Jon Binner

Microwave Initiated Self-Propagating High-Temperature Synthesis of SiC

The use of microwave energy to initiate self-propagating, high-temperature synthesis (SHS) of Si + graphite mixtures has been investigated. The results indicate that, unlike with conventional ignition techniques, green densities in excess of 80% of theoretical can be ignited and the combustion wavefront can be crudely controlled. It was found that the induction time for ignition increased with increasing green density and that a higher microwave power level was required with the denser green pellets to achieve the same ignition time. Combustion front velocity increased with green density. The degree of densification was found to decrease with increasing green density. For a given green density, the degree of densification increased with increasing microwave power. The product contained a significant proportion of ultrafine (36–72 nm diameter) SiC whiskers; despite this, final densities as high as 83.6% of theoretical could be obtained without the use of applied pressure. This compares with the ∼50% densities obtained via conventional ignition techniques.

Evidence for non-thermal microwave effects using single and multimode hybrid conventional/microwave systems.

Clear evidence for the microwave effect has been observed during experiments in which a variety of materials have been heated using experimental systems that allowed both conventional and conventional-microwave hybrid heating. A hybrid single mode cavity has been used to investigate the microwave effect during phase changes in silver iodide, barium titanate and benzil, whilst a hybrid multimode cavity has been used to investigate the microwave effect during sintering and annealing of a range of ceramic materials with different dielectric properties. Although evidence for the microwave effect was not found in every case, where it was found the results could not be explained purely in terms of temperature gradients within the materials.

Heat flux mapping of oxyacetylene flames and their use to characterise Cf-HfB2 composites

Cost effective and fast ultra-high-temperature testing methods such as oxyacetylene torch testing are extremely useful for the rapid screening of ultra-high-temperature ceramic (UHTC) materials for hypersonic applications. There is no report in the literature, however, of an organised study to measure the heat flux and how it varies with gas flow rate, gas flow ratio and distance from the nozzle tip for an oxyacetylene flame. In this paper, the authors report for the first time the heat flux mapping of an oxidising, neutral and reducing flame. The measured heat flux was as high as ∼17 MW m−2 at a distance of 10 mm from the nozzle, which is much higher than that previously reported in the literature. Torch testing was carried out for Cf-HfB2 UHTC composites at this heat flux and the results are presented along with detailed microstructural characterisation.

Microwave Hybrid Sintering of Nanostructured YSZ Ceramics

Radiant and hybrid sintering experiments have been performed on dry and wet processed nanocrystalline 3-YSZ using both a conventional single stage and a new two stage sintering cycle. Whilst densities >98.5% of theoretical were achievable by all combinations, a nanostructure could only be retained using the two stage sintering approach. With hybrid heating the average grain sizes for die pressed samples were in the range 70 – 80 nm whilst for the more homogeneous slip cast samples a final average grain size of just 64 nm was achieved for a body with a final density of >99%. It is believed that the primary advantage offered by hybrid heating is the ability to use a much faster initial heating rate, 20 versus just 7oC min-1, without risking damage to the samples. Whilst detailed characterisation of the properties of these nanostructured ceramics is still underway, preliminary results have suggested that neither the hardness or toughness has been improved compared to conventional, submicron-sized 3-YSZ. As a result of detailed crystallographic characterisation this is believed to be due to a grain size dependent shift in the phase boundary composition for nano YSZ ceramics leading to ‘over stabilisation’ at any given yttria content.

Investigation of Electrochemical, Optical and Thermal Effects during Flash Sintering of 8YSZ

This paper reports the electrochemical, optical and thermal effects occurring during flash sintering of 8 mol % yttria-stabilized zirconia (8YSZ). In-situ observations of polycrystalline and single crystal specimens revealed electrochemical blackening/darkening during an incubation period prior to flash sintering. The phenomenon is induced by cathodic partial reduction under DC fields. When using a low frequency AC field (0.1–10 Hz) the blackening is reversible, following the imposed polarity switching. Thermal imaging combined with sample colour changes and electrical conductivity mapping give a complete picture of the multi-physical phenomena occurring during each stage of the flash sintering event. The partial reduction at the cathode causes a modification of the electrical properties in the sample and the blackened regions, which are close to the cathode, are more conductive than the remainder of the sample. The asymmetrical nature of the electrochemical reactions follows the field polarity and causes an asymmetry in the temperature between the anode and cathode, with the positive electrode tending to overheat. It is also observed that the phenomena are influenced by the quality of the electrical contacts and by the atmosphere used.

