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Chowdhury A, Maitra S, Das HS, Sen A, Samanta GK, Datta P.Interceram 2007;56:98.Abstract : A review. As an engineering material, cordierite has many applications in different fields exploiting its unique elec., mech. and thermal properties. The synthetic aspect of cordierite is of const. interest to researchers. Elucidation of its structure and establishing the properties of its structure has always been considered a fascinating subject by researchers. In the present paper these different aspects of cordierite are briefly reviewed.
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> > >Ceramics in Asia
98 Vol. 56 (2007) [2]
Synthesis, Properties and Applications of Cordierite Ceramics, Part 2A. Chowdhury, S. Maitra, H.S. Das, A. Sen, G.K. Samanta, P. Datta
5 Applications of cordierite ceramics
Cordierite is widely used in various fields of ce-
ramics. Its traditional applications are as fol-
lows:
• Refractory products ➝ saggars, kiln furniture
(widely popular in whiteware industries), gas
burners, etc.
• Electro-ceramics ➝ resistors, fusibles, flame
guards, etc.
• Tablewares ➝ Flameproof application devel-
opments in fast-firing techniques which allow
wide temperature variations during the cool-
ing cycle have renewed interest in this type of
body.
• Cordierite is common as a refractory filler. Re-
fractory fillers are frequently blended with
powdered solder glass to increase the strength
Anirban Chowdhury is apost-graduate research stu-dent working in the area ofsol gel ferroelectrics for hisPhD at the Institute for Ma-terials Research, University
of Leeds, UK. He earned his BTech in Ceramicsfrom the College of Ceramic Technology, Uni-versity of Calcutta and MTech in Materials Sci-ence from IIT Kanpur. He received the presti-gious ORS award and a Tetley & Lupton Schol-arship for 2005–2008.
AbstractAs an engineering material, cordierite has manyapplications in different fields exploiting itsunique electrical, mechanical and thermal prop-erties. The synthetic aspect of cordierite is ofconstant interest to researchers. Elucidation ofits structure and establishing the properties ofits structure has always been considered a fas-cinating subject by researchers. In the presentpaper these different aspects of cordierite arebriefly reviewed.
Keywords:
Cordierite, processing, properties, applications
Interceram 56 (2007) [2]
of the finished seal and/or to lower the ther-
mal contraction coefficient of the composite.
• The MgO–Al2O3–SiO2 system is a very popu-
lar one for glass-ceramics where cordierite is
the dominant phase along with clinoenstatite
(MgO-SiO2). These materials are character-
ized by higher temperature stability under load
than lithium aluminosilicates together with
good thermal and mechanical shock resist-
ance. Their low permittivity and high resistiv-
ity lead to a broad range of applications, e.g.
microwave component materials, radomes, etc.
• A very recent application for cordierite is in
making thick films.
5.1 Applications in kilns and furnaces Cordierite is extensively used as a material for
kiln furniture in whiteware industries due to its
excellent thermal shock resistance. Mohr [44]
worked on the development of cordierite kiln
furniture, focusing on parameters such as the
effect of grog addition (low expansion grog, like
fused silica, can be used in special cases; gener-
ally, grogs with thermal expansion larger than
cordierite are preferred), the effects of time and
temperature, and the development of slag re-
sistance (good grades of kyanite and kaolin, cal-
cined to 1580–1600 °C provide excellent grogs
for commercial cordierites).
5.2 Cordierite-mullite composites A major field of application for cordierite lies in
the production of composites and fibre strength-
ening. Different attempts have been made to de-
velop cordierite-mullite composites with good
thermal shock resistance as well as high me-
chanical strength.Camerucci et al. [45] prepared
cordierite and cordierite-mullite ceramics by
the slip casting method. The rheological behav-
iour of the slip became Newtonian when the sol-
id content was reduced to 60 mass-% and a plas-
ticizer was added. This led to higher green den-
sities (~63 %) of the body. Different firing cy-
cles were tested to improve the sintered density,
which ultimately reached values between 96.5
and 97.5 % of the theoretical density. In all cas-
es,both the green and the sintered densities were
significantly higher than those obtained by ax-
ial pressing.Yu et al. [46] studied the influence
of different silica fume contents on the struc-
ture and properties of mullite-cordierite com-
posites. The cordierite content increases while
mullite decreases with increasing silica fume
contents. The optimum formulation is as fol-
lows: cordierite - 66.3 %, mullite - 33.7 % and
bulk density - 2.69 g/cm3. Hipedinger et al. [47]
developed a cold-setting refractory material us-
ing the magnesia-phosphate reaction.A cement
paste based on alumina, silica fume, magnesia
and orthophosphoric acid was designed to form
cordierite-mullite during heating. This cement
paste set at room temperature and
MgHPO4·3H2O (newberyite) phase was ob-
served.
