Hexagonal Barium Aluminosilicate via Spark Plasma Sintering
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Solution Overview
Problem
Current methods for preparing barium aluminosilicate (BAS) with a hexagonal structure require multiple heat treatment steps, often resulting in heterogeneous and cracked materials, whereas there is a need for a method that achieves a single heat treatment step to produce a homogeneous, dense, and non-cracked BAS with a hexagonal structure suitable for aerospace applications.
Innovation Solution
A method involving a single sintering step using a pulsed electric field (Spark Plasma Sintering, SPS) with a mixture of powders including aluminium hydroxide, barium carbonate, and silica, which reacts to form barium aluminosilicate with a hexagonal structure, overcoming the limitations of traditional multi-step heat treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple heat treatment steps are used to prepare barium aluminosilicate with hexagonal structure, then the material can be formed, but the material becomes heterogeneous and cracked
Solution Approach 1:
The patent combines multiple heat treatment steps into a single sintering operation using Spark Plasma Sintering technology. The simultaneous application of pulsed electric current and pressure during heating allows the material to densify and form the hexagonal structure in one step, avoiding the heterogeneous and cracked results that occur with sequential heat treatments.
Solution Approach 2:
The patent employs pulsed electric current rather than continuous heating. The periodic application of electric current pulses during the sintering process enables controlled heating and pressure application, allowing the material to transform to hexagonal BAS structure while maintaining homogeneity and preventing cracks that would result from continuous or multi-step heating.
2Productivity
If traditional multi-step heat treatment is used, then barium aluminosilicate can be synthesized, but processing time is extended
Solution Approach 1:
The patent uses Spark Plasma Sintering to rapidly transform the precursor mixture into hexagonal barium aluminosilicate in a single fast sintering step. The pulsed electric current and pressure enable the material to skip intermediate stages and directly form the desired hexagonal structure, reducing processing time from multiple steps to one step while ensuring material integrity through controlled densification.
3Shape
If multiple heat treatment steps are applied, then hexagonal structure can be achieved, but the material develops cracks and heterogeneity
Solution Approach 1:
The patent applies pressure simultaneously with heating during the sintering process. This preliminary application of pressure before the material fully densifies prevents crack formation during the transformation to hexagonal structure. The combined pressure-heat treatment ensures uniform densification and maintains structural integrity while achieving the desired hexagonal crystal structure.
Solution Approach 2:
The patent changes the heating method from traditional continuous or multi-step heating to pulsed electric current heating with simultaneous pressure application. This parameter change in the heat treatment process allows the material to transform to hexagonal BAS structure while maintaining homogeneity and preventing cracks, achieving both structural form and integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of a homogeneous, dense, and non-cracked barium aluminosilicate with a hexagonal structure in a single step, enhancing its suitability for aerospace applications by improving material integrity and reducing processing time.
Implementation Method 1
a single sintering step using a pulsed electric field (Spark Plasma Sintering, SPS)
Implementation Method 2
pulsed electric field (Spark Plasma Sintering, SPS) with a mixture of powders
Implementation Method 3
mixture of powders of precursors of said aluminosilicate comprising a powder of aluminium hydroxide Al(OH)3 which reacts to form barium aluminosilicate with a hexagonal structure
Data Source
AI summary
The invention relates to a method for preparing a material based on an aluminosilicate selected from barium aluminosilicate BAS, barium-strontium aluminosilicate BSAS, and strontium aluminosilicate SAS, said aluminosilicate consisting of aluminosilicate with a hexagonal structure, characterised in that it includes a single sintering step in which a mixture of powders of precursors of said aluminosilicate, including an aluminium hydroxide Al(OH)3 powder, are sintered by a hot-sintering technique with a pulsed electric field SPS; whereby a material based on an aluminosilicate, said aluminosilicate consisting of an aluminosilicate with a hexagonal structure is obtained. The material based on an aluminosilicate prepared by said method can be used in a method for preparing a composite material consisting of an aluminosilicate matrix reinforced by reinforcements made of metalloid or metal oxide.