Bioactive Glass-Ceramic Scaffolds from Novel 'Inorganic Gel Casting' and Sinter-Crystallization

Co-vitrification of municipal solid waste incinerator fly ash and bottom slag: Glass detoxifying characteristics and porous reformation

Safety and efficient dispose of municipal solid waste incineration (MSWI) fly ash with high toxicity has emerged as a worldwide challenge. Vitrification provides the advantages of capacity reduction, detoxification, and solidification of heavy metals, which has the potential to dispose of hazardous waste on a large scale. Herein, co-vitrification of MSWI fly ash and bottom slag has been accomplished based on the characteristics of calcium and silicon composition. A novel approach for producing glass ceramic foams by alkaline activation-crystallization was developed to realize the disposal of the obtained glass. The effect of MSWI fly ash/bottom slag ratios on the glass network, crystallization ability of the basic glass, pore structure, and physical properties of the porous green body was investigated. The results revealed that with increasing MSWI fly ash proportion, the Si-O of [SiO₄] in the basic glass changed significantly and the crystallization ability steadily reduced. Si-O and Al-O in basic glass are easy to corrode under alkaline conditions, releasing Ca²⁺ and forming a low solubility product, calcium silicate hydrate. When the crystallization temperature increases from 950 ℃ to 1150 ℃, it is more conducive to the precipitation of the gehlenite phase. Extending the crystallization time promotes three-dimensional growth of crystals that are coupled with each other to form a network structure and a multi-stage pore structure. The pore structure was developed with the help of NH₃ and H₂ generated by the secondary aluminum ash (SAA). Through the preparation of glass ceramic foams, the raw materials were detoxified. The toxic heavy metals showed extremely low leaching concentrations, which were smaller than the limit of TCLP. The prepared samples had 70.22-80.61% of porosity, 0.78-1.19 g/cm³ of low bulk density, and 0.54-7.86 MPa of compressive strength.

A review of glass ceramic foams prepared from solid wastes: Processing, heavy-metal solidification and volatilization, applications

The safe utilization of solid wastes containing heavy metals plays a crucial role in environmental preservation. As an efficient technology to achieve this goal, the preparation of glass ceramic foams from solid wastes can produce an excellent solidification effect on heavy metals. At present, there have been plenty of efforts made to achieve an excellent combination of such characteristics as mechanical strength, bulk density, thermal conductivity and so on, with the purpose to ensure the application in various high value-added fields. Due to the concentration on their application in the construction sector such as the use of thermal and acoustic insulation materials, some researchers seek to expand the scope of their applications. In this paper, a review is conducted into the methods used to prepare solid waste-based glass ceramic foams. Depending on the exact processing route, these methods can be categorized into two classes, which are powder sintering and inorganic gel casting. Not only heavy metals hinder the application of solid waste, they can also cause irreversible pollution to the wider environment. Solidification and volatilization represent the two routes associated with heavy-metal migration during the preparation of glass ceramic foams. Both traditional and innovative applications are indicated in this review. Furthermore, a discussion is conducted about the prospects and challenges facing different processing strategies, heavy-metal migration and applications.

Production of Porous Ceramic Materials from Spent Fluorescent Lamps

Spent fluorescent lamps (SFL) are classified as hazardous materials in the European Waste Catalogue, which includes residues from various hi-tech devices. The most common end-of-life treatment of SFL consists in the recovery of rare earth elements from the phosphor powders, with associated problems in the management of the glass residues, which are usually landfilled. This study involves the manufacturing of porous ceramics from both the coarse glass-rich fraction and the phosphor-enriched fraction of spent fluorescent lamps. These porous materials, realizing the immobilization of Rare Earth Elements (REEs) within a glass matrix, are suggested for application in buildings as thermal and acoustic insulators. The proposed process is characterized by: (i) alkaline activation (2.5 M or 1 M NaOH aqueous solution); (ii) pre-curing at 75 °C; (iii) the addition of a surfactant (Triton X-100) for foaming at high-speed stirring; (iv) curing at 45 °C; (v) viscous flow sintering at 700 °C. All the final porous ceramics present a limited metal leaching and, in particular, the coarse glass fraction activated with 2.5 M NaOH solution leads to materials comparable to commercial glass foams in terms of mechanical properties.

