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Chemical variability is a main strength of glass. Glass powders are therefore promising candidates for manufacturing a broad diversity of sintered materials like sintered ¬glass-ceramics, glass matrix composites or glass bonded ceramics with tailored mechanical, thermal, electrical and optical properties and complex shape. Its wide and precise adjustability makes this class of materials, even if it may not be obvious at first sight, a key component of advanced technologies. Manufacture and processing of initial glass powders often allow even more flexibility in materials design. At the same time, however, they can cause additional problems. The lecture illustrates possible consequences of glass powder processing upon glass crystallization and sintering as well as chances for targeted utilization. Simple kinetic models describing the effect of particle size distribution, surface crystallization and rigid inclusions on sintering as well effects of different milling and seeding on sinter crystallization are presented.
Nowadays, the use of bioactive glasses is established for bone regeneration; however glasses are used mostly as powders, granules or in a paste. Sintered scaffolds are not used clinically, because of the inherent problem of crystallization during the sintering process, resulting in poor mechanical properties and reduced bioactivity. Therefore it was the aim to design new bioactive glasses, which combine improved processing and sintering with bioactivity.
Compared with the well-known Bioglass® 45S5 (SiO2-P2O5-CaO-Na2O) the calcium/alkali oxide ratio was increased, sodium oxide was partially replaced by potassium oxide and up to 8 mol% calcium fluoride were added, in order to stabilize the glass against crystallization.
The sintering behavior of the new glasses was characterized by heating microscopy and compared to that of Bioglass® 45S5. Results show that the new glasses achieve a sintered density of 88-99 % in contrast to only 57-67% for Bioglass® 45S5. In addition, FTIR and XRD analyses show that Bioglass® 45S5 crystallizes during sintering while for the new glasses no crystalline phases were detected. The thermal properties of all glasses were studied by DTA and DSC measurements, and the influence of grain size was characterized. These studies showed an increase of sintering temperature and final porosity with increasing particle size. The structure of sintered compacts during and after sintering was examined using light and electron microscopy (SEM).
The manufacture of sintered glasses and glass-ceramics, glass Matrix composites and glass-bounded ceramics or pastes is often affected by gas bubble formation. Against this background, we studied sintering and foaming of barium silicate glass powders used as SOFC sealants using different powder milling scenarios. Sintering was measured by means of heating microscopy backed up by XPD, DTA, Vacuum Hot Extraction (VHE) and optical and electron microscopy. Foaming increased significantly as milling progressed. For moderately milled glass powders, subsequent storage in air could also promote foaming. Although the powder compacts were uniaxially pressed and sintered in air, the milling environment significantly affected foaming. The strength of this effect increased in the order Ar >> N2 < air < CO2. Conformingly, VHE studies revealed that the pores of aerated samples predominantly encapsulated CO2, even for powders milled in Ar and N2. Results of this study thus indicate that foaming is caused by carbonaceous species trapped on the glass powder surface. Foaming could be substantially reduced by milling in water and 10 wt% HCl.
Electric contacts based on silver-glass dispersions are key components in optoelectronic microsystems and control modules for medical, information & communication and energy technology in our networked society. Driven by the complexity of modern production processes and ever shorter time-to-market requirements, the fast and specific development of tailored silver-glass dispersions has become a bottleneck of technology development. Nevertheless, the underlying mechanisms of silver dissolution, transport, and reprecipitation, and the resulting micro structure evolution during firing are poorly understood. The broad literature on the precipitation of colloidal silver particles and the related processes of silver dissolution and diffusion mostly refer to very small volume fractions of silver. Transferring these results to the sintering of glass-containing silver dispersions, is therefore highly questionable. In this case, silver dissolution, electrical contact between silver particles, transport and reprecipitation take place under special conditions. This includes short diffusion lengths (particle size < 10 μm), the presence of three-phase contacts silver - glass - sintering atmosphere, as well as silver reprecipitation at the sintering contacts as the driving force of silver transport. Here, a dynamic balance of the silver concentration can be expected to result from the ratio between silver dissolution and reprecipitation. The aim of the project is to gain basic insight into the mechanisms of dissolution, transport and reprecipitation of silver in sintering silver glass dispersions. In this context, the main focus is on gaining basic knowledge about the dissolution of metallic silver in low melting oxide glasses as the limiting factor of the sintering of silver-glass composites. In particular, we will strive to gain insight into the effect of the oxygen content of the sintering atmosphere, of the oxygen dissolved in the silver particles, of silver oxide on the surface of the silver powder, of the electric contact between the silver particles, as well as the basicity of the glass. Furthermore, we strive for insights into the silver mobility and the silver concentration that can be attained (silver solubility) in oxide glasses with a low melting point. Summing up all these aspects, a closed explanatory model for silver dissolution, transport and reprecipitation during the sintering of glass silver dispersions will be introduced.
