AlF3-assisted flux growth of mullite whiskers and their application in fabrication of porous mullite-alumina monoliths

Mullite is a promising material with its competitive thermochemical and mechanical properties. Although mullite could be obtained by several synthesis methods, the flux method emerges with its advantages over other methods. However, obtaining mullite whiskers with a high aspect ratio and length for ceramic reinforcements is still challenging. In this work, mullite whiskers were grown from AlF3-assisted flux. The addition of AlF3 to flux salt not only decreases the formation temperature of mullite to as low as 700 ​°C and suppresses the formation of corundum side phase, but also increases the length and aspect ratio of the whiskers. The obtained mullite whiskers were used as reinforcement for porous alumina monoliths prepared by the freeze casting route and subsequent sintering at 1500 ​°C. The fabricated mullite-alumina monoliths show competitive compressive strength of 25.7 ​MPa while having as high as 70.6% porosity, which makes them a potential candidate for membrane applications.DFG, 414044773, Open Access Publizieren 2021 - 2022 / Technische Universität Berli

High performing additively manufactured bone scaffolds based on copper substituted diopside

The inclusion of small amounts of copper is often reported to enhance the mechanical and biointegrative performance of bioceramics towards tissue engineering applications. In this work, 3D scaffolds were additively manufactured by robocasting of precipitation derived copper doped diopside. Compositions were chosen in which magnesium sites in diopside were substituted by copper up to 3 at.%. Microstructure, mechanical performance, bioactivity, biodegradability, drug release, biocompatibility, in vitro angiogenesis and antibacterial activity were studied. Results indicate that copper is incorporated in the diopside structure and improves materials’ fracture toughness. Scaffolds with > 80% porosity exhibited compressive strengths exceeding that of cancellous bone. All compositions showed bioactivity and drug release functionalities. However, only samples with 0–1 at.% copper substitution showed favorable proliferation of osteogenic sarcoma cells, human umbilical vein endothelial cells and fibroblasts, while larger amounts of copper had cytotoxic behavior. In vitro angiogenesis was significantly enhanced by low levels of copper. Copper-containing materials showed anti-Escherichia coli activity, increasing with copper content. We show that across multiple indicators, copper substituted diopside of the composition CaMg0.99Cu0.01Si2O6, exhibits high performance as a synthetic bone substitute, comparing favorably with known bioceramics. These findings present a pathway for the enhancement of bioactivity and mechanical performance in printable bioceramics

Sintering of ceramics for clay in situ resource utilization on Mars

The sintering of wet processed Mars global simulant green bodies is explored. Green bodies shaped using slip casting, throwing on a potter’s wheel and additive manufacturing, including material extrusion (robocasting) and layerwise slurry deposition (LSD) are sintered in terrestrial and simulated Mars atmosphere. A sintering schedule is developed using hot stage microscopy, water absorption, sintering shrinkage and sintering mass loss. Sintered parts are characterized in respect to their density, porosity, phase composition, microstructure and mechanical properties. Densification behavior for different green bodies was generally similar, enabling the fabrication of larger green bodies (tiles, cups, bowls) and parts with fines details (test cubes and cuneiform tables) with low water absorption. Sintered LSD discs had a bending strength between terracotta and typical porcelains with 57.5/53.3 ​MPa in terrestrial/simulated Mars atmosphere. Clay ISRU for sintered ceramics can be considered an eminently favorable construction technology for soft and hard ISRU on Mars.DFG, 414044773, Open Access Publizieren 2019 - 2020 / Technische Universität Berli

Clay in situ resource utilization with Mars global simulant slurries for additive manufacturing and traditional shaping of unfired green bodies

The wet processing of regolith simulant for clay in situ resource utilization (ISRU) on Mars is presented. The two raw materials from the Mars global simulant family, one without clay (MGS-1) and one with clay - sodium montmorillonite smectite - (MGS-1C) were milled and mixed to produce a simulant with small particle size and reduced clay content (MGS-1C/8). All three simulants and the pure clay raw material were extensively characterized using XRF, synchrotron XRD, gas adsorption and gas pycnometry methods. In a straightforward processing approach, MGS-1C/8 was mixed with water and different dispersant approaches were investigated, all of which gave stable slurries. Particle size distribution, rheology, ion concentration, pH and electrical conductivity of these slurries were characterized. The slurry systems can easily be adapted to fit all typical ceramic shaping routes and here parts of varying complexity from slip casting, throwing on a potter's wheel and additive manufacturing, including material extrusion (robocasting) and binder jetting (powder bed 3D printing) were produced. The unique properties of the sodium montmorillonite clay, which is readily accessible in conjunction with magnesium sulfate on the Martian surface, acted as a natural nanosized binder and produced high strength green bodies (unfired ceramic body) with compressive strength from 3.3 to 7.5 MPa. The most elaborate additive manufacturing technique layerwise slurry deposition (LSD) produced water-resistant green bodies with a compressive strength of 30.8 ± 2.5 MPa by employing a polymeric binder, which is similar or higher than the strength of standard concrete. The unfired green bodies show sufficient strength to be used for remote habitat building on Mars using additive manufacturing without humans being present

