Cellular Ceramics Structure, Manufacturing, Properties and Applications

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ISBN: 9783527313204 | 3527313206
Cover: Hardcover
Copyright: 7/11/2005

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Authored by leading experts in this emerging field, this book gives an overview of the main aspects related to the structure, characterization, processing, properties and industrial as well as novel applications of cellular ceramics.

Preface

xix

List of Contributors

xxi

Part 1 Introduction

(30)

Cellular Solids -- Scaling of Properties

(15)

Michael F. Ashby

Introduction

(1)

Cellular or ``Lattice'' Materials

(1)

Bending-Dominated Structures

(5)

Mechanical Properties

(3)

Thermal Properties

(1)

Electrical Properties

(1)

Maxwell's Stability Criterion

(2)

Stretch-Dominated Structures

(4)

Summary

(2)

Liquid Foams -- Precursors for Solid Foams

(13)

Denis Weaire

Simon Cox

Ken Brakke

The Structure of a Liquid Foam

(3)

The Elements of Liquid Foam Structure

(3)

Real Liquid Foams

(1)

Quasistatic Processes

(2)

Beyond Quasistatics

(2)

Summary

(3)

Part 2 Manufacturing

(194)

Ceramics Foams

(24)

Jon Binner

Introduction

(1)

Replication Techniques

(8)

Slurry Coating and Combustion of Polymer Foams

(4)

Pyrolysis and CVD Coating of Polymer Foams

(1)

Structure of Reticulated Ceramics

(3)

Foaming Techniques

(10)

Incorporation of an External Gas Phase

(4)

In Situ Gas Evolution

(3)

Gelation

(2)

Ceramic Foam Structure

(1)

Other Techniques

(2)

Summary

(3)

Honeycombs

(30)

John Wight

Introduction

(1)

Forming the Honeycomb Geometry

(6)

Background

(2)

Honeycomb Extrusion Die

(3)

Nonextrusion Fabrication Processes

(1)

Composition

(3)

Paste

(1)

Mixing

(1)

The Binder

(1)

Thermal Processing

(3)

Diffusion: Drying and Debinding

(1)

Melt Manipulation

(1)

Sinter Shrinkage Manipulation

(1)

Post-Extrusion Forming

(13)

Reduction Extrusion

(3)

Hot Draw Reduction

(9)

Summary

(5)

Three-Dimensional Periodic Structures

(14)

Jennifer A. Lewis

James E. Smay

Introduction

(1)

Direct-Write Assembly

(2)

Colloidal Inks

(2)

Ink Flow during Deposition

(3)

Shape Evolution of Spanning Filaments

(2)

Direct-Write Assembly of 3D Periodic Structures

(3)

Summary

(2)

Connected Fibers: Fiber Felts and Mats

101

(21)

Janet B. Davis

David B. Marshall

Introduction

101

(1)

Oxide Fibers

102

(4)

Melt-Blown Silica Fibers

102

(2)

Blown Alumina--Silica Fibers

104

(1)

Drawn Alumina--Borosilicate Fibers

105

(1)

Fiber Product Forms

106

(3)

Continuous Monofilaments

107

(1)

Fiber Mat

107

(2)

Bulk Fiber

109

(1)

High-Performance Insulation for Space Vehicles

109

(11)

Rigid Space Shuttle Tiles

110

(6)

Flexible Insulation Blankets

116

(1)

Innovations in Thermal Protection Systems

117

(3)

Summary

120

(2)

Microcellular Ceramics from Wood

122

(15)

Heino Sieber

Mrityunjay Singh

Introduction

122

(2)

Fabrication of Porous Biocarbon Templates

124

(2)

Preparation of Carbide-Based Biomorphous Ceramics

126

(5)

Processing by Silicon-Melt Infiltration

127

(2)

Gas-Phase Processing

129

(2)

Preparation of Oxide-Based Biomorphous Ceramics

131

(3)

Summary

134

(3)

Carbon Foams

137

(21)

James Klett

Introduction

137

(1)

History

137

(1)

Terminology

138

(3)

Carbon

139

(1)

Graphite

139

(1)

Graphitization

139

(1)

Foam

140

(1)

Foaming Processes

141

(12)

Thermosetting Precursors

141

(3)

Thermoplastic Precursors

144

(9)

Properties of Carbon and Graphite Foam

153

(2)

Summary

155

(3)

Glass Foams

158

(19)

