Papers by Author: Hideki Hyuga

Abstract: SiC substrates were successfully bonded by tape-cast SiC-Al2O3-Y2O3 interlayers in the temperature range of 1800-1900 °C for 60 min at 15 MPa pressure in flowing Ar. Based on microstructure observations, we find that the α-SiC interlayers result in equiaxed microstructure at all joining temperatures while the tape-cast β-SiC leads to a microstructure varying from a mixed characteristic to an elongated one with joining temperature. The detailed image analysis suggests the close interlayer thickness, the quicker grain growth rate of β-SiC relative to α-SiC one and the good agreement between aspect ratio and morphology in all joints. Moreover, the SiC grains of interlayer near to interface develop preferentially from the external SiC grains of substrate, which is possibly related to the morphology difference between substrate and interlayer and the grain growth behaviors. Finally, the SiC joined with tapes exhibits an average bending strength over 359 MPa and usually fracture within SiC bases.

Abstract: In order to lower environmental impact in manufacturing, it is necessary to know the processes of consumption and emission of resource and energy with bird’s eyes view point. In this paper, exergy analysis was conducted in case when heater tube used in the molten aluminum was made of steel and ceramics. As results, it is revealed that ceramics have effectiveness in the reduction of environmental burden through the lifecycle process, while ceramics consumes much higher exergy than the steel one in production stage.

Abstract: Exergy is a measure which can commonly deal with the quantification of the variety of resources, products and energy coming in and going out the manufacturing systems. In this study, exergy analysis was conducted on ceramics and steel heater protection tube used in aluminum casting, and the amount of exergies consumed through their life cycle were calculated. In the production stage, ceramic heater tube consumes much higher exergy than the steel one does, however, analysis throughout the life cycle including production, operation and waste in seven years shows that exergy consumption for the ceramic tube is less than that of the steel tube.

Abstract: The widely used Si3N4-SiC sidewall refractories for aluminum smelting cells, and β SiAlON-SiC composites that can be potentially used for this purpose, have been produced by reaction bonding and their corrosion performance assessed in simulated aluminum electrochemical cell conditions. The formation of the Si3N4 and SiAlON phases were studied by reaction bonding of silicon powders in a nitrogen atmosphere at low temperatures to promote the formation of silicon nitride, followed by a higher heating step to produce β SiAlON composites of different composition. The corrosion performance was studied in a laboratory scale aluminum electrolysis cell where samples were exposed to both liquid attack from molten salt bath and corrosive gas attack. The corrosion resistance of the samples was shown to be dependent on the composition but more importantly on the environment during corrosion, with samples in the gas phase showing higher corrosion.

Abstract: Six kinds of silicon nitrides with different microstructures were fabricated by changing the amount of sintering additives, Al2O3 and Y2O3. The hardness decreased with an increase in the amount of additives, whereas the indentation fracture resistance increased in the samples with large amount of additives due to the formation of coarse and elongated grains. The wear property of various Si3N4 ceramics was investigated in the sliding contact test without lubricant and was compared with the mechanical properties. The specific wear rate varied notably from 4x10-4 to 6x10-6 mm-3N-1m-1 depending on the compositions, which was difficult to explain directly from the hardness and fracture resistance. An indentation fracture model for material removal could correlate the wear properties with a function of hardness and fracture resistance of the materials, suggesting that the indentation model was likely to be valid for analyzing the wear behavior in this study.

Abstract: Graphite powder was treated with lanthanum, aluminum and magnesium phosphate solution, and oxidation resistance of the obtained graphite powder was evaluated. Oxidation starting temperature and oxidation completion temperature of graphite powder treated with various phosphates were 50-100oC higher than those of as-received graphite powder. Graphite powder treated with small amount of lanthanum phosphate exhibited the higher oxidation starting temperature than graphite powder treated with aluminum and magnesium phosphates. LaP5O14 would partially exited on graphite powder, and protect the edge carbon atoms of graphite and reduce the reactivity of carbon atoms toward oxygen, resulting in improving the oxidation resistance.

Abstract: The influence of two measuring conditions, the elapsed time after indentation and the condition of edge of an indenter, on the indentation fracture toughness of silicon nitrides was assessed. No slow crack-growth after unloading was confirmed by optical microscopic observation of a crack tip induced by the indentation, which led to the negligible difference in fracture toughness measured at 1 and 30 min after the indentation. Measurements with relatively new and used indenters gave almost the same fracture toughness data, indicating that the crack lengths were hardly affected by the slight damage of the corner of the indenter. It was suggested that the large scattering of the indentation fracture toughness reported by the round-robin tests such as VAMAS was not originated from these factors.

Abstract: Effect of microstructure of silicon nitride on the fracture toughness, KIc evaluated by the IF method was studied with various indentation loads ranging from 49 N to 490 N, since practical assessment of fracture toughness of small Si3N4 parts is needed in the ceramic ball bearing market. The plot of KIc against the as-indented crack length revealed the rising R-curve behavior for the coarse Si3N4 and slight R-curve for the fine Si3N4. By comparing KIc estimated from the SEPB and IF methods using 4 different equations, it was revealed that the IF equation which gave the nearest value to KIc from SEPB was different depending on the microstructures. These results were discussed in conjunction with their R-curve behavior and the effective crack length in the SEPB specimens.