Hostname: page-component-76fb5796d-2lccl Total loading time: 0 Render date: 2024-04-27T04:22:27.929Z Has data issue: false hasContentIssue false
  • English
  • Français

Dense and crack-free mullite films obtained from a hybrid sol–gel/dip-coating approach

Published online by Cambridge University Press:  18 April 2017

Zhaoxi Chen ,
Ruslan Burtovyy ,
Konstantin G. Kornev ,
Igor Luzinov  and
Fei Peng
Zhaoxi Chen
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Ruslan Burtovyy
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Konstantin G. Kornev
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Igor Luzinov
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Fei Peng*
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
*
a)Address all correspondence to this author. e-mail: fpeng@clemson.edu
Get access

Abstract

A novel hybrid processing has been developed to achieve dense and crack-free mullite films with large critical thicknesses. The amorphous solid nanoparticles obtained from the mullite sol–gel precursor were mixed with the same liquid precursor to form stable suspensions, which were subsequently used to form mullite coatings with the dip-coating method, followed by drying and firing. The hybrid precursor suspensions resulted in highly close-packed nanoparticles, which reduced shrinkage during sintering. Selecting the solvent with a low evaporation rate and high surface tension can effectively eliminate the surface instability caused by the lateral flow during solvent evaporation. The mullite film density was significantly improved at low sintering temperatures, because of the high packing density and viscous flow at above the glass transition temperature of the amorphous gel nanoparticles before crystallization. Dense and crack-free mullite films with 500–600 nm thickness can be obtained from the novel hybrid approach.

Keywords

coatingsol–gelamorphous
Type
Articles
Information
Journal of Materials Research , Volume 32 , Issue 9 , 15 May 2017 , pp. 1665 - 1673
Check for updates
Copyright
Copyright © Materials Research Society 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Contributing Editor: Sam Zhang