Giovanni Scarinci

Giovanna Brusatin

Enrico Bernardo

Introduction

158

(1)

Historical Background

158

(2)

Starting Glasses

160

(1)

Modern Foaming Process

161

(5)

Initial Particle Size of the Glass and the Foaming Agent

161

(2)

Heating Rate

163

(1)

Foaming Temperature

164

(1)

Heat-Treatment Time

164

(1)

Chemical Dissolved Oxygen

164

(1)

Cooling Rate

165

(1)

Foaming Agents

166

(4)

Foaming by Thermal Decomposition

166

(1)

Foaming by Reaction

167

(3)

Glass Foam Products

170

(1)

Alternative Processes and Products

171

(4)

Foams from Evaporation of Metals

172

(1)

High-Silica Foams from Phase-Separating Glasses

172

(1)

Microwave Heating

172

(1)

Glass Foam from Silica Gel

173

(1)

High-Density Glass Foam

173

(1)

Partially Crystallized Glass Foam

173

(1)

Foaming of CRT Glasses

174

(1)

Summary

175

(2)

Hollow Spheres

177

(16)

Srinivasa Rao Boddapati

Rajendra K. Bordia

Introduction

177

(1)

Processing Methods

178

(10)

Sacrificial-Core Method

178

(1)

Layer-by-Layer Deposition

179

(3)

Emulsion/Sol--Gel Method

182

(3)

Spray and Coaxial-Nozzle Techniques

185

(3)

Reaction-Based and Other Methods

188

(1)

Cellular Ceramics from Hollow Spheres (Syntactic Foams)

188

(1)

Properties

188

(1)

Applications

189

(1)

Summary

190

(3)

Cellular Concrete

193

(32)

Michael W. Grutzeck

Introduction

193

(1)

Types of Cellular Concrete

194

(4)

Low Temperature Cured Cellular Concrete

195

(2)

Autoclave-Cured Cellular Concrete

197

(1)

Per-Capita Consumption

198

(1)

Overview of Cellular Concrete

199

(7)

The Gas Phase

199

(1)

The Matrix Phase

200

(6)

Portland Cement

206

(5)

History

207

(1)

Fabrication of Portland Cement

207

(1)

Hydration

208

(3)

Properties of Calcium Silicate Hydrate in Cellular Concretes

211

(8)

Cast-in-Place or Precast Cellular Concrete

212

(2)

Autoclaved Aerated Concrete (AAC)

214

(5)

Durability of Cellular Concrete

219

(2)

Summary

221

(4)

Part 3 Structure

225

(64)

Characterization of Structure and Morphology

227

(40)

Steven Mullens

Jan Luyten

Juergen Zeschky

Introduction and Theoretical Background

227

(5)

The Importance of Foam Structure Characterization

227

(1)

Structure-Dependent Properties

228

(2)

Parameters Describing the Structure of the Foams

230

(2)

Characterization of Foam Pore Structure

232

(1)

Sample Preparation

233

(30)

Characterization Methods

233

(29)

Comparison of Methods

262

(1)

Summary

263

(4)

Modeling Structure--Property Relationships in Random Cellular Materials

267

(22)

Anthony P. Roberts

Introduction

267

(1)

Theoretical Structure--Property Relations

268

(5)

Modeling and Measuring Structure

273

(7)

Computational Structure--Property Relations

280

(5)

Summary

285

(4)

Part 4 Properties

289

(112)

Mechanical Properties

291

(22)

Roy Rice

Introduction

291

(1)

Modeling the Porosity Dependence of Mechanical Properties of Cellular Ceramics

292

(7)

Earlier Models

292

(2)

Gibson--Ashby Models

294

(1)

Minimum Solid Area (MSA) Models

295

(3)

Computer Models

298

(1)

Porosity Effects on Mechanical Properties of Cellular Ceramics

299

(8)

Honeycomb Structures

299

(2)

Foams and Related Structures

301

(6)

Discussion

307

(3)

Measurement--Characterization Issues

307

(1)

Impact of Fabrication on Microstructure

308

(1)

Porosity--Property Trade-Offs

309

(1)

Summary

310

(3)

Permeability

313

(29)

Murilo Daniel de Mello Innocentini

Pilar Sepulveda

Fernando dos Santos Ortega

Introduction

313

(1)

Description of Permeability

313

(2)

Experimental Evaluation of Permeability

315

(2)

Models for Predicting Permeability

317

(14)

Granular Media

318

(2)

Fibrous Media

320

(1)

