• Industry Promotion Research
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• v.6 no.4
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• pp.1-9
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• 2021

The purpose of this study is to manufacture lightweight aggregates for recycling water treatment sludge, to identify the physical properties of the aggregates, and present a method of utilizing the manufactured lightweight aggregates. The chemical composition and thermal properties were examined via a raw materials analysis. The aggregate examined here was fired by the rapid sintering method and the single-particle density and water absorption rate were measured. Water treatment sludge has high ignition loss and high fire resistance. When 30wt% of purified sludge was added, the single-particle density of the aggregates was in the range of 0.8~1.2g/cm³ at a temperature of 1,150~1,200℃. At temperatures of 1200℃ or higher, ultra-light aggregates having a single-particle density of 0.8 or less could be produced. When applied to concrete by replacing the general aggregate in the concrete, a specimen having strength values of 200 to 450 kgf/cm² on 28 days was obtained, and when applied as a filter material, the performance was equal to or higher than that of ordinary sand.

• Korean Journal of Chemical Engineering
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• v.35 no.11
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• pp.2185-2190
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• 2018

Methane activation through oxychlorination is in the spotlight due to the relatively mild reaction conditions at atmospheric pressure and in the temperature range of $450-550^{\circ}C$. Although $CeO_2$ is known to exhibit good activity for methane oxychlorination, significant amounts of by-products such as $CO_2$, CO and carbon deposits are produced during the reaction over $CeO_2$. We investigated the effect of iron in $FeO_x/CeO_2$ catalysts on methane oxychlorination. $FeO_x/CeO_2$ with 3 wt% iron shows the maximum yield at $510^{\circ}C$ with 23% conversion of methane and 65% selectivity of chloromethane. XRD and $H_2$ TPR results indicate that iron-cerium solid solution was formed, resulting in the production of more easily reduced cerium oxide and the suppression of catalysts sintering during the reaction. Furthermore, the selectivity of by-products decreased more significantly over $FeO_x/CeO_2$ than cerium oxide, which can be attributed to the facilitation of HCl oxidation arising from the enhanced reducibility of the former sample.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.35 no.3
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• pp.292-296
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• 2022

(La_0.5Nd_0.2Sr_0.3)MnO₃ specimens were prepared by a solid-state reaction. In all specimens, X-ray diffraction patterns of an orthorhombic structure were shown. The fracture surfaces of (La_0.5Nd_0.2Sr_0.3)MnO₃ specimens showed a transgranular fracture pattern be possibly due to La ions (0.122 nm) as a perovskite A-site dopant substituting for Nd ions (0.115 nm) having a small ionic radius. The full-width at half maximum (FWHM) of the Mn 2p XPS spectra showed a value greater than that [8] of the single valence state, which is believed to be due to the overlapping of Mn²⁺, Mn³⁺, and Mn⁴⁺ ions. The dependence of Mn 2p spectra on the Mn³⁺/Mn⁴⁺ ratio according to sintering time was not observed. Electrical resistivity resulted in the minimum value of 100.7 Ω-cm for the specimen sintered for 9 hours. All specimens show a typical negative temperature coefficient of resistance (NTCR) characteristics. In the 9-hour sintered specimen, TCR, activation energy, and B25/65-value were -1.24%/℃, 0.19 eV, and 2,445 K, respectively.

• Journal of Powder Materials
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• v.29 no.6
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• pp.468-476
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• 2022

Yttria-stabilized zirconia (YSZ) has a low thermal conductivity, high thermal expansion coefficient, and excellent mechanical properties; thus, it is used as a thermal barrier coating material for gas turbines. However, during long-time exposure of YSZ to temperatures of 1200℃ or higher, a phase transformation accompanied by a volume change occurs, causing the YSZ coating layer to peel off. To solve this problem, YSZ has been doped with trivalent and tetravalent oxides to obtain coating materials with low thermal conductivity and suppressed phase transformation of zirconia. In this study, YSZ is doped with trivalent oxides, Nd₂O₃, Yb₂O₃, Al₂O₃, and tetravalent oxide, TiO₂, and the thermal conductivity of the obtained materials is analyzed according to the composition; furthermore, the relative density change, microstructure change, and m-phase formation behavior are analyzed during long-time heat treatment at high temperatures.