The development of competitive thermoelectric generators using oxide ceramics and multilayer technology requires the investigation of suitable sintering procedures. The sintering of Ca3Co4O9, which is the most promising p-type oxide regarding its figure of merit, is a special challenge, as the material starts to decompose at 926 °C. Pressure-assisted sintering (PAS), as known from large-scale production of low temperature co-fired ceramics, was used to sinter multilayers of Ca3Co4O9 green tape at 900 °C with different pressures and dwell times. In-situ shrinkage measurements, microstructural investigations and electric measurements were performed. Relative density increases from 57.4 % after free sintering for 24 h to 93.7 % after 2 h of PAS with 10 MPa axial load. The combination of tape casting and PAS induces a pronounced alignment of the anisotropic grains. In comparison to freely sintered multilayers, the electrical conductivity in the casting direction is thereby strongly increased by a factor of 5. With respect to dry-pressed bars, the improvement amounts to a factor of 15. This study shows that PAS is a proper technique to produce dense Ca3Co4O9 panels with good thermoelectric properties similar to hot-pressed tablets, even in large-scale production.
Glass powders are promising candidates for manufacturing a broad diversity of sintered materials like sintered glass-ceramics, glass matrix composites or glass bonded ceramics with tailored mechanical, thermal, electrical and optical properties and complex shape. Its wide and precise adjustability makes this class of materials a key component for advanced technologies. Processing of glass or composite powders often allow even more flexibility in materials design. At the same time, however, processing can have substantial effects on the glass powder surface and sinterability. Thus, mechanical damage and surface contamination can strongly enhance surface crystallization, which may retard or even fully prevent densification. Whereas sintering and concurrent crystallization have been widely studied, partially as cooperative effort of the TC7 of the ICG, and although glass powder sintering is predominantly applied for glasses of low crystallization tendency, sintering is also limited by gas bubble formation or foaming. The latter phenomenon is much less understood and can occur even for slow crystallizing glass powders. The lecture illustrates possible consequences of glass powder processing on glass sintering, crystallization and foaming.
Glass powders are promising candidates for manufacturing a broad diversity of sintered materials like sintered glass-ceramics, glass matrix composites or glass bonded ceramics with properties and complex shape. Powder processing, however, can substantially affect sinterability, e.g. by promoting surface crystallization. On the other hand, densification can be hindered by gas bubble formation for slow crystallizing glass powders. Against this background, we studied sintering and foaming of silicate glass powders with different crystallization tendency for wet milling and dry milling in air, Ar, N2, and CO2 by means of heating microscopy, DTA, Vacuum Hot Extraction (VHE), SEM, IR spectroscopy, XPS, and ToF-SIMS. In any case, foaming activity increased significantly with progressive milling. For moderately milled glass powders, subsequent storage in air could also promote foaming. Contrarily, foaming could be substantially reduced by milling in water and 10 wt% HCl. Although all powder compacts were uniaxially pressed and sintered in air, foaming was significantly affected by different milling atmosphere and was found most pronounced for milling in CO2 atmosphere. Conformingly, VHE studies revealed that foaming is mainly driven by carbonaceous species, even for powders milled in other gases. Current results of this study thus indicate that foaming is caused by carbonaceous species trapped on the glass powder surface.
Glass powders are promising candidates for manufacturing a broad diversity of sintered materials like sintered glass-ceramics, glass matrix composites, glass bonded ceramics or pastes. Powder processing, however, can substantially affect sinterability, e.g. by promoting surface crystallization. On the other hand, densification can be hindered by gas bubble formation for slow crystallizing glass powders. Against this background, we studied sintering and foaming of silicate glass powders with different crystallization tendency for wet milling and dry milling in air, Ar, N2, and CO2 by means of heating microscopy, DTA, Vacuum Hot Extraction (VHE), SEM, IR spectroscopy, XPS, and ToF-SIMS. In any case, foaming activity increased significantly with progressive milling. For moderately milled glass powders, subsequent storage in air could also promote foaming. Contrarily, foaming could be substantially reduced by milling in water and 10 wt% HCl. Although all powder compacts were uniaxially pressed and sintered in air, foaming was significantly affected by different milling atmosphere and was found most pronounced for milling in CO2 atmosphere. Conformingly, VHE studies revealed that foaming is mainly driven by carbonaceous species, even for powders milled in other gases. Current results of this study thus indicate that foaming is caused by carbonaceous species trapped on the glass powder surface.
Network modifier ions can decisively influence properties and structure of low melting alkali-zinc-borate glasses and thus cause complex effects on the liquid phase sintering of silver-glass metallization pastes. This effect was studied for X2O-ZnO-B2O3 (X = Li, Na, Rb) glasses for silver-glass metallization pastes. Viscosity and the glass transition temperature, Tg, were measured with rotational viscometry and dilatometry. Dried model pastes with 30 vol% LZB, NZB or RZB glass were prepared for sintering studies by means of heating microscopy measuring the silhouette area shrinkage of uniaxially pressed powder compacts during heating at 5 K/min. For comparison, the silhouette area shrinkage of pure glass and silver powder compacts were determined. Glass-silver wetting was investigated during heating of bulk glass cylinders placed on silver substrates. Glass RZB turned out to have the lowest viscosity among the glasses under study. Its glass transformation temperature, Tg, was found at 444 °C and it caused the lowest sintering onset for its glass and paste powder compacts. Slightly increased values of Tg were found for NZB and LZB (468 °C and 466 °C, respectively) and a slightly retarded sintering was found for both paste powder compacts. These results indicate that liquid phase sintering of silver-glass pastes under air atmosphere is mainly influenced by glass viscosity.