Advanced Open-Celled Structures from Low-Temperature Sintering of a Crystallization-Resistant Bioactive Glass

Most materials for bone tissue engineering are in form of highly porous open-celled components (porosity >70%) developed by means of an adequate coupling of formulations and manufacturing technologies. This paper is dedicated to porous components from BGMS10 bioactive glass, originally designed to undergo viscous flow sintering without crystallization, which is generally known to degrade the bioactivity of 45S5 bioglass. The adopted manufacturing technologies were specifically conceived to avoid any contamination and give excellent control on the microstructures by simple operations. More precisely, 'green' components were obtained by digital light processing and direct foaming of glass powders suspended in a photosensitive organic binder or in an aqueous solution, activated with an organic base, respectively. Owing to characteristic quite large sintering window of BGMS10 glass, sintering at 750 °C caused the consolidation of the structures generated at room temperature, without any evidence of viscous collapse.

Effect of Phenolic Resin on Micropores Development in Carbon Foam with High Performance

A novel high-performance carbon foam (CF) was fabricated through the addition of phenolic resin (PR) into a coal tar pitch (CTP) based precursor. The effects of mass fraction of a PR additive on the crystalline structures, morphologies, compressive strength (σ) and thermal conductivity (λ) of resultant CF material were investigated systematically. Characterization showed a strong dependence of CF’s performance from the composition and optical texture of the precursor, which were mainly depending on the polycondensation and polymerization reactions between PR and raw CTP. Comparing with the strength of pristine CF at 6.5 MPa, the σ of mCF-9 (13.1 MPa) was remarkably enhanced by 100.1%. However, the λ of mCF-9 substantially reduced to 0.9 m⁻¹K⁻¹ compared with 18.2 W m⁻¹K⁻¹ of pristine CF. Thus, this modification strategy to produce microporous CF materials from raw CTP provides a new protocol for the fabrication of high-performance carbon based materials.

Influence of Manufacturing Parameters on Mechanical Properties of Porous Materials by Selective Laser Sintering

This paper presents a study on the tensile properties of Alumide and polyamide PA2200 standard samples produced by Additive manufacturing (AM) based on selective laser sintering (SLS). Because of the orthogonal trajectories of the laser beam during exposure, different orientations of the samples may lead to different mechanical properties. In order to reveal this process issue, four orientations of the samples in building envelope were investigated. For data reliability, all the other process parameters were constant for each material and every orientation. The tensile tests highlight small differences in elastic properties of the two materials, while significant differences in strength properties and energy absorption were observed. Nevertheless, Young modulus indicates high stiffness of the Alumide comparing to PA2200 samples. The stereo microscopy reveals a brittle fracture site for Alumide and a ductile fracture with longitudinal splitting zones for PA2200. From the orientation point of view, similar properties of samples oriented at 0 and 90 degrees for all investigated mechanical properties were observed. However, tensile strength was less influenced by the sample orientations.

Extension of the 'Inorganic Gel Casting' Process to the Manufacturing of Boro-Alumino-Silicate Glass Foams

A new technique for the production of glass foams, based on alkali activation and gel casting, previously applied to soda-lime glass, was successfully extended to boro-alumino-silicate glass, recovered from the recycling of pharmaceutical vials. A weak alkali activation (2.5 M NaOH or NaOH/KOH aqueous solutions) of fine glass powders (below 70 µm) allowed for the obtainment of well-dispersed concentrated aqueous suspensions, undergoing gelation by treatment at low temperature (75 °C). Unlike soda-lime glass, the progressive hardening could not be attributed to the formation of calcium-rich silicate hydrates. The gelation was provided considering the chemical formulation of pharmaceutical glass (CaO-free) to the formation of hydrated sodium alumino-silicate (N-A-S-H) gel. An extensive direct foaming was achieved by vigorous mechanical stirring of partially gelified suspensions, comprising also a surfactant. A sintering treatment at 700 °C, was finally applied to stabilize the cellular structures.

