Effect of sintering atmosphere on the crystallizations, porosity, and thermal expansion coefficient of cordierite honeycomb ceramics

High-porosity cordierite ceramics were sintered in two different atmospheres, that is, in air (oxidizing) or in double-enclosed crucibles (mildly reducing). Paste slurries of cordierite compositions mixed with organic binders and pore formers were extruded into honeycomb-type substrates to produce diesel particulate filters (DPFs). The present study was conducted to explore the effects of sintering atmosphere on pore size, crystallization, amorphous phase, and thermal expansion coefficient (CTE) of sintered DPF honeycombs. Crystal phases were quantitatively analyzed using the Rietveld refinement method using powder X-ray diffraction (XRD) data. Amorphous phases were quantified using the Rietveld-internal standard method, and their presence was qualitatively confirmed by high-resolution transmission electron microscopy (HRTEM) and selected area electron diffraction (SAED) analysis. The most notable features observed were a dramatic decrease in the pore-size distribution and an enhanced rate of cordierite/indialite phase crystallization when sintering was performed in a double-enclosed crucible. A relatively high concentration of carbon monoxide (CO) in the double-enclosed crucible reduced the liquid-phase viscosity. This low-viscosity liquid phase spread relatively easily on the surfaces of crystal phases and enhanced the crystallization rate owing to a relatively large liquid-solid contact area in the mildly reducing atmosphere. The higher CTEs of DPFs produced in air compared with those produced in enclosed crucibles are discussed in relation to the amounts of amorphous and crystal impurity phases and crystal texture.

Automated summary

The study investigated the effects of sintering atmosphere on DPF honeycomb pore size, crystallization, amorphous phase, and CTE. Sintering in double-enclosed crucibles resulted in decreased pore-size distribution and enhanced cordierite/indialite phase crystallization rate. The higher CTE of DPFs produced in mildly reducing atmospheres was attributed to the increased crystallization rate due to reduced liquid-phase viscosity.