A novel, low temperature (<90˚C) process for the formation of an interpenetrating phase composite (IPC) of aluminum and carbonated calcium silicate (CaSiO3) was developed. The key enabling process steps were Infiltration and subsequent hydrothermal liquid phase densification of CaSiO3 in the pores of an aluminum foam. CaSiO3 suspension flow was enhanced by pH adjustment and addition of a sodium polyacrylate dispersant, allowing for high solids content (58 vol%) suspensions to be used. The CaSiO3 infiltrated into the aluminum foam achieved 65% relative density, comparable to control CaSiO3 samples. Carbonation of the CaSiO3 was conducted within a pressure steamer at 90˚C and 20psig CO2. Extent of carbonation of the infiltrated CaSiO3 was determined from mass gain, x-ray diffraction, and thermal gravimetric analysis and averaged about 50%, comparable to control CaSiO3 samples. The final bulk density of the IPC was 2.2 g/cm3. Compression strength of the IPC exceeded that of the aluminum foam and carbonated CaSiO3, greater than 110 MPa. Stress was resisted after initial failure for large strains by the IPC. These properties place the formed composite in a unique area of infiltrated Al IPC property space. No evidence for chemical interaction between the infiltrated CaSiO3 and Al foam was found. Rather, adhesion between the component-materials was determined to be limited to mechanical interlock between CaSiO3 particulate and surface features of the Al foam. Surface modification of the Al foam via zeolite coating, anodizing and HCl etching was conducted to change the surface morphology of the Al. Zeolite coatings produced 50 μm thick coatings with pores ranging from 0.01-10 μm. Anodic oxide coatings produced shallow dimpling and cracking on the Al foam surface. HCl etching created muli-scale pitting with features ranging from 0.01-100 μm. IPCs were formed with the surface modified Al foams and tested in compression. Failure analysis of the Al-carbonated CaSiO3 interface showed that increasing Al surface roughness led to separation between the bulk carbonated CaSiO3 and the entrapped carbonated CaSiO3 particles. This change in interface microstructure and failure behavior did not induce significant changes in compressive strength.
Subject (authority = RUETD)
Topic
Materials Science and Engineering
Subject (authority = ETD-LCSH)
Topic
Hyrdrothermal carbonization
RelatedItem (type = host)
TitleInfo
Title
Rutgers University Electronic Theses and Dissertations
Identifier (type = RULIB)
ETD
Identifier
ETD_6567
PhysicalDescription
Form (authority = gmd)
electronic resource
InternetMediaType
application/pdf
InternetMediaType
text/xml
Extent
1 online resource (xvi, 181 p. : ill.)
Note (type = degree)
Ph.D.
Note (type = bibliography)
Includes bibliographical references
Note (type = statement of responsibility)
by Terrence Edward Whalen
RelatedItem (type = host)
TitleInfo
Title
Graduate School - New Brunswick Electronic Theses and Dissertations
Identifier (type = local)
rucore19991600001
Location
PhysicalLocation (authority = marcorg); (displayLabel = Rutgers, The State University of New Jersey)
Rutgers University. Graduate School - New Brunswick
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Type
License
Name
Author Agreement License
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