Bioactive Glass-Ceramic Foam Scaffolds from 'Inorganic Gel Casting' and Sinter-Crystallization

Highly porous bioactive glass-ceramic scaffolds were effectively fabricated by an inorganic gel casting technique, based on alkali activation and gelification, followed by viscous flow sintering. Glass powders, already known to yield a bioactive sintered glass-ceramic (CEL2) were dispersed in an alkaline solution, with partial dissolution of glass powders. The obtained glass suspensions underwent progressive hardening, by curing at low temperature (40 °C), owing to the formation of a C–S–H (calcium silicate hydrate) gel. As successful direct foaming was achieved by vigorous mechanical stirring of gelified suspensions, comprising also a surfactant. The developed cellular structures were later heat-treated at 900–1000 °C, to form CEL2 glass-ceramic foams, featuring an abundant total porosity (from 60% to 80%) and well-interconnected macro- and micro-sized cells. The developed foams possessed a compressive strength from 2.5 to 5 MPa, which is in the range of human trabecular bone strength. Therefore, CEL2 glass-ceramics can be proposed for bone substitutions.

Bone biomaterials and interactions with stem cells

Bone biomaterials play a vital role in bone repair by providing the necessary substrate for cell adhesion, proliferation, and differentiation and by modulating cell activity and function. In past decades, extensive efforts have been devoted to developing bone biomaterials with a focus on the following issues: (1) developing ideal biomaterials with a combination of suitable biological and mechanical properties; (2) constructing a cell microenvironment with pores ranging in size from nanoscale to submicro- and microscale; and (3) inducing the oriented differentiation of stem cells for artificial-to-biological transformation. Here we present a comprehensive review of the state of the art of bone biomaterials and their interactions with stem cells. Typical bone biomaterials that have been developed, including bioactive ceramics, biodegradable polymers, and biodegradable metals, are reviewed, with an emphasis on their characteristics and applications. The necessary porous structure of bone biomaterials for the cell microenvironment is discussed, along with the corresponding fabrication methods. Additionally, the promising seed stem cells for bone repair are summarized, and their interaction mechanisms with bone biomaterials are discussed in detail. Special attention has been paid to the signaling pathways involved in the focal adhesion and osteogenic differentiation of stem cells on bone biomaterials. Finally, achievements regarding bone biomaterials are summarized, and future research directions are proposed.

Fabrication and Characterization of Porous MgAl₂O₄ Ceramics via a Novel Aqueous Gel-Casting Process

A novel and aqueous gel-casting process has been successfully developed to fabricate porous MgAl₂O₄ ceramics by using hydratable alumina and MgO powders as raw materials and deionized water as hydration agent. The effects of different amounts of deionized water on the hydration properties, apparent porosity, bulk density, microstructure, pore size distribution and compressive strength of the samples were investigated. The results indicated that the porosity and the microstructure of porous MgAl₂O₄ ceramics were governed by the amounts of deionized water added. The porous structure was formed by the liberation of physisorbed water and the decomposition of hydration products such as bayerite, brucite and boehmite. After determining the addition amounts of deionized water, the fabricated porous MgAl₂O₄ ceramics had a high apparent porosity (52.5-65.8%), a small average pore size structure (around 1-3 μm) and a relatively high compressive strength (12-28 MPa). The novel aqueous gel-casting process with easy access is expected to be a promising candidate for the preparation of Al₂O₃-based porous ceramics.