Silicate dielectric ceramics for millimetre wave applications

Silicate ceramics are of considerable promise as high frequency dielectrics in emerging millimetre wave applications including high bandwidth wireless communication and sensing. In this review, we show how high quality factors and low, thermally stable permittivities arise in ordered silicate structures. On the basis of a large number of existing studies, the dielectric performance of silicate ceramics is comprehensively summarized and presented, showing how microstructure and SiO4 tetrahedral connectivity affect polarizability and dielectric losses. We critically examine the appropriateness of silicate materials in future applications as effective millimetre wave dielectrics with low losses and tuneable permittivities. The development of new soft chemistry based processing routes for silicate dielectric ceramics is identified as being instrumental towards the reduction of processing temperatures, thus enabling silicate ceramics to be co-fired in the production of components functioning in the mm wave regime

Towards the colonization of Mars by in-situ resource utilization: Slip cast ceramics from Martian soil simulant.

Here we demonstrate that by applying exclusively Martian resources a processing route involving suspensions of mineral particles called slurries or slips can be established for manufacturing ceramics on Mars. We developed water-based slurries without the use of additives that had a 51 wt. % solid load resembling commercial porcelain slurries in respect to the particle size distribution and rheological properties. These slurries were used to slip cast discs, rings and vases that were sintered at temperatures between 1000 and 1130 °C using different sintering schedules, the latter were set-up according the results of hot-stage microscopic characterization. The microstructure, porosity and the mechanical properties were characterized by SEM, X-ray computer tomography and Weibull analysis. Our wet processing of minerals yields ceramics with complex shapes that show similar mechanical properties to porcelain and could serve as a technology for future Mars colonization. The best quality parts with completely vitrificated matrix supporting a few idiomorphic crystals are obtained at 1130 °C with 10 h dwell time with volume and linear shrinkage as much as ~62% and ~17% and a characteristic compressive strength of 51 MPa

High performing additively manufactured bone scaffolds based on copper substituted diopside

The inclusion of small amounts of copper is often reported to enhance the mechanical and biointegrative performance of bioceramics towards tissue engineering applications. In this work, 3D scaffolds were additively manufactured by robocasting of precipitation derived copper doped diopside. Compositions were chosen in which magnesium sites in diopside were substituted by copper up to 3 at.%. Microstructure, mechanical performance, bioactivity, biodegradability, drug release, biocompatibility, in vitro angiogenesis and antibacterial activity were studied. Results indicate that copper is incorporated in the diopside structure and improves materials fracture toughness. Scaffolds with more than 80% porosity exhibited compressive strengths exceeding that of cancellous bone. All compositions showed bioactivity and drug release functionalities. However, only samples with 0 to 1 at.% copper substitution showed favorable proliferation of osteogenic sarcoma cells, human umbilical vein endothelial cells and fibroblasts, while larger amounts of copper had cytotoxic behavior. In vitro angiogenesis was significantly enhanced by low levels of copper. Copper containing materials showed anti Escherichia coli activity, increasing with copper content. We show that across multiple indicators, copper substituted diopside of the composition CaMg0.99Cu0.01Si2O6, exhibits high performance as a synthetic bone substitute, comparing favorably with known bioceramics. These findings present a pathway for the enhancement of bioactivity and mechanical performance in printable bioceramics

NaGdSi2_2O6_6 – A novel antiferromagnetically coupled silicate with Vierer chain structure

Ceramics based on pyroxenes and pyroxenoids present new pathways towards diverse functional materials. In this study, a novel sodium gadolinium pyroxene of the composition NaGdSi$_2$O$_6$ was successfully synthesised via a chelation-polymerization based sol-gel method and its crystal structure was determined by Rietveld refined synchrotron X-ray powder diffraction. NaGdSi$_2$O$_6$ crystallises in monoclinic symmetry with space group P2$_1$/c and unit cell parameters of a ​= ​5.44069(8) Å, b ​= ​13.83410(17) Å, c ​= ​7.66897(9) Å and β ​= ​109.9929(6)° (Z ​= ​4). The structure has been identified to be an inosilicate with a strongly undulated single tetrahedral chain along c with a chain periodicity of 4 (Vierer chain). Vierer chain-type NaGdSi$_2$O$_6$ shows a weak antiferromagnetic coupling, however there is no evidence for long-range magnetic order above 2 ​K

