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Geopolymer-based nepheline ceramics: effect of sintering profile on morphological characteristics and flexural strength

2022 , Romisuhani Ahmad , Wan Mastura Wan Ibrahim , Mohd. Mustafa Al Bakri Abdullah , Phakkhananan Pakawanit , Petrica Vizureanu , Arman Shah Abdullah , Andrei Victor Sandu , Fakhryna Hannanee Ahmad Zaidi

The focus of this study is the fabrication of innovative and sustainable ceramic-based geopolymer with improved low temperatures performances. Kaolin was mixed with liquid sodium silicate (Na₂SiO₃) and 12M of sodium hydroxide (NaOH) solution using alkali activator ratio of 0.24 and solid-to-liquid ratio of 1:1 to synthesize kaolin geopolymer. The effect of the sintering profile on the microstructure, pore evolution and flexural strength were investigated. The heating exposure aided consolidation and created a fairly uniform microstructure, resulting in a smooth surface texture. In comparison to the unheated geopolymer, 3D pore distribution showed a significant increase in the range size of ~30 µm with the appearance of isolated and intergranular pores. The flexural strength at 1200 °C with a heating rate of 5 °C/min and was increased by 146.4% to 85.4 MPa, as compared to the heating rate of 2 °C/min. The sintering process has an impact on the final microstructure formation thus improving the characteristic of geopolymer-based nepheline ceramic.

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Role of sintering temperature in production of nepheline ceramics-based geopolymer with addition of ultra-high molecular weight polyethylene

2022 , Romisuhani Ahmad , Mohd. Mustafa Al Bakri Abdullah , Wan Mastura Wan Ibrahim , Kamarudin Hussin , Jitrin Chaiprapa , Jerzy J. Wysłocki , Katarzyna Błoch , Fakhryna Hannanee Ahmad Zaidi , Marcin Nabiałek

The primary motivation of developing ceramic materials using geopolymer method is to minimize the reliance on high sintering temperatures. The ultra-high molecular weight polyethylene (UHMWPE) was added as binder and reinforces the nepheline ceramics based geopolymer. The samples were sintered at 900 °C, 1000 °C, 1100 °C, and 1200 °C to elucidate the influence of sintering on the physical and microstructural properties. The results indicated that a maximum flexural strength of 92 MPa is attainable once the samples are used to be sintered at 1200 °C. It was also determined that the density, porosity, volumetric shrinkage, and water absorption of the samples also affected by the sintering due to the change of microstructure and crystallinity. The IR spectra reveal that the band at around 1400 cm−1 becomes weak, indicating that sodium carbonate decomposed and began to react with the silica and alumina released from gels to form nepheline phases. The sintering process influence in the development of the final microstructure thus improving the properties of the ceramic materials.

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Publication

Role of sintering temperature in production of nepheline ceramics-based geopolymer with addition of ultra-high molecular weight polyethylene

2021 , Romisuhani Ahmad , Mohd. Mustafa Al Bakri Abdullah , Jitrin Chaiprapa , Kamarudin Hussin , Wan Mastura Wan Ibrahim , Fakhryna Hannanee Ahmad Zaidi , Jerzy J. Wysłocki , Katarzyna Błoch , Marcin Nabiałek

The primary motivation of developing ceramic materials using geopolymer method is to minimize the reliance on high sintering temperatures. The ultra-high molecular weight polyethylene (UHMWPE) was added as binder and reinforces the nepheline ceramics based geopolymer. The samples were sintered at 900 °C, 1000 °C, 1100 °C, and 1200 °C to elucidate the influence of sintering on the physical and microstructural properties. The results indicated that a maximum flexural strength of 92 MPa is attainable once the samples are used to be sintered at 1200 °C. It was also determined that the density, porosity, volumetric shrinkage, and water absorption of the samples also affected by the sintering due to the change of microstructure and crystallinity. The IR spectra reveal that the band at around 1400 cm−1 becomes weak, indicating that sodium carbonate decomposed and began to react with the silica and alumina released from gels to form nepheline phases. The sintering process influence in the development of the final microstructure thus improving the properties of the ceramic materials.