Vincent Garnier

Optimized Slurries for Spray Drying: Different Approaches to Obtain Homogeneous and Deformable Alumina-Zirconia Granules

Spray drying is widely used for producing granulated feed materials for compaction process, which is the current industrial method for manufacturing alumina-zirconia femoral heads. The optimization of the granules compaction behavior requires the control of the slurry rheology. Moreover, for a dual-phase ceramic suspension, the even phase distribution has to be kept through the atomization step. Here we present two approaches addressing the key issues involved in the atomization of a composite system. Alumina-10 vol % zirconia powders were prepared by either a powder mixing route, or by the surface modification of a commercial α-alumina powder with a zirconium salt. Slurries from both powders were spray dried. The correlation between slurry rheology and pH, granules morphology and sintered microstructures was here investigated and discussed on the ground of the two feed materials characteristics. The processing conditions were optimized to obtain dense and homogeneous alumina-zirconia micro-nano composites by both processing routes.

Pure & crystallized 2D Boron Nitride sheets synthesized via a novel process coupling both PDCs and SPS methods

Within the context of emergent researches linked to graphene, it is well known that h-BN nanosheets (BNNSs), also referred as 2D BN, are considered as the best candidate for replacing SiO2 as dielectric support or capping layers for graphene. As a consequence, the development of a novel alternative source for highly crystallized h-BN crystals, suitable for a further exfoliation, is a prime scientific issue. This paper proposes a promising approach to synthesize pure and well-crystallized h-BN flakes, which can be easily exfoliated into BNNSs. This new accessible production process represents a relevant alternative source of supply in response to the increasing need of high quality BNNSs. The synthesis strategy to prepare pure h-BN is based on a unique combination of the Polymer Derived Ceramics (PDCs) route with the Spark Plasma Sintering (SPS) process. Through a multi-scale chemical and structural investigation, it is clearly shown that obtained flakes are large (up to 30 μm), defect-free and well crystallized, which are key-characteristics for a subsequent exfoliation into relevant BNNSs.

Nanopowder dispersion and spray-drying process: the case of Cr2O3

Abstract The work reported in this paper was performed in order to develop and to optimize the dispersion of Cr2O3 nanopowders by a ball-milling method and to produce spherical micrometer-sized granules by spray-drying. The targeted application for such granules is the development of wear resistant nanostructured Cr2O3 coatings by plasma spraying. Cr2O3 nanopowders were dispersed in deionized water. The suitable dispersant (DarvanC) was determined by zeta potential measurements and the dispersant quantity was optimized by rheological tests. The influence of milling time, diameter of milling balls and weight ratio of milling balls to powder was studied by granulometric measurements. A well-dispersed and stable suspension was then obtained and spray-dried. Dense and spherical micrometer-sized granules, with a monodispersed distribution centered about 50μm, have been achieved and Cr2O3 plasma-sprayed coatings have been realized.

Advanced synthesis of highly-crystallized hexagonal boron nitride by coupling PDCs and SPS processes – influence of the crystallization promoter and sintering temperature

Hexagonal boron nitride nanosheets (BNNSs) are promising 2D materials due to their exceptional chemical and thermal stabilities together with their electrical insulation properties. A combined synthesis method involving the polymer-derived ceramics (PDCs) route and the spark plasma sintering (SPS) process is proposed, leading to well-crystallized and pure layered h-BN crystals, prone to be exfoliated into large BNNSs. Here we focus more specifically on the influence of two key parameters of the process to be optimized: the Li3N concentration (0-10 wt%) and the SPS temperature (1200 °C-1950 °C). The presence of Li3N, added as crystal promoter in the pre-ceramic powder, significantly improves the crystallinity level of the product, as evidenced by XRD, SEM and Raman spectrometry. SPS temperature strongly modifies the size of the resulting h-BN flakes. The influence of SPS temperature on both purity and crystallinity is studied using cathodoluminescence. h-BN flakes larger than 200 μm2 (average flake area) are obtained. Few-layered BNNSs are successfully isolated, through exfoliation process.