The sol–gel autocombustion as a route towards highly CO 2 -selective, active and long-term stable Cu/ZrO 2 methanol steam reforming catalysts

Ploner, Kevin; Nezhad, Parastoo Delir Kheyrollahi; Gili, Albert; Kamutzki, Franz; Gurlo, Aleksander; Doran, Andrew; Cao, Pengfei; Heggen, Marc; Köwitsch, Nicolas; Armbrüster, Marc; "The sol–gel autocombustion as a route towards highly CO 2-selective, active and long-term stable Cu/ZrO 2 methanol steam reforming catalysts", Mater. Chem. Front., (2021) 5, 5093-5105, DOI: 10.1039/D1QM00641JThe adaption of the sol–gel autocombustion method to the Cu/ZrO2 system opens new pathways for the specific optimisation of the activity, long-term stability and CO2 selectivity of methanol steam reforming (MSR) catalysts. Calcination of the same post-combustion precursor at 400 °C, 600 °C or 800 °C allows accessing Cu/ZrO2 interfaces of metallic Cu with either amorphous, tetragonal or monoclinic ZrO2, influencing the CO2 selectivity and the MSR activity distinctly different. While the CO2 selectivity is less affected, the impact of the post-combustion calcination temperature on the Cu and ZrO2 catalyst morphology is more pronounced. A porous and largely amorphous ZrO2 structure in the sample, characteristic for sol–gel autocombustion processes, is obtained at 400 °C. This directly translates into superior activity and long-term stability in MSR compared to Cu/tetragonal ZrO2 and Cu/monoclinic ZrO2 obtained by calcination at 600 °C and 800 °C. The morphology of the latter Cu/ZrO2 catalysts consists of much larger, agglomerated and non-porous crystalline particles. Based on aberration-corrected electron microscopy, we attribute the beneficial catalytic properties of the Cu/amorphous ZrO2 material partially to the enhanced sintering resistance of copper particles provided by the porous support morphology

Elucidating the role of earth alkaline doping in perovskite-based methane dry reforming catalysts.

To elucidate the role of earth alkaline doping in perovskite-based dry reforming of methane (DRM) catalysts, we embarked on a comparative and exemplary study of a Ni-based Sm perovskite with and without Sr doping. While the Sr-doped material appears as a structure-pure Sm1.5Sr0.5NiO4 Ruddlesden Popper structure, the undoped material is a NiO/monoclinic Sm2O3 composite. Hydrogen pre-reduction or direct activation in the DRM mixture in all cases yields either active Ni/Sm2O3 or Ni/Sm2O3/SrCO3 materials, with albeit different short-term stability and deactivation behavior. The much smaller Ni particle size after hydrogen reduction of Sm1.5Sr0.5NiO4, and of generally all undoped materials stabilizes the short and long-term DRM activity. Carbon dioxide reactivity manifests itself in the direct formation of SrCO3 in the case of Sm1.5Sr0.5NiO4, which is dominant at high temperatures. For Sm1.5Sr0.5NiO4, the CO : H2 ratio exceeds 1 at these temperatures, which is attributed to faster direct carbon dioxide conversion to SrCO3 without catalytic DRM reactivity. As no Sm2O2CO3 surface or bulk phase as a result of carbon dioxide activation was observed for any material - in contrast to La2O2CO3 - we suggest that oxy-carbonate formation plays only a minor role for DRM reactivity. Rather, we identify surface graphitic carbon as the potentially reactive intermediate. Graphitic carbon has already been shown as a crucial reaction intermediate in metal-oxide DRM catalysts and appears both for Sm1.5Sr0.5NiO4 and NiO/monoclinic Sm2O3 after reaction as crystalline structure. It is significantly more pronounced for the latter due to the higher amount of oxygen-deficient monoclinic Sm2O3 facilitating carbon dioxide activation. Despite the often reported beneficial role of earth alkaline dopants in DRM catalysis, we show that the situation is more complex. In our studies, the detrimental role of earth alkaline doping manifests itself in the exclusive formation of the sole stable carbonated species and a general destabilization of the Ni/monoclinic Sm2O3 interface by favoring Ni particle sintering