• Journal of Powder Materials
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• v.30 no.2
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• pp.123-129
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• 2023

High-temperature and high-pressure post-processing applied to sintered thermoelectric materials can create nanoscale defects, thereby enhancing their thermoelectric performance. Here, we investigate the effect of hot isostatic pressing (HIP) as a post-processing treatment on the thermoelectric properties of p-type Bi_0.5Sb_1.5Te_3.0 compounds sintered via spark plasma sintering. The sample post-processed via HIP maintains its electronic transport properties despite the reduced microstructural texturing. Moreover, lattice thermal conductivity is significantly reduced owing to activated phonon scattering, which can be attributed to the nanoscale defects created during HIP, resulting in an ~18% increase in peak zT value, which reaches ~1.43 at 100℃. This study validates that HIP enhances the thermoelectric performance by controlling the thermal transport without having any detrimental effects on the electronic transport properties of thermoelectric materials.

• Journal of the Korean Society for Heat Treatment
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• v.35 no.2
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• pp.57-65
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• 2022

In this study, the effect of the initial particle size distribution (PSD) of (K_0.5Na_0.5)NbO₃ powders on the microstructure of sintered ceramics was investigated. (K_0.5Na_0.5)NbO₃ powders with uni-, bi-, tri-, and quad-modal PSDs were obtained through a planetary ball-mill. For the specimens sintered at 1080℃, the growth of abnormal grains was promoted from the powders exhibiting quad- and tri-modal PSDs with a high content of large particles, resulting in a microstructure in which huge abnormal grains were predominant. However, as the number of peaks in PSD and the overall particle size decreased, the abnormal grain growth was suppressed and the grain growth of small particles started, resulting in a microstructure with a uniform grain size. For the specimens sintered at 1100℃, huge abnormal grains were not observed due to the decrease in the critical driving force for 2D nucleation even when powders with quad- and tri-modal PSDs were used. It was confirmed that when powder with unimodal PSD was used, a uniform microstructure that was not significantly affected by the sintering temperature could be obtained. The results of this study demonstrate that the microstructure of (K_0.5Na_0.5)NbO₃-based ceramics can be controlled by controlling the particle size of the initial powder.

• Korean Journal of Materials Research
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• v.33 no.7
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• pp.285-294
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• 2023

Porous ceramics are used in various industrial applications based on their physical properties, including isolation, storage, and thermal barrier properties. However, traditional manufacturing environments require additional steps to control artificial pores and limit deformities, because they rely on limited molding methods. To overcome this drawback, many studies have recently focused on fabricating porous structures using additive manufacturing techniques. In particular, the binder jet technology enables high porosity and various types of designs, and avoids the limitations of existing manufacturing processes. In this study, we investigated process optimization for manufacturing porous ceramic filters using the binder jet technology. In binder jet technology, the flowability of the powder used as the base material is an important factor, as well as compatibility with the binder in the process and for the final print. Flow agents and secondary binders were used to optimize the flowability and compatibility of the powders. In addition, the effects of the amount of added glass frit, and changes in sintering temperature on the microstructure, porosity and mechanical properties of the final printed product were investigated.

• Korean Journal of Materials Research
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• v.34 no.1
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• pp.27-33
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• 2024

Al₂O₃ has excellent sintering properties and is important in semiconductor manufacturing processes that require high-temperature resistance and chemical inertness in a plasma environment. In this study, a comprehensive analysis of the chemical characteristics, physical properties, crystal structure, and dispersion stability of three commercially available Al₂O₃ powders was conducted. The aim was to provide a technological foundation for selecting and utilizing appropriate Al₂O₃ powders in practical applications. All powders exhibited α-Al₂O₃ as the main phase, with the presence of beta-phase Na₂O-11Al₂O₃ as the secondary phase. The highest Na⁺ ion leaching was observed in the aqueous slurry state due to the presence of the secondary phase. Although the average particle size difference among the three powders was not significant, distinct differences in particle size distribution were observed. ALG-1SH showed a broad particle size distribution, P162 exhibited a bimodal distribution, and AES-11 displayed a uniform unimodal distribution. High-concentration Al₂O₃ slurries showed differences in viscosity due to ion release when no dispersant was added, affecting the electrical double-layer thickness. Polycarboxylate was found to effectively enhance the dispersion stability of all three powders. In the dispersion stability analysis, ALG-1SH exhibited the slowest sedimentation tendency, as evidenced by the low TSI value, while P162 showed faster precipitation, influenced by the particle size distribution.

