of its usage is to prevent oxygen and nitrogen pick-up by molten steel from the gas. Furthermore, to achieve the desired flow conditions in the mould. Therefore, the SEN can be considered as a vital factor for a stable casting process and the steel quality. In addition, the steelmaking processes occur at high temperatures around 1873 K, so the interaction between the refractory materials of the SEN and molten steel is unavoidable. Therefore, the knowledge of the SEN behaviors during preheating and casting processes is necessary for the design of the steelmaking processes  The internal surfaces of modern SENs are coated with a glass/silicon powder layer to prevent the SEN graphite oxidation during preheating. The effects of the interaction between the coating layer and the SEN base refractory materials on clogging were studied. A large number of accretion samples formed inside alumina-graphite clogged SENs were examined using FEG-SEM-EDS and Feature analysis. The internal coated SENs were used for continuous casting of stainless steel grades alloyed with Rare Earth Metals (REM). The post-mortem study results clearly revealed the formation of a multi-layer accretion. A harmful effect of the SENs decarburization on the accretion thickness was also indicated. In addition, the results indicated a penetration of the formed alkaline-rich glaze into the alumina-graphite base refractory. More specifically, the alkaline-rich glaze reacts with graphite to form a carbon monoxide gas. Thereafter, dissociation of CO at the interface between SEN and molten metal takes place. This leads to reoxidation of dissolved alloying elements such as REM (Rare Earth Metal). This reoxidation forms the “In Situ” REM oxides at the interface between the SEN and the REM alloyed molten steel. Also, the interaction of the penetrated glaze with alumina in the SEN base refractory materials leads to the formation of a high-viscous alumina-rich glaze during the SEN preheating process. This, in turn, creates a very uneven surface at the SEN internal surface. Furthermore, these uneven areas react with dissolved REM in molten steel to form REM aluminates, REM silicates and REM alumina-silicates. The formation of the large “in-situ” REM oxides and the reaction of the REM alloying elements with the previously mentioned SEN´s uneven areas may provide a large REM-rich surface in contact with the primary inclusions in molten steel. This may facilitate the attraction and agglomeration of the primary REM oxide inclusions on the SEN internal surface and thereafter the clogging. The study revealed the disadvantages of the glass/silicon powder coating applications and the SEN decarburization. The decarburization behaviors of Al2O3-C, ZrO2-C and MgO-C refractory materials from a commercial Submerged Entry Nozzle (SEN), were also investigated for different gas atmospheres consisting of CO2, O2 and Ar. The gas ratio values were kept the same as it is in a propane combustion flue gas at different Air-Fuel-Ratio (AFR) values for both Air-Fuel and Oxygen-Fuel combustion systems. Laboratory experiments were carried out under nonisothermal conditions followed by isothermal heating. The decarburization ratio (α) values of all three refractory types were determined by measuring the real time weight losses of the samples. The results showed the higher decarburization ratio (α) values increasing for MgO-C refractory when changing the Air-Fuel combustion to Oxygen-Fuel combustion at the same AFR value. It substantiates the SEN preheating advantage at higher temperatures for shorter holding times compared to heating at lower temperatures during longer holding times for Al2O3-C samples. Diffusion models were proposed for estimation of the decarburization rate of an Al2O3-C refractory in the SEN. Two different methods were studied to prevent the SEN decarburization during preheating: The effect of an ZrSi2 antioxidant and the coexistence of an antioxidant additive and a (4B2O3 ·BaO) glass powder on carbon oxidation for non-isothermal and isothermal heating conditions in a controlled atmosphere. The coexistence of 8 wt% ZrSi2 and 15 wt% (4B2O3 ·BaO) glass powder of the total alumina-graphite refractory base materials, presented the most effective resistance to carbon oxidation. The 121% volume expansion due to the Zircon formation during heating and filling up the open pores by a (4B2O3 ·BaO) glaze during the green body sintering led to an excellent carbon oxidation resistance. The effects of the plasma spray-PVD coating of the Yttria Stabilized Zirconia (YSZ) powder on the carbon oxidation of the Al2O3-C coated samples were investigated. Trials were performed at non-isothermal heating conditions in a controlled atmosphere. Also, the applied temperature profile for the laboratory trials were defined based on the industrial preheating trials. The controlled atmospheres consisted of CO2, O2 and Ar. The thicknesses of the decarburized layers were measured and examined using light optic microscopy, FEG-SEM and EDS. A 250-290 μm YSZ coating is suggested to be an appropriate coating, as it provides both an even surface as well as prevention of the decarburization even during heating in air. In addition, the interactions between the YSZ coated alumina-graphite refractory base materials in contact with a cerium alloyed molten stainless steel were surveyed. The YSZ coating provided a total prevention of the alumina reduction by cerium. Therefore, the prevention of the first clogging product formed on the surface of the SEN refractory base materials. Therefore, the YSZ plasma-PVD coating can be recommended for coating of the hot surface of the commercial SENs.