Cellular Media

321

(10)

Viscous and Inertial Flow Regimes in Porous Media

331

(7)

Summary

338

(4)

Thermal Properties

342

(19)

Thomas Fend

Dimosthenis Trimis

Robert Pitz-Paal

Bernhard Hoffschmidt

Oliver Reutter

Introduction

342

(1)

Thermal Conductivity

342

(8)

Experimental Methods to Determine the Effective Thermal Conductivity without Flow

345

(3)

Method to Determine the Effective Thermal Conductivity with Flow

348

(2)

Specific Heat Capacity

350

(1)

Thermal Shock

350

(2)

Volumetric Convective Heat Transfer

352

(7)

Nusselt/Reynold Correlations and Comparison with Theoretical Data

354

(5)

Summary

359

(2)

Electrical Properties

361

(20)

Hans-Peter Martin

Joerg Adler

Introduction and Fundamentals

361

(5)

Specific Aspects of Electrical Properties of Cellular Solids

366

(10)

Honeycombs

367

(1)

Biomimetic Ceramic Structures

368

(1)

Ceramic Foams

369

(5)

Ceramic Fibers

374

(2)

Electrical Applications of Cellular Ceramics

376

(3)

Foam Ceramic Heaters

376

(2)

Electrically Conductive Honeycombs

378

(1)

Summary

379

(2)

Acoustic Properties

381

(20)

Iain D.J. Dupere

Tian J. Lu

Ann P. Dowling

Introduction

381

(1)

Acoustic Propagation

381

(3)

Linearized Equations of Motion

381

(1)

Wave Equation

382

(1)

Relationships between Acoustic Parameters under Inviscid Conditions

383

(1)

Acoustic Energy

384

(1)

Acoustic Properties

384

(3)

Acoustic Impedance and Admittance

384

(2)

Acoustic Wavenumber

386

(1)

Reflection Coefficient, Transmission Coefficient, and Transmission Loss

386

(1)

Absorption Coefficient

387

(1)

Experimental Techniques

387

(2)

Moving-Microphone Technique

387

(1)

Two- and Four-Microphone Techniques

388

(1)

Empirical Models

389

(1)

Theoretical Models

390

(7)

Viscous Attenuation in Channels (Rayleigh's Model)

390

(1)

Acoustic Damping by an Array of Elements Perpendicular to the Propagation Direction

391

(1)

Generalized Models

392

(1)

Complex Viscosity and Complex Density Models

392

(1)

Direct Models

393

(2)

Biot's Model

395

(1)

Lambert's Model

396

(1)

Acoustic Applications of Cellular Ceramics

397

(1)

Summary

398

(3)

Part 5 Applications

401

(220)

Liquid Metal Filtration

403

(13)

Rudolph A. Olson III

Luiz C. B. Martins

Introduction

403

(1)

Theory of Molten-Metal Filtration

404

(4)

Commercial Applications

408

(6)

Aluminum

408

(2)

Iron Foundry

410

(2)

Steel

412

(2)

Summary

414

(2)

Gas (Particulate) Filtration

416

(23)

Debora Fino

Guido Saracco

Introduction

416

(1)

Properties of (Catalytic) Cellular Filters

417

(1)

Applications

418

(15)

Diesel Particulate Abatement

418

(10)

Abatement of Gaseous Pollutants and Fly-Ash

428

(5)

Modeling

433

(3)

Summary

436

(3)

Kiln Furnitures

439

(70)

Andy Norris

Rudolph A. Olson III

Introduction

439

(2)

Application of Ceramic Foam to Kiln Furniture

441

(8)

Longer Life

441

(5)

More Uniform Atmosphere Surrounding the Fired Ware

446

(1)

Reduction of Frictional Forces during Shrinkage

447

(1)

Chemical Inertness

447

(1)

Cost Benefits

448

(1)

Manufacture of Kiln Furniture

449

(3)

Foam Replication Process

449

(2)

Foams Manufactured by using Fugitive Pore Formers

451

(1)

Summary

452

(54)

Applications of Volumetric Porous Burners

498

(8)

Summary

506

(3)

Acoustic Transfer in Ceramic Surface Burners

509

(14)

Koen Schreel

Philip de Goey

Introduction

509

(2)

Acoustic Transfer

511

(1)

Analytical Model

512

(2)

Acoustic Transfer Coefficient for Realistic Porous Ceramics

514

(7)

Numerical Results

515

(3)