References

REFERENCES

Kriven, W.M., Palko, J.W., Sinogeikin, S., Bass, J.D., Sayir, A., Brunauer, G., Boysen, H., Frey, F., and Schneider, J.: High temperature single crystal properties of mullite. J. Eur. Ceram. Soc. 19, 2529 (1999).Google Scholar
Dokko, P.C., Pask, J.A., and Mazdiyasni, K.S.: High-temperature mechanical properties of mullite under compression. J. Am. Ceram. Soc. 60, 150 (1977).CrossRefGoogle Scholar
Kanzaki, S., Tabata, H., Kumazawa, T., and Ohta, S.: Sintering and mechanical properties of stoichiometric mullite. J. Am. Ceram. Soc. 68, C-6 (1985).Google Scholar
Lee, K.N.: Current status of environmental barrier coatings for Si-based ceramics. Surf. Coat. Technol. 133, 1 (2000).Google Scholar
Miller, R.A.: Thermal barrier coatings for aircraft engines: History and directions. J. Therm. Spray Technol. 6, 35 (1997).Google Scholar
Kulkarni, T., Wang, H.Z., Basu, S.N., and Sarin, V.K.: Compositionally graded mullite-based chemical vapor deposited coatings. J. Mater. Res. 24, 470 (2009).Google Scholar
Monteiro, O.R., Wang, Z., and Brown, I.G.: Deposition of mullite and mullite-like coatings on silicon carbide by dual-source metal plasma immersion. J. Mater. Res. 12, 2401 (1997).Google Scholar
Hou, P., Basu, S.N., and Sarin, V.K.: Nucleation mechanisms in chemically vapor-deposited mullite coatings on SiC. J. Mater. Res. 14, 2952 (1999).Google Scholar
Mulpuri, R.P. and Sarin, V.K.: Synthesis of mullite coatings by chemical vapor deposition. J. Mater. Res. 11, 1315 (1996).Google Scholar
Brinker, C.J. and Scherer, G.W.: Sol–gel Science: The Physics and Chemistry of Sol–gel Processing (Academic press, New York, 2013).Google Scholar
Roy, J., Das, S., and Maitra, S.: Sol gel-processed mullite coating—A review. Int. J. Appl. Ceram. Technol. 12, S2 (2014).Google Scholar
Chen, Y.Y. and Wei, W.C.J.: Formation of mullite thin film via a sol–gel process with polyvinylpyrrolidone additive. J. Eur. Ceram. Soc. 21, 2535 (2001).Google Scholar
Wang, N., Yang, X.Z., Li, J.B., Lin, H., and Chi, B.: Fabrication and characterization of porous mullite coating on porous silicon carbide support. Key Eng. Mater. 280, 1301 (2004).Google Scholar
Ansar, S.A., Bhattacharya, S., Dutta, S., Ghosh, S.S., and Mukhopadhyay, S.: Development of mullite and spinel coatings on graphite for improved water-wettability and oxidation resistance. Ceram. Int. 36, 1837 (2010).Google Scholar
Jayasankar, M., Anilkumar, G.M., Smitha, V.S., Mukundan, P., Madhusoodana, C.D., and Warrier, K.G.K.: Low temperature needle like mullite grain formation in sol–gel precursors coated on SiC porous substrates. Thin Solid Films 519, 7672 (2011).Google Scholar
Selvaraj, U., Komarneni, S., and Roy, R.: Structural differences in mullite xerogels from different precursors characterized by 27Al and 29Si MASNMR. J. Solid State Chem. 106, 73 (1993).Google Scholar
Cassidy, D.J., Woolfrey, J.L., Bartlett, J.R., and Ben-Nissan, B.: The effect of precursor chemistry on the crystallisation and densification of sol–gel derived mullite gels and powders. J. Sol-Gel Sci. Technol. 10, 19 (1997).Google Scholar
Ban, T., Hayashi, S., Yasumori, A., and Okada, K.: Characterization of low temperature mullitization. J. Eur. Ceram. Soc. 16, 127 (1996).Google Scholar
Kozuka, H., Takenaka, S., Tokita, H., Hirano, T., Higashi, Y., and Hamatani, T.: Stress and cracks in gel-derived ceramic coatings and thick film formation. J. Sol-Gel Sci. Technol. 26, 681 (2003).Google Scholar
Atkinson, A. and Guppy, R.M.: Mechanical stability of sol–gel films. J. Mater. Sci. 26, 3869 (1991).Google Scholar
Chen, Z., Burtovyy, R., Kornev, K., Luzinov, I., Xu, D., and Peng, F.: The effect of polymer additives on the critical thicknesses of mullite thin films obtained from the monophasic sol–gel precursors. J. Sol-Gel Sci. Technol. 80, 285 (2016).Google Scholar
Brinker, C.J., Hurd, A.J., Schunk, P.R., Frye, G.C., and Ashley, C.S.: Review of sol–gel thin film formation. J. Non-Cryst. Solids 147, 424 (1992).Google Scholar
Chen, S.Y. and Chen, I.W.: Cracking during pyrolysis of oxide thin films-phenomenology, mechanisms, and mechanics. J. Am. Ceram. Soc. 78, 2929 (1995).CrossRefGoogle Scholar
Kozuka, H. and Takenaka, S.: Single-step deposition of gel-derived lead zirconate titanate films: Critical thickness and gel film to ceramic film conversion. J. Am. Ceram. Soc. 85, 2696 (2002).Google Scholar
Jing, C., Zhao, X., and Zhang, Y.: Sol–gel fabrication of compact, crack-free alumina film. Mater. Res. Bull. 42, 600 (2007).Google Scholar
Kishimoto, T. and Kozuka, H.: Sol–gel preparation of TiO2 ceramic coating films from aqueous solutions of titanium sulfate (IV) containing polyvinylpyrrolidone. J. Mater. Res. 18, 466 (2003).Google Scholar
Kozuka, H. and Kajimura, M.: Single-step dip coating of crack-free BaTiO3 films >1 μm thick: Effect of poly(vinylpyrrolidone) on critical thickness. J. Am. Ceram. Soc. 83, 1056 (2000).Google Scholar
