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A. Nekahi, S. Firoozi / Materials Research Bulletin 46 (2011) 1377–1383
was formed. Thermodynamics calculations showed that once there
was not enough magnesium available to reduce all TiO2 and B2O3,
Reactions (2) and (3) will proceed to form Mg3B2O6 and Mg2TiO4
compounds, respectively. However, if the formation of the gas
phase was prevented during the synthesis, i.e., the gas phase was
not included as a possible product in the simulation; results
showed that none of these two by-products form at equilibrium
conditions. Bigli et al. [5] reported that addition of 10–40% excess
Mg, which was used to compensate the evaporation of Mg, lowered
the content of Mg2TiO4 but had no effect on Mg3B2O6 content. This
suggests that insufficiency of magnesium due to evaporation is not
the only mechanism in formation of these two by-products. It is
possible that because of the very fast rate of the reactions,
thermodynamic equilibrium may not be attained and some MgO,
which is the main reaction product and abundantly available, react
with the remaining TiO2 and B2O3 and form these two by-products.
The same thermodynamic prediction was made for the sample
with the salts mixture and similar results were observed as for the
sample without the salts mixture. Hence, the thermodynamic
prediction was in agreement with the observation in Figs. 1 and 2.
Max. T
2800
2600
2400
2200
2000
1350
1150
950
750
550
350
150
Ignition T
Delta T
Adiabatic T
0
15
30
45
60
Wt% salts mixture
Fig. 5. Effect of salt mixture content on the ignition, maximum temperature of
combustion and their differences, as well as the adiabatic combustion temperature.
higher amount of salts mixture translated into a lower tempera-
ture increase during the combustion synthesis.
3.2. Thermal analysis of the combustion synthesis
Volume combustion synthesis is a reactive diffusion process,
where the ignition temperature is controlled by the rate limiting
step [20]. Ignition temperature depends on different parameters
such as the reactant particle size, heating rate, mechanical
activation, compaction pressure, relative density, formation of a
liquid phase and diluents [5,20–23]. Niyomwas et al. [24] and
Khandra et al. [13] separately performed a DTA of TiO2–B2O3–Mg
mixture. They both reported an endothermic effect at 650 8C due to
the melting of magnesium and then ignition occurred at about
685 8C. Khandra et al. [13] also reported that adding NaCl up to
20 wt% had no effect on the ignition temperature. Bigli et al. [5]
used the volume combustion synthesis of TiO2–B2O3–Mg mixture
to form TiB2 compound. They reported an ignition temperature of
690 8C; however after ball milling of the reactants, a more vigorous
reaction occurred at a much lower temperature of 220 8C. They
attributed this behaviour mainly due to the smaller particle size
and enhanced particle contact. Weimin et al. [14] also performed a
DTA of TiO2–B2O3–Mg system. They measured two exothermic
peaks; the first peak appeared at about 600 8C because of the
reaction of solid Mg and TiO2 and the second much larger peak at
about 645 8C due to the reaction of the rest of the Mg with B2O3 and
formation of TiB2. Since in these experiments, a different reactant
particle sizes, heating rate, and relative density were used, it is not
possible to determine the effect of each variable on the ignition
process. However, a comparison of these results suggest that the
particle size and contact area had a major role on the ignition
temperature and the maximum combustion temperature.
In this study, one smaller exothermic peak was observed before
the ignition in the samples with 0 and 15% salts mixture (Fig. 4).
This corresponds to a two-step synthesis process that based on
what described by Weimin et al. [14] indicates that the first
reaction occurred between Mg and TiO2 particles, in which the
latter had the smallest particle size among the reactants. The
second exothermic peak was due to the reaction of the liquid Mg
and the rest of the reactants and subsequently the formation of
TiB2. This suggests that formation of liquid magnesium was
necessary for ignition of the samples with 0–15% salts mixture and
also 15% salts mixture was not enough to significantly change the
ignition temperature. The samples with more than 15% salts
mixture showed only one highly exothermic reaction (Fig. 4) below
the melting temperature of magnesium indicating a one step
synthesis process, which suggests a fast reaction mechanism
between the oxides and solid magnesium in the medium of liquid
salts mixture.
Differential thermal (DT) results of the synthesis process are
shown in Fig. 4. Results showed two different types of behaviour
for the samples with no added salt and salts mixture. The samples
with 30–60% salts mixture had only one distinct exothermic peak
below the melting temperature of Mg (650 8C); however the
sample without added salt showed one small endothermic peak at
the melting temperature of Mg at 649 8C, one exothermic effect at
665 8C and ignition1 occurred at 785 8C. The behaviour of the
sample with 15% salts mixture was in between the two mentioned
behaviours. DT curves showed a small exothermic effect at 580 8C
and ignition occurred at 660 8C.
The effect of the added salts mixture on the ignition
temperature, maximum measured combustion temperature,
difference between these two, and adiabatic combustion temper-
ature is shown in Fig. 5. Adiabatic combustion temperature of
Reaction (4) with salts mixture addition between 0 and 60 wt% was
calculated using FactSage [18] thermochemical software.
5Mg þ TiO2 þ B2O3 þ nð0:5KClꢁ0:25NaClꢁ0:25CaCl2Þ
¼ 5MgO þ TiB2 þ nð0:5KClꢁ0:25NaClꢁ0:25CaCl2Þ
(4)
The results showed that the addition of the salts mixture
decreased the adiabatic temperature of the synthesis from 2827 8C
for the sample with no salt to 2400 8C for the sample with 60% salts
mixture. Thermal analysis results showed that the addition of salts
mixture from 0 to 60% resulted in a significant decrease in the
maximum combustion temperature from 1316 to 687 8C, accord-
ingly. It also showed a decrease in the ignition temperature from
786 to 499 8C for the samples with 0–60% salt addition,
accordingly. The maximum measured combustion temperature
was significantly lower than the theoretical adiabatic temperature
of the synthesis, which was mainly due to the heat losses to the
surroundings as well as the low response time of the shielded
thermocouple.
The addition of the salts mixture increases the heat capacity of
the reacting mixture and since an equal amount of heat is released
for all samples during the combustion synthesis,
a lower
temperature increase is expected. This corresponds well with
the reported difference between the maximum combustion
temperature and the ignition temperature in Fig. 5, in which the
1
The onset temperature of the major exothermic peak is the ignition
temperature.