Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Wat, Amy; Hall, Ashley L.; Yang, Qi Rong (Bruce); Lu, Ryan; Sobalvarro Converse, Elizabeth; Ye, Congwang; King, Gabriella C.S.; Kuntz, Joshua D.; Worsley, Marcus A.; Cahill, James T.; Du Frane, Wyatt L.

doi:10.1016/j.ceramint.2021.12.161

Title: Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Journal Article · Mon Dec 20 00:00:00 EST 2021 · Ceramics International

DOI:https://doi.org/10.1016/j.ceramint.2021.12.161· OSTI ID:1885659

^[1]; Hall, Ashley L. ^[1]; Yang, Qi Rong (Bruce) ^[1];

^[1];

^[1]; Ye, Congwang ^[1];

^[1];

^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Ceramic nanograined materials have desirable characteristics compared to their macroparticle counterparts but are rarely used in industrial applications due to issues with poor handleability and health hazards. Due to interparticle forces that become more dominant as the particle size decreases, it is difficult to use nanomaterials to fill dies, spread on surfaces, or flow through hoppers found in various manufacturing processes. In this work, we report a scalable gelcasting solution and unique emulsification process to create microspheres composed of nanoscale powders to enhance the flowability and handleability of nanomaterials. The gelcasting solution and emulsification process can be used with any nanoparticle composition that can be suspended in a liquid phase. This paper reports the effects of various parameters on zirconium diboride microsphere formation, such as surfactant content and mixing conditions. The microspheres maintain the nano-scale characteristics of the powder but improve its flowability by using cross-linked polyvinyl alcohol to combine irregularly shaped zirconium diboride nanoparticles with a particle diameter of 60 nm into larger spherical particles with a d₅₀~25 μm. This hierarchical feedstock engineering design combine the positive characteristics of materials across both length scales and improve the flowability of the feedstock from a Hausner Ratio of 1.56 to 1.19. The materials produced using this technique can be used in thermal plasma spray, die filling for hot pressing or spark plasma sintering, and binder jet printing applications.

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Research Organization:: Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC52-07NA27344; LC000L059; LLNL-JRNL-829180

OSTI ID:: 1885659

Alternate ID(s):: OSTI ID: 1870946

Report Number(s):: LLNL-JRNL-829180; 1044723

Journal Information:: Ceramics International, Vol. 48, Issue 16; ISSN 0272-8842

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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