The porous mullite ceramics doped with such metal oxides as ZrO2, WO3 and MgO in quantity of 5 wt% were prepared by slip casting method. The mullite phase was the main and dominant phase of ZrO2-, WO3- and MgO-doped samples, which were sintered at the temperatures of 1650°C, 1500°C, respectively. The ZrO2, WO3 and MgO had the positive effect on the increase of porosity and decrease of thermal conductivity of porous mullite ceramics and the degree of this effect was in the order of ZrO2<MgO<WO3.
Mullite ceramics are well known as materials with a high temperature stability, strength and creep resistance. In this research, the effect of a modification with magnesia-stabilized zirconia and yttria-stabilized zirconia, separately, as well as in a mixture with WO3, in 1:1 and 1:2 ratios on the thermal properties of porous mullite ceramics was investigated. The porous mullite-containing ceramics were prepared by a slip casting of the concentrated slurry of raw materials with the addition of a suspension of Al paste for the pore formation due to the H2 evolution as a result of the reaction of Al with water. The formed samples were sintered at 1600 °C and the holding time was 1 h. The materials were characterized using X-ray diffractometry, scanning electron microscopy, mercury porosimetry, the laser flash contactless method, thermal shock resistance testing and the non-destructive impulse excitation method for determining the elasticity modulus. The modification of the porous mullite ceramic with a mixture of ZrO2 and WO3 oxides had a positive effect by decreasing the thermal conductivity, due to the increased porosity, in comparison to the undoped samples and samples with only ZrO2. The doubling of the WO3 amount in the modifying oxide mixtures improved the ceramic thermal shock resistance. The porous mullite ceramics which were modified with magnesia-stabilized zirconia (2.8 mol% MgO) and WO3 had a lower thermal conductivity and improved thermal shock resistance than the samples with yttria-stabilized zirconia (8 mol% Y2O3) and WO3.
Mullite and mullite–alumina ceramics materials with dominance of the mullite phase are used in different areas of technology and materials science. Porous mullite ceramics materials can be used simultaneously as refractory heat insulators and also as materials for constructional elements. The purpose of this work was to investigate the WO3 nanoparticle influence on the evolution of the aluminum tungstate and zircon crystalline phases in mullite ceramics due to stabilization effects caused by different microsize ZrO2 and WO3. The use of nano-WO3 prevented the dissociation of zircon in the ceramic samples with magnesia-stabilized zirconia (MSZ), increased porosity by approximately 60 ± 1%, increased the intensity of the aluminum tungstate phase, decreased bulk density by approximately 1.32 ± 0.01 g/cm3, and increased thermal shock resistance by ensuring a loss of less than 5% of the elastic modulus after 10 cycles of thermal shock.
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