Microwave heated chemical vapour infiltration of SiC powder impregnated SiC fibre preforms

Abstract Abstract A microwave heated methyl trichlorosilane based chemical vapour infiltration technique has been used to form SiCf/SiC composites from SiC fibre preforms preimpregnated with SiC powder using two different fabrication techniques. While infiltration rates obtained from samples loaded with powder were generally higher than for preforms without powder, preferential infiltration occurred in regions where the SiC powder was most concentrated as a result of the initial non-uniform distribution of the powder across the preforms. The consequence was density gradients in the final composites. Nevertheless, average densities as high as 75% could be achieved in a 10 h process.

Hybrid microwave∕conventionally heated calorimeter

The design and construction of a calorimeter in which the specimen may be heated by microwave radiation and∕or hot air is described. The apparatus was used to examine the effect of microwave radiation on the melting of benzil (89°C) and the solid-state phase transition of silver iodide (147°C). Reproducibility of transition temperature determinations were within ±1°C. No changes were observed for benzil but silver iodide exhibited an apparent reduction in transition temperature to around 120°C in the presence of microwaves, which increased with the level of microwave irradiation.

Modelling gas flow pressure gradients in gelcast ceramic foam diesel particulate filters

Abstract New mathematical models are proposed that predict fluid flow pressure gradients in gelcast ceramic foam diesel exhaust particulate filters by considering the foam structure conceptually as serially connected orifices. The resulting multiple orifice mathematical (MOM) model is based on the sum of a viscous term derived from an extended Ergun model and the kinetic energy loss derived from the Bernoulli and conservation of mass equations. The MOM model was calibrated using experimental data obtained from measuring the air flowrate and pressure drop across a physical large-scale three-dimensional model of a cellular foam structure produced using rapid manufacturing techniques. The calibrated model was then validated using fluid flow data obtained from gelcast ceramic foam filters of various cell sizes and was found to require no empirical recalibration for each gelcast ceramic foam sample. The MOM model for clean filters was extended to predict pressure gradients of filters loaded with particulate matter (PM). The prediction of pressure gradients through gelcast ceramic filters using the MOM model for clean and PM-loaded cases was shown to be in reasonable agreement with experimental data. The models were finally applied to design a filter for a turbocharged, charge-cooled, 2.0l, four-stroke, common rail, direct injection passenger car diesel engine.

Spray Freeze Granulation of Nano Powders for Die Pressing

The processing of nanocrystalline yttria doped zirconia powder via dry forming routes has been investigated via the granulation of the powder using spray freeze drying (SFD). Free-flowing and crushable powders suitable for either die or isosatic pressing have been achieved via the combination of SFD with additions of up to 2 vol% of Freon 11; the latter reducing the strength of the granules whilst not affecting the powder flowability into the die. The approach has allowed relic-free green bodies of up to 55% of theoretical density to be produced using pressures as low as 250 MPa.

Low Power Autoselective Regeneration of Monolithic Wall Flow Diesel Particulate Filters

This paper presents research into a novel autoselective electric discharge method for regenerating monolithic wall flow diesel particulate filters using low power over the entire range of temperatures and oxygen concentrations experienced within the exhaust systems of modern diesel engines. The ability to regenerate the filter independently of exhaust gas temperature and composition significantly reduces system complexity compared to other systems. In addition, the system does not require catalyst loading and uses only massproduced electronic and electrical components, thus reducing the cost of the after-treatment package. Purpose built exhaust gas simulation test rigs were used to evaluate, develop and optimise the autoselective regeneration system. On-engine testing demonstrated the performance of the autoselective regeneration process under real engine conditions. Typical regeneration performance is presented and discussed with the aid of visual observations, particulate mass measurements, back pressure measurements and energy consumption. The research demonstrates the potential of the novel autoselective method for diesel particulate filter regeneration. The autoselective process does not require an exhaust by-pass and enables the system to be low power, catalyst-free and exhaust temperature independent.