Measurements

518

(3)

Summary

521

(2)

Solar Radiation Conversion

523

(24)

Thomas Fend

Robert Pitz-Paal

Bernhard Hoffschmidt

Oliver Reutter

Introduction

523

(2)

The Volumetric Absorber Principle

525

(1)

Optical, Thermodynamic, and Fluid-Mechanical Requirements of Cellular Ceramics for Solar Energy Conversion

526

(6)

Examples of Cellular Ceramics Used as Volumetric Absorbers

532

(4)

Extruded Silicon Carbide Catalyst Supports

532

(1)

Ceramic Foams

533

(1)

SiC Fiber Mesh

534

(1)

Screen-Printed Absorbers (Direct-Typing Process)

535

(1)

Material Combinations

536

(1)

Absorber Tests

536

(3)

Physical Restrictions of Volumetric Absorbers and Flow Phenomena in cellular ceramics

539

(6)

Experimental Determination of Nonstable Flow

544

(1)

Summary

545

(2)

Biomedical Applications: Tissue Engineering

547

(24)

Julian R. Jones

Aldo R. Boccaccini

Introduction

547

(1)

Regenerative Medicine and Biomaterials

548

(1)

Bioactive Ceramics for Tissue Engineering

549

(1)

Scaffold Biomaterials for Tissue Engineering

550

(2)

Cellular Bioceramics as Scaffolds in Tissue Engineering

552

(13)

HA and Other Calcium Phosphates

552

(8)

Melt-Derived Bioactive Glasses

560

(1)

Sol--Gel-derived Bioactive Glasses

560

(4)

Other Bioceramics Exhibiting Cellular Structure

564

(1)

Properties of Some Selected Bioactive Ceramic Foams

565

(1)

Summary

566

(5)

Interpenetrating Composites

571

(9)

Jon Binner

Introduction

571

(1)

Metal--Ceramic Interpenetrating Composites

572

(3)

Polymer--Ceramic Interpenetrating Composites

575

(3)

Summary

578

(2)

Porous Media in Internal Combustion Engines

580

(16)

Miroslaw Weclas

Introduction

580

(1)

Novel Engine Combustion Concepts with Homogeneous Combustion Processes

581

(2)

Application of Porous-Medium Technology in IC Engines

583

(4)

The PM Engine Concept: Internal Combustion Engine with Mixture Formation and Homogeneous Combustion in a PM Reactor

587

(3)

PM Engine with Closed PM Chamber

588

(1)

PM Engine with Open PM Chamber

589

(1)

An Update of the MDI Engine Concept: Intelligent Engine Concept with PM Chamber for Mixture Formation

590

(2)

Two-Stage Combustion System for DI Diesel Engine

592

(2)

Summary

594

(2)

Other Developments and Special Applications

596

(25)

Paolo Colombo

Edwin P. Stankiewicz

Introduction

596

(1)

Improving the Mechanical Properties of Reticulated Ceramics

596

(4)

Ceramic Foams by Reaction Bonding

597

(1)

Overcoating of Conventional Reticulated Ceramics

598

(1)

Infiltration of the Struts of Reticulated Ceramics

599

(1)

Microcellular Ceramic Foams

600

(1)

Porous Ceramics with Aligned Pores

601

(1)

Porous Superconducting Ceramics

602

(1)

Porous Yb2O3 Ceramic Emitter for Thermophotovoltaic Applications

603

(1)

Ceramic Foams for Advanced Thermal Management Applications

604

(2)

Ceramic Foams for Impact Applications

606

(3)

Hypervelocity Impact Shields for Spacecrafts and Satellites

606

(2)

Armour Systems

608

(1)

Heat Exchangers

609

(2)

Ceramic Foams for Semiconductor Applications

611

(1)

Duplex filters

611

(1)

Lightweight Structures

612

(1)

Ceramic Foams as Substrates for Carbon Nanotube Growth

613

(1)

Metal Oxide Foams as Precursors for Metallic Foams

614

(1)

Zeolite Cellular Structures

615

(1)

Current Collectors in Solid Oxide Fuel Cells

616

(1)

Sound Absorbers

616

(1)

Bacteria/Cell Immobilization

617

(1)

Light Diffusers

617

(1)

Summary

618

(3)

Concluding Remarks

621

(4)

Index

625

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Cellular Ceramics Structure, Manufacturing, Properties and Applications

Summary

Author Biography

Table of Contents

Supplemental Materials