Biomorphic ceramics from wood-derived precursors

Materials development is driven by microstructural complexity and, in many cases, inspired by biological systems such as bones, shells and wood. In one approach, one selects the main microstructural features responsible for improved properties and design processes to obtain materials with such microstructures (continuous-fibre-reinforced ceramics, porous ceramics, fibrous ceramic monoliths, etc.). In a different approach, it is possible to use natural materials directly as microstructural templates. Biomorphic ceramics are produced from natural and renewable resources (wood or wood-derived products). A wide variety of SiC-based ceramics can be fabricated by infiltration of silicon or silicon alloys into cellulose-derived carbonaceous templates, providing a low-cost route to advanced ceramic materials with near-net shape potential and amenable to rapid prototyping. These materials have tailorable microstructure and properties, and behave like ceramic materials manufactured by advanced ceramic processing approaches. This review aims to be a comprehensive description of the development of bioSiC ceramics: from wood templates and their microstructure to potential applications of bioSiC materials.Ministerio de Economía y Competitividad MAT2016-76526-R, MAT2013-41233-

Structural evolution in iron-catalyzed graphitization of hard carbons

Despite the recent interest in catalytic graphitization to obtain graphite-like materials from hard-carbon sources, many aspects of its mechanism are still poorly unknown. We performed a series of in situ experiments to study phase transformations during graphitization of a hard-carbon precursor using an iron catalyst at temperatures up to 1100 °C and ex situ total scattering experiments up to 2000 °C to study the structural evolution of the resulting graphitized carbon. Our results show that upon heating and cooling, iron undergoes a series of reductions to form hematite, magnetite, and wüstite before forming a carbide that later decomposes into metallic iron and additional graphite and that the graphitization fraction increases with increasing peak temperature. Structural development with temperature results in decreasing sheet curvature and increased stacking, along with a decrease in turbostratic disorder up to 1600 °C. Higher graphitization temperatures result in larger graphitic domains without further ordering of the graphene sheets. Our results have implications for the synthesis of novel biomass-derived carbon materials with enhanced crystallinity.Ministerio de Ciencia, Innovación y Universidades PID2019- 107019

Thermal Conductivity of Partially Graphitized Biocarbon Obtained by Carbonization of Medium-Density Fiberboard in the Presence of a Ni-Based Catalyst

The thermal conductivity k and resistivity ρ of biocarbon matrices, prepared by carbonizing medium-density fiberboard at Tcarb = 850 and 1500°C in the presence of a Ni-based catalyst (samples MDFC( Ni)) and without a catalyst (samples MDF-C), have been measured for the first time in the temperature range of 5–300 K. X-ray diffraction analysis has revealed that the bulk graphite phase arises only at Tcarb = 1500°C. It has been shown that the temperature dependences of the thermal conductivity of samples MDFC- 850 and MDF-C-850(Ni) in the range of 80–300 K are to each other and follow the law of k(T) ~ T1.65, but the use of the Ni-catalyst leads to an increase in the thermal conductivity by a factor of approximately 1.5, due to the formation of a greater fraction of the nanocrystalline phase in the presence of the Ni-catalyst at Tcarb = 850°C. In biocarbon MDF-C-1500 prepared without a catalyst, the dependence is k(T) ~ T1.65, and it is controlled by the nanocrystalline phase. In MDF-C-1500(Ni), the bulk graphite phase formed increases the thermal conductivity by a factor of 1.5–2 compared to the thermal conductivity of MDF-C-1500 in the entire temperature range of 5–300 K; k(T = 300 K) reaches the values of ~10 W m–1 K–1, characteristic of biocarbon obtained without a catalyst only at high temperatures of Tcarb = 2400°C. It has been shown that MDF-C-1500(Ni) in the temperature range of 40‒300 K is characterized by the dependence, k(T) ~ T1.3, which can be described in terms of the model of partially graphitized biocarbon as a composite of an amorphous matrix with spherical inclusions of the graphite phaseRussian Foundation for Basic Research 14-03- 0049

