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Gradient Al2O3-Ni composites for aggressive substance transport: a novel approach using centrifugal gel casting

Zygmuntowicz Justyna, Tańska Joanna, Wiecińska Paulina, Piotrkiewicz Paulina, Konopka Katarzyna, Szafran Mikołaj, Wachowski Marcin, Michalski Bartosz, Kaszuwara Waldemar

Composites Theory and Practice

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2025

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R. 25 nr 2

144-156

EN

This study focuses on the development and characterization of Al2O3-Ni composite materials designed for use in environments where high corrosion resistance and mechanical strength are critical. The composites were formed using the centrifugal gel casting method to produce pipes with a gradient structure. The inner layer of the pipes consisted mainly of Al2O3, while the outer layer incorporated nickel particles. Rheological, thermogravimetric, and microstructural analyses were conducted to optimize the composite's formulation and processing conditions. The results showed that a monomer content of 3% by weight of 2-hydroxyethyl acrylate (HEA) provided an optimal balance between workability and polymer network formation. Corrosion tests revealed that while the alumina-rich inner layer exhibited good chemical resistance, the presence of nickel particles on the surface led to localized corrosion, particularly in acidic environments. The findings indicate that further refinement of the casting process is necessary to improve the distribution of the nickel particles and enhance the material's overall corrosion resistance.

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Al₂O₃-Ni composites: impact of cooling on composites in centrifugal gel casting

Zygmuntowicz Justyna, Tańska Joanna, Wiecińska Paulina, Piotrkiewicz Paulina, Konopka Katarzyna, Szafran Mikołaj, Wachowski Marcin, Szachogłuchowicz Ireneusz, Kaszuwara Waldemar

Composites Theory and Practice

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2025

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R. 25 nr 2

113-122

EN

This study investigates the influence of polymerization kinetics and the processing sequence on the microstructure and mechanical performance of Al₂O₃-Ni composites fabricated via centrifugal gel casting. Two fabrication approaches were compared, differing in the sequence of component addition and the temperature of the casting mass. The optimized method, involving cooling the suspension to below 5°C prior to the addition of nickel powder and the polymerization initiator, significantly extended the gelation idle time from 225 s to 475 s, allowing improved control over polymerization and particle dispersion. As a result, the microstructure exhibited enhanced phase homogeneity and reduced porosity. Compression tests demonstrated substantial enhancement in mechanical performance: the compres sive strength increased from 22 MPa in the non-optimized series to 185 MPa in the optimized series, representing more than an eightfold improvement. These findings highlight a practical strategy for tuning the polymerization behavior to engineer high-performance ceramic-metal composites with potential applications in structural and functional components.

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Centrifugal gel casting of graded Al2O3-Ni composites using 2-carboxyethyl acrylate

Zygmuntowicz Justyna, Tańska Joanna, Wiecińska Paulina, Piotrkiewicz Paulina, Konopka Katarzyna, Szafran Mikołaj, Wachowski Marcin, Szachogłuchowicz Ireneusz, Michalski Bartosz, Kaszuwara Waldemar

Advances in Materials Science

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2025

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Vol. 25, nr 3(85)

85--103

EN

This study presents the fabrication and characterization of functionally graded Al2O3-Ni ceramic-metal composites using centrifugal gel casting with 2-carboxyethyl acrylate (CEA) as the monomer. Two Series of composites were produced under different centrifugal conditions to investigate their influence on nickel distribution, microstructure, and mechanical performance. The CEA-based gel system enabled the formation of dense green bodies with improved phase dispersion and sintering behavior. Microstructural analysis revealed that lower rotational speed and longer casting time (2500 rpm, 110 min) led to a more uniform radial distribution of nickel particles and reduced agglomeration. This microstructural improvement resulted in significantly higher compressive strength (1620 kN) compared to the faster cast series (977 kN). Digital image correlation confirmed more distributed strain fields and delayed fracture in the optimized samples. These findings demonstrate that casting parameters and monomer chemistry can be effectively tailored to engineer dense, robust, and gradient-structured ceramic–metal composites for high-performance applications.