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Dense and crack-free mullite films obtained from a hybrid sol–gel/dip-coating approach

Published online by Cambridge University Press:  18 April 2017

Zhaoxi Chen ,
Ruslan Burtovyy ,
Konstantin G. Kornev ,
Igor Luzinov  and
Fei Peng
Zhaoxi Chen
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Ruslan Burtovyy
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Konstantin G. Kornev
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Igor Luzinov
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
Fei Peng*
Affiliation:
Department of Materials Science and Engineering, Clemson University, Clemson, SC 29634
*
a)Address all correspondence to this author. e-mail: [email protected]
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Abstract

A novel hybrid processing has been developed to achieve dense and crack-free mullite films with large critical thicknesses. The amorphous solid nanoparticles obtained from the mullite sol–gel precursor were mixed with the same liquid precursor to form stable suspensions, which were subsequently used to form mullite coatings with the dip-coating method, followed by drying and firing. The hybrid precursor suspensions resulted in highly close-packed nanoparticles, which reduced shrinkage during sintering. Selecting the solvent with a low evaporation rate and high surface tension can effectively eliminate the surface instability caused by the lateral flow during solvent evaporation. The mullite film density was significantly improved at low sintering temperatures, because of the high packing density and viscous flow at above the glass transition temperature of the amorphous gel nanoparticles before crystallization. Dense and crack-free mullite films with 500–600 nm thickness can be obtained from the novel hybrid approach.

Keywords

coatingsol–gelamorphous
Type
Articles
Information
Journal of Materials Research , Volume 32 , Issue 9 , 15 May 2017 , pp. 1665 - 1673
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Copyright
Copyright © Materials Research Society 2017 

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Footnotes

Contributing Editor: Sam Zhang

References

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