Influência da granulometria e de aditivos no comportamento reológico do rejeito de lavagem da bauxita

Na mineração da bauxita no município de Paragominas-PA, são descartados no processo de beneficiamento rejeitos com teor de sólido de 33,5 % e granulometria muito fina com D₅₀ abaixo de 5 μm. Esses fatores contribuem para que esta suspensão formada basicamente por silico aluminatos, com elevada concentração de argila caulinita, apresente alta viscosidade e alta tensão inicial de escoamento. Foi realizada análise granulométrica e determinadas as composições químicas e mineralógicas do material. A análise granulométrica foi feita por peneiramento a úmido e as frações finas foram determinadas pela técnica da difração a laser. A determinação da composição química foi feita por Espectrometria de Fluorescência de Raios-X, obtendo-se considerável teor de alumina aproveitável, 21, 28%. A composição mineralógica foi determinada por Difração de Raios-X (DRX), obtendo-se gibsita, hematita, quartzo e caulinita. Realizou-se a determinação dos fatores de atrito da polpa, utilizando equação para fluidos que seguem o modelo de Herschel-Bulkley e utilizando as correlações de Dodge e Metzner. Utilizou-se o viscosímetro VT550, com sensor tipo cilindros coaxiais SV1, para realizar testes de defloculação e floculação utilizando diferentes aditivos reológicos. Os aditivos utilizados foram: hexametafosfato de sódio, hidroxamato, sulfato de alumínio, poliacrilato de sódio e poliacrilamida 25% aniônica. A programação foi taxa de cisalhamento de 100 s^-1, tempo de 20s e temperatura de 32ºC. Os defloculantes podem ser utilizados para melhorar o processo de bombeamento e os floculantes podem ser utilizados como auxiliadores no processo de sedimentação nos espessadores, auxiliando no processo de separação sólido-líquido. Foram realizadas ainda, análises de viscosidade em polpas com diferentes pH e em amostras passante a 400# Tyler, com o objetivo de avaliar se a granulometria e o pH influenciavam no comportamento dos aditivos. Pelo estudo observou-se que a granulometria e o pH influenciam no comportamento dos aditivos, pois quanto menor a granulometria mais eficiente é a atuação do aditivo e o seu comportamento como floculante ou defloculante está condicionado ao ajuste do pH.

Ação sonoquímica e influência das condições de tratamento térmico na preparação de cimentos do sistema binário CaO-Al2O3

Foram preparados cimentos do sistema binário CaO-Al₂O₃ por meio de uma rota que emprega o processo sonoquímico seguido de tratamento térmico. Convencionalmente estes compostos são fabricados a partir da fusão ou da sinterização de uma mistura de calcário com bauxito ou com alumina. O maior inconveniente associado a este tipo de síntese é a necessidade de temperaturas elevadas e o grande consumo de energia. Na rota sonoquímica a cálcia, juntamente com a alumina em suspensão aquosa, são introduzidas num banho de ultra-som por tempo determinado. Em seguida, após a evaporação da água, o material resultante é tratado termicamente. Quando um sistema é submetido ao processo sonoquímico, alterações na morfologia superficial das partículas podem ser induzidas pelas ondas ultra-sônicas, incluindo a redução do tamanho dessas partículas. Como conseqüência, estes materiais tornam-se mais reativos, facilitando a síntese final dos aluminatos de cálcio durante o tratamento térmico. Foi estudada a ação das ondas ultra-sônicas e a influência das condições de tratamento térmico em duas composições molares de cálcia:alumina de 1:1 e 1:2. As temperaturas empregadas foram 1000 ºC, 1200 ºC e 1300 ºC com patamares de 1 e 6 h. O material obtido foi caracterizado por microscopia eletrônica de varredura, difração de raios X e as fases presentes foram semi-quantificadas pelo método de Rietveld. Também foram realizados ensaios de compressão diametral para avaliar a resistência mecânica dos produtos da síntese. Foram preparadas pastas constituídas de cimento, alumina e água, utilizando como cimento os aluminatos de cálcio preparados pelo processo sonoquímico e um cimento comercial, como referência.

Síntese, caracterização estrutural, espectroscópica e análise do potencial fotocatalítico do aluminato de cobalto e potencial catalítico na preparação do biodiesel

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Vacuum infiltration of copper aluminate by liquid aluminium

This paper studies attained microstructures and reactive mechanisms involved in vacuum infiltration of copper aluminate preforms with liquid aluminium. At high temperatures, under vacuum, the inherent alumina film enveloping the metal is overcome, and aluminium is expected to reduce copper aluminate, rendering alumina and copper. Under this approach, copper aluminate toils as a controlled infiltration path for aluminium, resulting in reactive wetting and infiltration of the preforms. Ceramic preforms containing a mixture of Al2O3 and CuAl2O4 were infiltrated with aluminium under distinct vacuum levels and temperatures, and the resulting reaction and infiltration behaviour is discussed. Copper aluminates stability ranges depend on vacuum level and oxygen partial pressure, which determine both CuAl2O4 and CuAlO2 ability for liquid aluminium infiltration. At 1100 °C and 0.76 atm vacuum level CuAl2O4 is stable, indicating pO2 above 0.11 atm. Reactive infiltration is achieved via reaction between aluminium and CuAl2O4; however, fast formation of an alumina film blocking liquid aluminium wicking results in incipient infiltration. At 1000 °C and 3.8 × 10−7 atm vacuum level, CuAlO2 decomposes to Cu and Al2O3 indicating a pO2 below 6.0 × 10−7 atm; infiltration of the ceramic is hindered by the non-wetting behaviour of the resulting metal alloy. At 1000 °C and 1.9 × 10−6 atm vacuum level CuAlO2 is stable, indicating pO2 above 6.0 × 10−7 atm. Extensive infiltration is achieved via redox reaction between aluminium and CuAlO2, rendering a microstructure characterised by uniform distribution of alumina particles amid an aluminium matrix. This work evidences that liquid aluminium infiltration upon copper aluminate-rich preforms is a feasible route to produce Al–matrix alumina-reinforced composites. The associated reduction reaction renders alumina, as fine particulate composite reinforcements, and copper, which dissolves in liquid aluminium contributing as a matrix strengthener.