Slabs of cast calcium sulfate dihydrate have been used for decades as a heat transfer barrier in commercial and residential construction and are assessed in accordance with the parameters defined by ASTM C1396. The study described herein hypothesizes that minor impurities have significant effects on the high-temperature performance of these casts. Five thermocouples are cast into a 20-mm-thick slab at approximately 4-mm intervals are measured between ambient and approximately 1000°C in a furnace. Thermal diffusivity and inertia are estimated from this temperature profile. This study compares natural, flue gas desulfurized (FGD) and reagent grade hemihydrates that have been converted into the dihydrate form with distilled water; the common additives kaolin and borax are used to modify the cast. The thermocouple data allow an effective thermal diffusivity (α′) and an effective thermal inertia (I′) to be calculated. The hemihydrate source and kaolin content are found to affect the high-temperature performance; the FGD source increases the thermal inertia, and kaolin inhibits the formation of other borate compounds through intercalation.
Gypsum wallboard has been used for over 100 years as a barrier to the spread of fire in residential and commercial structures. The gypsum molecule, CaSO4·2H2O, provides two crystalline waters that are released upon heating providing an endothermic effect. Manufacturers have recognized that the source of the gypsum ore is a factor that affects all aspects of its performance; thus, it is hypothesized that the impurities present in the gypsum ore are the causes of the performance differences. Differential Thermal Analysis/Thermogravimetric Analysis (DTA/TGA) and X-ray Diffraction (XRD) were used to compare and characterize samples of gypsum ore representing sources of natural, synthetic from a Flue Gas Desulfurization process (FGD) and blends thereof. The hemihydrate phase of representative natural, FGD, and reagent grade calcium sulfate were rehydrated with distilled water and evaluated by DTA/TGA. Analysis of the data shows distinct areas of similarity separated by the conversion to anhydrite ∼250 °C. Compositional reconstructions based on DTA/TGA and XRD data were compared and although, the results were comparable, the DTA/TGA suggests thermally active compounds that were not detected by XRD. Anhydrite, silica and halite were reported by XRD but were not thermally reactive in the temperature range evaluated by DTA/TGA (ambient to 1050 °C). The presence of carbonate compounds (e.g., calcite and dolomite) were indicated by XRD and estimated from the thermal decomposition reaction ∼700 °C.
There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects. Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. Finally, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.
The rapid release of energy from reactive multilayer foils can create extreme local temperature gradients near substrate materials. In order to fully exploit the potential of these materials, a better understanding of the interaction between the substrate or filler material and the foil is needed. Specifically, this work investigates how variations in local properties within the substrate (i.e. differences between properties in constituent phases) can affect heat transport into the substrate. This can affect the microstructural evolution observed within the substrate, which may affect the final joint properties. The effect of the initial substrate microstructure on microstructural evolution within the heat-affected zone is evaluated experimentally in two Sn-Zn alloys and numerical techniques are utilized to inform the analysis.
Reactive multilayer foils have the potential to be used as local high intensity heat sources for a variety of applications. Much of the past research effort concerning these materials have focused on understanding the structure-property relationships of the foils that govern the energy released during a reaction. To enhance the ability of researchers to more rapidly develop technologies based on reactive multilayer foils, a deeper and more predictive understanding of the relationship between the heat released from the foil and microstructural evolution in the neighboring materials is needed. This work describes the development of a numerical model for the purpose of evaluating new foil-substrate combinations for screening and optimization. The model is experimentally validated using a commercially available Ni-Al multilayer foils and different alloys.
Calcium sulfate dihydrate is the primary ingredient in passive gypsum drywall fire barrier systems. The endothermic properties of calcium sulfate dihydrate are well known and exploited in these systems. Researchers in fire modeling have extensively studied the endothermic properties of gypsum up to 500°C. This study reports on the influence of selected chemical and mineral constituents on dimensional and thermal property changes in gypsum casts in excess of the critical crystal dehydration temperature (between 500° and 1000°C). Gypsum from natural and flue gas desulfurization (FGD) sources used in commercial operations were evaluated for changes by differential thermal analysis/thermogravimetric analysis (DTA/TGA), Fourier transform infrared (FTIR) spectroscopy, Raman spectra analysis, X-ray diffraction (XRD), and scanning electron microscopy (SEM). Petalite and Gerstley borate were added to a basic formula used in commercially manufactured wallboard for fire barrier systems. The analysis of the data identified significant changes in density and hardness of the gypsum casts related to the addition of Petalite and Gerstley borate.