The aim of this study was to evaluate the effect of Y2O3:Al2O3 additives and sintering temperature on thermal shock resistance of silicon carbide sintered via liquid phase. Silicon carbide samples containing 10 mol% Y2O3:Al2O3 (1:3 and 1:4) were prepared, compacted and sintered at 1750, 1850 and 1950 °C in a graphite resistive furnace. Thermal shock resistance was evaluated after each thermal cycle performed at 600, 750 and 900 °C followed by abrupt cooling in water. Samples with two Y2O3:Al2O3 proportions did not show major differences when sintered at the same temperature, though, rising the sintering temperature improves Y2O3:Al2O3 modified-SiC thermal shock resistance.
In order to decrease environmental impact, caused by mud discarding and clay extraction in the ceramic industry, it was used residual mud from marble and granite companies for structural ceramic. Samples were collected in twelve different marble companies located at the metropolitan region of São Paulo. However, only four samples were selected, based on its different characteristics. Claystone was the raw material chosen to prepare the structural ceramic, considering its high use in this segment. Samples and claystone were both analysed by the following procedures: granulometric analysis, x-rays fluorescent chemical analysis and x-rays diffraction mineralogical analysis, besides, tests in the samples were conducted following NBR 10004 standards. Once raw materials were characterized, the plasticity test was conducted. Test specimen were molded with different levels of mud, then burned and submitted to technological tests, such as: mechanical resistance, water absorption, porosity, specific gravity and retraction, material dilation before burning process and scanning electron microscopy. The final results have shown the viability of using this kind of mud, and pointed some advantages on its usage, but taking in consideration some previous conditions to be adopted.
The behavior of ceramic materials towards thermal shock resistance is a topic of great interest, due to applications in which the reliability against sudden temperature variations is required. In this thesis, it was studied how the variation in the proportion of Y 2 O 3 :Al 2 O 3 additives and different parameters on the processing of liquid phase sintered silicon carbide may influence thermal shock resistance of this material. Samples were prepared with molar composition 90%SiC+10%Y 2 O 3 :Al 2 O 3 , by varying oxides molar proportion between 2:1 and 1:4, with and without previous reaction of the additives. Mixtures were compacted and sintered in a resistive graphite furnace at 1750, 1850 and 1950°C, and by hot pressing at 1750 and 1850°C, and evaluated for densification. After analysis of the first results, pressureless sintering and the mixtures with proportions of 1:3 and 1:4 of previously reacted Y 2 O 3 :Al 2 O 3 were selected for the study of thermal shock resistance. Thermal cycles were performed by heating at temperatures of 600, 750 and 900°C and sudden cooling in water at room temperature. The evaluation of samples regarding thermal shock resistance was conducted by determination of elasticity modulus, porosity, flexural strength and microstructural analysis of the cracks. The samples sintered at 1950°C temperature are those that exhibit the best performance in relation to thermal shock resistance, while the variation in the proportions Y 2 O 3 :Al 2 O 3 from 1:3 to 1:4 do not significantly change this property. Under the conditions used, the maximum temperature for liquid phase sintered SiC application must be limited to 750°C, which allows its use as a component of heat exchanges, bearings, pump bearings, gas turbines and sensors of automotive and aeronautical engines.
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