Porous Graphene-like Carbon from Fast Catalytic Decomposition of Biomass for Energy Storage Applications

A novel carbon material made of porous graphene-like nanosheets was synthesized from biomass resources by a simple catalytic graphitization process using nickel as a catalyst for applications in electrodes for energy storage devices. A recycled fiberboard precursor was impregnated with saturated nickel nitrate followed by high-temperature pyrolysis. The highly exothermic combustion of in situ formed nitrocellulose produces the expansion of the cellulose fibers and the reorganization of the carbon structure into a three-dimensional (3D) porous assembly of thin carbon nanosheets. After acid washing, nickel particles are fully removed, leaving nanosized holes in the wrinkled graphene-like sheets. These nanoholes confer the resulting carbon material with ≈75% capacitance retention, when applied as a supercapacitor electrode in aqueous media at a specific current of 100 A·g–1 compared to the capacitance reached at 20 mA·g–1, and ≈35% capacity retention, when applied as a negative electrode for lithium-ion battery cells at a specific current of 3720 mA·g–1 compared to the specific capacity at 37.2 mA·g–1. These findings suggest a novel way for synthesizing 3D nanocarbon networks from a cellulosic precursor requiring low temperatures and being amenable to large-scale production while using a sustainable starting precursor such as recycled fiberwood.Spanish Government Agency Ministerio de Economí a y Competitividad (MINECO) (grant number MAT2016-76526-R)

Precision and accuracy of stress measurement with a portable X-ray machine using an area detector

The use of portable X-ray stress analyzers, which utilize an area detector along with the newly adopted 'cosα' or full-ring fitting method, has recently attracted increasing interest. In laboratory conditions, these measurements are fast, convenient and precise because they employ a single-exposure technique that does not require sample rotation. In addition, the effects of grain size and orientation can be evaluated from the Debye ring recorded on the area detector prior to data analysis. The accuracy of the measured stress, however, has been questioned because in most cases just a single reflection is analyzed and the sample-to-detector distances are relatively short. This article presents a comprehensive analysis of the uncertainty associated with a state-of-the-art commercial portable X-ray device. Annealed ferrite reference powders were used to quantify the instrument precision, and the accuracy of the stress measurement was tested by in situ tensile loading on 1018 carbon steel and 6061 aluminium alloy bar samples. The results show that the precision and accuracy are sensitive to the instrument (or sample) tilt angle (ψ0) as well as to the selected hkl reflection of the sample. The instrument, sample and data analysis methods all affect the overall uncertainty, and each contribution is described for this specific portable X-ray system. Finally, on the basis of the conclusions reached, desirable measurement/analysis protocols for accurate stress assessments are also presented

Compressive strength degradation in ZrB2-based ultra-high temperature ceramic composites

The high temperature compressive strength behavior of zirconium diboride (ZrB2)-silicon carbide (SiC) particulate composites containing either carbon powder or SCS-9a silicon carbide fibers was evaluated in air. Constant strain rate compression tests have been performed on these materials at room temperature, 1400, and 1550°C. The degradation of the mechanical properties as a result of atmospheric air exposure at high temperatures has also been studied as a function of exposure time. The ZrB2-SiC material shows excellent strength of 3.1±0.2GPa at room temperature and 0.9±0.1GPa at 1400°C when external defects are eliminated by surface finishing. The presence of C is detrimental to the compressive strength of the ZrB2-SiC-C material, as carbon burns out at high temperatures in air. As-fabricated SCS-9a SiC fiber reinforced ZrB2-SiC composites contain significant matrix microcracking due to residual thermal stresses, and show poor mechanical properties and oxidation resistance. After exposure to air at high temperatures an external SiO2 layer is formed, beneath which ZrB2 oxidizes to ZrO2. A significant reduction in room temperature strength occurs after 16-24h of exposure to air at 1400°C for the ZrB2-SiC material, while for the ZrB2-SiC-C composition this reduction is observed after less than 16h. The thickness of the oxide layer was measured as a function of exposure time and temperatures and the details of oxidation process has been discussed.The European Office of Aerospace Research and Development, Air Force Office of Scientific Research, Air Force Research Laboratory, FA8655-07-1-308

