The preference for a ceramic matrix composite, in many applications, is due to its allowance for alterations, with regards to the filler or reinforcement used. Among the well-known ceramic matrix composites, is the carbon nanotube reinforced ceramic matrix composite. This ceramic composite, which possesses excellent properties, is used exclusively for high-end applications. However, other than the fact that this composite is prone to damage, in a high temperature environment during the sintering process, its use also comes at a high cost. Among the solutions to these drawbacks, is the introduction of carbon into the ceramic composite, through the chemical vapour infiltration (CVI) process. Initially, pyrolysis of biomass is applied on the empty fruit bunch (EFB), for the generation of tar vapour. Pyrolytic carbon is then produced through secondary reaction, during contact with the ceramic surface. The findings, derived from previous studies, indicate that the physical properties of ZTA improve with the infiltration of carbon, until optimum holding time is arrived at. The optimum holding time, of 2.5 hours for the CVI process, is due to the lowest surface area (3.605 m2/g) and the highest density (3.787 g/cm3). This can be attributed to the reduction in porosity, as the holding time increased. Thus, it can be concluded that carbon infiltration will significantly reduce the porosity, and improve the ceramic properties, of zirconia-toughened alumina (ZTA).
This study examines the effect of adding various amount of polyvinyl alcohol (PVA) from 1 wt. % to 5 wt. % as function to produce porosity of the microstructure on Zirconia-Toughened Alumina (ZTA). Porosity is required in this study which aims to increase the efficiency of carbon infiltration on the porous composite through chemical vapor infiltration (CVI). Moreover, carbon production from empty fruit bunch (EFB) was used as a reinforcement on ceramic composites in this system. The microstructure of samples was characterised by using scanning electron microscopy (SEM). The density shows the lowest at 2.864 g/cm3 when the percentage of binder is increased at 4wt.% of PVA without carbon infiltration but shows the highest density value which is 4.107 g/cm3 after carbon is infiltrated. Vickers hardness was used to identify the hardness of samples. It was found that ZTA composite with infiltrated carbon has better hardness (2053HV) with addition of 4wt.% of PVA. However, firing shrinkage showed no effect on the composite with or without carbon infiltration. The structure of crystalline carbon in composite was analyses by X-Ray Diffraction (XRD). Nevertheless, no peak for carbon is observed due to low carbon content and another alternative such as Raman spectroscopy was used to identify the presence of diffused carbon. Based on the result, carbon infiltration on composite will produce better physical and mechanical properties with the help of binders that produce pores for carbon to infiltrate.
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