• Journal of Powder Materials
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• v.31 no.3
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• pp.243-254
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• 2024

High-entropy alloys (HEAs) have been reported to have better properties than conventional materials; however, they are more expensive due to the high cost of their main components. Therefore, research is needed to reduce manufacturing costs. In this study, CoCrFeMnNi HEAs were prepared using metal injection molding (MIM), which is a powder metallurgy process that involves less material waste than machining process. Although the MIM-processed samples were in the face-centered cubic (FCC) phase, porosity remained after sintering at 1200℃, 1250℃, and 1275℃. In this study, the hot isostatic pressing (HIP) process, which considers both temperature (1150℃) and pressure (150 MPa), was adopted to improve the quality of the MIM samples. Although the hardness of the HIP-treated samples decreased slightly and the Mn composition was significantly reduced, the process effectively eliminated many pores that remained after the 1275℃ MIM process. The HIP process can improve the quality of the alloy.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2000.04a
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• pp.9-10
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• 2000

An important business-field of world-wide steel-industry is the coating of thin metal-sheets with zinc, zinc-aluminum and aluminum based materials. These products mostly go into automotive industry. in particular for the car-body. into building and construction industry as well as household appliances. Due to mass-production, the processing is done in large continuously operating plants where the mostly cold-rolled metal-strip as the substrate is handled in coils up to 40 tons unwind before and rolled up again after passing the processing plant which includes cleaning, annealing, hot-dip galvanizing / aluminizing and chemical treatment. In the liquid Zn, Zn-AI, AI-Zn and AI-Si bathes a combined action of corrosion and wear under high temperature and high stress onto the transfer components (rolls) accounts for major economic losses. Most critical here are the bearing systems of these rolls operating in the liquid system. Rolls in liquid system can not be avoided as they are needed to transfer the steel-strip into and out of the crucible. Since several years, ceramic roller bearings are tested here [1.2], however, in particular due to uncontrollable Slag-impurities within the hot bath [3], slide bearings are still expected to be of a higher potential [4]. The today's state of the art is the application of slide bearings based on Stellite\ulcorneragainst Stellite which is in general a 50-60 wt% Co-matrix with incorporated Cr- and W-carbides and other composites. Indeed Stellite is used as the bearing-material as of it's chemical properties (does not go into solution), the physical properties in particular with poor lubricating properties are not satisfying at all. To increase the Sliding behavior in the bearing system, about 0.15-0.2 wt% of lead has been added into the hot-bath in the past. Due to environmental regulations. this had to be reduced dramatically_ This together with the heavily increasing production rates expressed by increased velocity of the substrate-steel-band up to 200 m/min and increased tractate power up to 10 tons in modern plants. leads to life times of the bearings of a few up to several days only. To improve this situation. the Mechanical Alloying (MA) TeChnique [5.6.7.8] is used to prOduce advanced Stellite-based bearing materials. A lubricating phase is introduced into Stellite-powder-material by MA, the composite-powder-particles are coated by High Energy Milling (HEM) in order to produce bearing-bushes of approximately 12 kg by Sintering, Liquid Phase Sintering (LPS) and Hot Isostatic Pressing (HIP). The chemical and physical behavior of samples as well as the bearing systems in the hot galvanizing / aluminizing plant are discussed. DependenCies like lubricant material and composite, LPS-binder and composite, particle shape and PM-route with respect to achievable density. (temperature--) shock-reSistibility and corrosive-wear behavior will be described. The materials are characterized by particle size analysis (laser diffraction), scanning electron microscopy and X-ray diffraction. corrosive-wear behavior is determined using a special cylinder-in-bush apparatus (CIBA) as well as field-test in real production condition. Part I of this work describes the initial testing phase where different sample materials are produced, characterized, consolidated and tested in the CIBA under a common AI-Zn-system. The results are discussed and the material-system for the large components to be produced for the field test in real production condition is decided. Outlook: Part II of this work will describe the field test in a hot-dip-galvanizing/aluminizing plant of the mechanically alloyed bearing bushes under aluminum-rich liquid metal. Alter testing, the bushes will be characterized and obtained results with respect to wear. expected lifetime, surface roughness and infiltration will be discussed. Part III of this project will describe a second initial testing phase where the won results of part 1+11 will be transferred to the AI-Si system. Part IV of this project will describe the field test in a hot-dip-aluminizing plant of the mechanically alloyed bearing bushes under aluminum liquid metal. After testing. the bushes will be characterized and obtained results with respect to wear. expected lifetime, surface roughness and infiltration will be discussed.