Sliding wear resistance of biomorphic SiC ceramics

Biomorphic SiC ceramics were fabricated from four different wood precursors and their Knoop hardness and sliding wear resistance when sliding against a Si3N4 ball in air were studied. Tribological experiments were performed using a pin on disk apparatus, under normal loads of 2 and 5 N, at a sliding speed of 100 mm/s. The effects of specimen porosity and microstructure on measured wear were evaluated. A commercial sintered silicon carbide ceramic was also tested for comparison. Small differences in friction coefficient comparable to monolithic SiC ceramics were obtained. Several concurrent wear mechanisms are taking place: microfracture, plastic deformation in the Si phase and oxidation of the Si and/or SiC phase. The presence of an oxide tribolayer was assessed using fluorescence microscopy. Wear rates were found to scale with SiC content and depend on residual porosity in the composite

Sliding wear resistance of sintered SiC-fiber bonded ceramics

Advanced SiC-based ceramics and fiber reinforced composites are interesting materials for a wide variety of applications involving sliding wear conditions because of their excellent thermomechanical properties. The microstructure and wear resistance of sintered SiC fiber bonded ceramics (SA Tyrannohex) were studied. The material is composed of SiC-fibers in two orientations, with polygonal cross sections and cores having higher carbon content than their surroundings, as observed with SEM. A thin layer of C exists between the fibers. This layer has been found to be a turbostratic-layered structure oriented parallel to the fiber surface. XRD shows that the material is highly crystalline and composed mostly of β-SiC. Unlubricated wear behavior of the SA-Tyrannohex material when sliding against a Si3N4 ball in air at room temperature was evaluated. Experiments were performed using a pin on disk apparatus, under different normal loads of 2, 5 and 10 N at sliding speeds of 25, 50, 100 mm/s. A decrease of the friction coefficient with load was found due to the presence of the turbostratic carbon layer between the fibers. Wear rates of the order of 100 mm3/MJ were obtained, independently of sliding speed. Microfracture of the fibers is the main wear mechanism

Thermal conductivity of Fe graphitized wood derived carbon

Graphitic porous carbon materials from pyrolysis of wood precursors were obtained by means of a nanosized Fe catalyst, and their microstructure and electrical and thermal transport properties investigated. Thermal and electrical conductivity of graphitized carbon materials increase with the pyrolysis temperature, indicating a relationship between the degree of graphitization and thus in crystallite size with transport properties in the resulting carbon scaffolds. Evaluation of the experimental results indicate that thermal conductivity is mainly through phonons and increases with the temperature in Fe-catalyzed carbons suggesting that the mean free path of phonons in the material is small and defect scattering dominates over phonon-phonon interactions in the range from room temperature to 800 °C.Junta de Andalucía PE2012-TEP862Ministerio de Economía y Competitividad MAT2013-41233-

Permeability and mechanical integrity of porous biomorphic SiC ceramics for application as hot-gas filters

Biomorphic SiC is a biotemplated material fabricated by Si melt-infiltration of carbon preforms from wood pyrolysis. In this work, porous bioSiC ceramics from five different wood precursors, with porosities between 45 and 72% were studied for their feasibility in filtering applications.Gas permeability and mechanical stability were investigated as a function of the microstructure of the starting wood precursor. Air-permeation performance at room temperature was measured for a range of flow rates, and the permeability constants were assessed by fitting of Forchheimer's equation to the experimental data. Darcian permeabilities were achieved in the range 10-10 m, while inertial terms were in the range 10-10 m, showing a correlation with the average pore size and orientation of the larger channels. Regarding the mechanical stability, maximum compressive strength values were reached in the range of 3-115 MPa.These results improve our understanding of the ways in which the microstructure influences permeability and mechanical robustness, enabling the device requirements to be tailored by selecting the wood precursor. It was also shown that these materials are promising for hot-gas filtering applications.Ministerio de Economía y Competitividad MAT2013-41233-