Kozuka, H. and Takenaka, S.: Single-step deposition of gel-derived lead zirconate titanate films: Critical thickness and gel film to ceramic film conversion. J. Am. Ceram. Soc. 85, 2696 (2002).Google Scholar
Du, Z.H. and Ma, J.: The effect of PVP on the critical thickness and properties of PLZT ceramic films. J. Electroceram. 16, 565 (2006).Google Scholar
Barrow, D.A., Petroff, T.E., Tandon, R.P., and Sayer, M.: Characterization of thick lead zirconate titanate films fabricated using a new sol gel based process. J. Appl. Phys. 81, 876 (1997).Google Scholar
Wang, Z., Zhu, W., Zhao, C., and Tan, O.K.: Dense PZT thick films derived from sol–gel based nanocomposite process. Mater. Sci. Eng., B 99, 56 (2003).Google Scholar
Lee, B. and Zhang, J.: Preparation, structure evolution and dielectric properties of BaTiO3 thin films and powders by an aqueous sol–gel process. Thin Solid Films 388, 107 (2001).Google Scholar
Corker, D.L., Zhang, Q., Whatmore, R.W., and Perrin, C.: PZT ‘composite’ ferroelectric thick films. J. Eur. Ceram. Soc. 22, 383 (2002).Google Scholar
Erk, K.A., Deschaseaux, C., and Trice, R.W.: Grain-boundary grooving of plasma-sprayed yttria-stabilized zirconia thermal barrier coatings. J. Am. Ceram. Soc. 89, 1673 (2006).Google Scholar
Chen, Z., Zhang, Z., Tsai, C.C., Kornev, K., Luzinov, I., Fang, M., and Peng, F.: Electrospun mullite fibers from the sol–gel precursor. J. Sol-Gel Sci. Technol. 74, 208 (2015).CrossRefGoogle Scholar
Okada, K., Yasohama, S., Hayashi, S., and Yasumori, A.: Sol–gel synthesis of mullite long fibres from water solvent systems. J. Eur. Ceram. Soc. 18, 1879 (1998).Google Scholar
Song, K.C.: Preparation of mullite fibers from aluminum isopropoxide–aluminum nitrate–tetraethylorthosilicate solutions by sol–gel method. Mater. Lett. 35, 290 (1998).Google Scholar
Vázquez, J., López-Alemany, P.L., Villares, P., and Jiménez-Garay, R.: A study on glass transition and crystallization kinetics in Sb 0.12 as 0.36 Se 0.52 glassy alloy by using non-isothermal techniques. Mater. Chem. Phys. 57, 162 (1998).Google Scholar
Xu, W., Ren, J., and Chen, G.: Glass transition kinetics and crystallization mechanism in Ge–Ga–S–CsCl chalcohalide glasses. J. Non-Cryst. Solids 398, 42 (2014).Google Scholar
Hu, L. and Ye, F.: Liquid fragility calculations from thermal analyses for metallic glasses. J. Non-Cryst. Solids 386, 46 (2014).Google Scholar
Harris, D.J., Hu, H., Conrad, J.C., and Lewis, J.A.: Patterning colloidal films via evaporative lithography. Phys. Rev. Lett. 98, 148301 (2007).Google Scholar
Milne, S.J., Patel, M., and Dickinson, E.: Experimental studies of particle packing and sintering behaviour of monosize and bimodal spherical silica powders. J. Eur. Ceram. Soc. 11, 1 (1993).Google Scholar
Ji, C., Lan, W., and Xiao, P.: Fabrication of yttria-stabilized zirconia coatings using electrophoretic deposition: Packing mechanism during deposition. J. Am. Ceram. Soc. 91, 1102 (2008).Google Scholar
Lewis, J.A.: Colloidal processing of ceramics. J. Am. Ceram. Soc. 83, 2341 (2000).Google Scholar
Gu, Y., Chen, Z., Borodinov, N., Luzinov, I., Peng, F., and Kornev, K.G.: Kinetics of evaporation and gel formation in thin films of ceramic precursors. Langmuir 30, 14638 (2014).Google Scholar
Cima, M.J., Lewis, J.A., and Devoe, A.D.: Binder distribution in ceramic greenware during thermolysis. J. Am. Ceram. Soc. 72, 1192 (1989).Google Scholar
Chiu, R.C. and Cima, M.J.: Drying of granular ceramic films: II, drying stress and saturation uniformity. J. Am. Ceram. Soc. 76, 2769 (1993).Google Scholar
Sefiane, K., Tadrist, L., and Douglas, M.: Experimental study of evaporating water–ethanol mixture sessile drop: Influence of concentration. Int. J. Heat Mass Transfer 46, 4527 (2003).Google Scholar
Beuth, J.L.: Cracking of thin bonded films in residual tension. Int. J. Solids Struct. 29, 1657 (1992).Google Scholar
Xia, Z.C. and Hutchinson, J.W.: Crack patterns in thin films. J. Mech. Phys. Solids 48, 1107 (2000).Google Scholar
Xu, P., Mujumdar, A.S., and Yu, B.: Drying-induced cracks in thin film fabricated from colloidal dispersions. Drying Technol. 27, 636 (2009).Google Scholar
Kozuka, H.: On ceramic thin film formation from gels: Evolution of stress, cracks and radiative striations. J. Ceram. Soc. Jpn. 111, 624 (2003).Google Scholar
Tirumkudulu, M.S. and Russel, W.B.: Cracking in drying latex films. Langmuir 21, 4938 (2005).Google Scholar
Singh, K.B. and Tirumkudulu, M.S.: Cracking in drying colloidal films. Phys. Rev. Lett. 98, 218302 (2007).Google Scholar
Baranwal, R., Villar, M.P., Garcia, R., and Laine, R.M.: Flame spray pyrolysis of precursors as a route to nano-mullite powder: Powder characterization and sintering behavior. J. Am. Ceram. Soc. 84, 951 (2001).Google Scholar
Kalogeras, I.M. and Lobland, H.E.H.: The nature of the glassy state: Structure and transitions. J. Mater. Educ. 34, 69 (2012).Google Scholar