DETAILS OF R&D

FRGS (0746) Project Title: CONSOLIDATION OF CERAMIC POROUS MEMBRANE VIA DIFFERENT FABRICATION METHODS

PROJECT DETAILS

Consolidation : strengthening mechanism

PROJECT DETAILS

Ceramic membrane
Membrane : separation and filtering mechanism

PROJECT DETAILS

Failure of Ceramic membrane : shrinkage problem

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Hybrid and multilayer membrane preparation with certain technique

Single layer

Multilayer

Multilayer

Pressing

hot isostatic pressing

Printing (Result unsatisfied)

Slip casting (Result achieve the target)

Pressing

Hot isostatic pressing

Phase Inversion, combination of HIP and casting

Characterization: FeSEM, SEM, XRD, TEM, FTIR, etc. Performance test: Permeablity, flux measurement, rejection test

Selection of the most practical approach based on the time and availability of equipment

Comparison, analysis and report writing

Characterization: FeSEM, SEM, XRD, TEM, FTIR, etc. Performance test: Permeablity, flux measurement, rejection test

(a) Drying technique: natural oven, microwave (b) Sintering technique Addition of additive/ Fibre Particle size various range

Improvement stages: changes of parameter

Comparison of shrinkage using oven(a) and HIP(b) technique

Shri nkage for top layer (%)

7 6 5 4 3 2 1 0 25 36 45 Particle size (m) 90

HIP Conventional

7 Shrinkage for bottom layer (%) 6 5 4 3 2

HIP Conventional

1
0

25

36 45 Particle size (m)

90

3.65 3.60 3.55 3.50 3.45 3.40 3.35 3.30 3.25 3.20 25 36 45 90 Particle size (m)

1000

Microhardness (HV)

Density (g/cm3)

Conventional HIP

900 800 700 600 500 25 36 45 Particle size (m) 90

Conventional HIP

Effect of different mode of drying before sintering

Shrinkage of top layer (%)

6 5 4 3 2 1

Shrinkage of bottom layer (%)

25 m 36 m 45 m 90 m

7 6 5 4 3 2

25 m 36 m 45 m 90 m

1
0

0
Room Oven Microwave Method of drying

Room

Oven Microwave Method of drying

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Improvement stage : Effect of additive addition

7 Shrinkage for top layer (%) 6 5 4 3 2 1 0 without MgO additive with MgO additive Pellet Al2O3 Shrinkage for bottom layer (%)
2.3643

7 6 5 4

3
2 1 0 without MgO additive with MgO additive Pellet Al2O3

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Comparison of shrinkage using fiber addition in the green body(a) and fired body(b) for the top (blue) and bottom layer(red)

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DIFFERENT DRYING MODE TO THE FINAL MEMBRANE STRUCTURE

Al2O3

Al2O3

Al2O3

Al2O3

SiO2

SiO2

Al2O3

Al2O3

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CONCLUSION

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PAPER PUBLICATIONS

N.F. Ismail, Z.Harun, N.A.Badarulzaman, A Comparative Study of Double Layers Al2O3/Al2O3 and Al2O3/SiO2 Prepared By Microwave and Natural Drying, International Journal of Integrated Engineering, Vol. 4 No. 1 (2012) p. 16-21
Zawati Harun, Nur Farhani Ismail, Nur Azam Badarulzaman ,Effect of MgO Additive on Microstructure of Al2O3, Advanced Materials Research Vols. 488 - 489 (2012) pp 335-339. Zawati Harun, David Gethin, Drying(Consolidation) Porous Ceramic By considering the microscopic pore temperature gradient, Applied Mechanics and Materials Vol. 147 (2012) pp 210-214. Zawati Harun, Nazri Mohd Nawi, Mohd Faizal Batcha1and David Gethin, Modeling of Layering Ceramic Shell Mould, Applied Mechanics and Materials Vol. 232 (2012) pp 548-552. Zawati Harun, Noor Hasliza Kamarudin and Muhammad Zaini Yunos, PERMEABLE RICE HUSK FIBRE SHELL MOUL, Applied Mechanics and Materials Vol. 372 (2013) pp 331-335. Al2O3/Al2O3 and Al2O3/SiO2 Prepared By Microwave and N.F. Ismail, Z.Harun, N.A.Badarulzaman, A Comparative Study of Double Layers International Journal of Integrated Engineering, Vol. 4 No. 1 (2012) p. 16-21. Natural Drying, with rice husk, Key Engineering Materials: Composite Z.Harun, N. H. Kamarudin, N. A. Badarulzaman, Shell mould composite Vols. 471-472, pp. 922-927, 2011. Science and Technology, ceramic shell strength, already presented at the 2nd Z. Harun, N. H. Kamarudin, H. Mohd Taib, Effect of rice husk on fired International Conference on Sustainable Materials Engineering 2013, (ICoSM 2013). accepted papers will be published in an international journal (Advanced Materials Research)

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