5.3 Other composites of cordierite Taruta et al. [48] fabricated a machinable
cordierite-mica composite by low temperature
sintering. 40 mass-% mica-composition glass
powder was mixed with conventional magne-
sia, alumina and silica powders (raw materials
of cordierite) and then compacted and fired in
a sealed Pt container. Mica crystallized at about
730 °C, cordierite was suddenly formed at
1050–1100 °C, and densification was achieved
at 1000–1100 °C. The formation and sintering
of cordierite were promoted by a small amount
of fluorine gas or fluorides (AlF3) which evap-
orated from the glass at >800 °C, and HF gas
was formed by reaction of the fluorine with the
water evaporated from the glass. Machinability
was achieved by the interlocking microstruc-
ture of mica developed in the composite. Shi et
al. [49] prepared cordierite-ceria composite ce-
ramics with oxygen storage capacity. Oxygen
storage capacity (OSC) is an important param-
eter in three-way catalysts (TWC) for the pu-
rification of exhausts from automotive gasoline
engines. The authors prepared the composite
using the sol-gel method so as to append the
OSC to the support to which the catalyst is ap-
plied. CeO2 particles are uniformly and sepa-
rately distributed in the cordierite matrix, their
number and granularity being dependent on
the amount of Ce4+ addition. The cordierite and
10 mass-% CeO2 possess an apparent OSC, ap-
Ceramics in Asia
100 Vol. 56 (2007) [2]
propriate porosity, flexural strength and ther-
mal expansion coefficient. It will be helpful to
enhance the OSC of the catalytic converters and
so improve the purification effects for the ex-
hausts. Ma et al. [50] fabricated AlN-cordierite
composites using different AlN contents and in-
vestigated the effect of AlN content on the me-
chanical, thermal and dielectric properties of
these materials. It was observed that there ex-
ists an optimum AlN content for the mechani-
cal and thermal properties while the dielectric
property decreases with an increase in AlN con-
tent. Kaya et al. [51] fabricated stainless steel
(316L) fibre-reinforced cordierite-matrix com-
posites of tubular shape using electrophoretic
deposition and pressureless sintering. The sin-
tered composites, which had an internal and ex-
ternal deposit thickness of ~1 mm, were free of
surface cracks when a deposition time of 2.5 min
was used.Metal-fibre-reinforced cordierite com-
posites such as those developed here may con-
stitute a promising alternative for manufactur-
ing damage-tolerant tubular components for
applications at temperatures up to ~900 °C.Shyu
and Wang [52] studied the relationship of the
amount and viscosity of glass with the sintered
densities of cordierite-borosilicate glass com-
posites. The dielectric constant of these com-
posites was in the range of 4.9–5.7 at 1 MHz.
Sonje et al. [53] incorporated cordierite as a low
coefficient of thermal expansion (CTE) ceram-
ic particulate filler into different epoxy resins to
produce an isotropic low CTE polymeric com-
posite material for electronic circuit board ap-
plications. The dependence of the CTE values
on the properties of the epoxy resins, the nature
of interfacial bonding and the dispersion of the
fillers in the resin matrix were also studied.
5.4 Cordierite coatings Weaver et al. [54] studied the role of bulk nu-
cleation in the formation of crystalline cordierite
coatings produced by air plasma spraying.
Cordierite glasses doped with 6.3, 8.3 and 10.1
mass-% TiO2 were plasma sprayed onto SiO2-
based refractory concrete substrates. Only the
cordierite powders containing 8.3 and 10.1
mass-% TiO2 produced crystalline coatings. For
compositions with less than 8 mass-% TiO2 the
crystallization is believed to be controlled by
surface nucleation at imperfections. Bulk nu-
cleation-controlled crystallization was observed
at compositions above 8 mass-% TiO2 and the
presence of Al2TiO5 was detected in these com-
positions. Ferraris et al. [55] synthesized
cordierite-mullite coating to be applied on
SiCf/SiC composites. The composites were coat-
ed by a simple and low cost slurry technique and
heat treated at 1180 °C for 1 h in order to obtain
a uniform, pore-free and crystalline coating
through the glass-ceramic method. The melt-
ing point of the crystalline phases formed in the
coating during the coating process (cordierite,
2MgO-2Al2O3-5SiO2 and mullite, 3Al2O3-2SiO2
rate of 3 : 1 mass-%) was measured at about
1430 °C. Perham et al. [56] also worked in a
somewhat similar direction as they developed
a method for the joining of SiC substrates us-
ing a cordierite glass-ceramic which, being
amorphous, melts the SiC substrates to form a
strong bond when rapidly fired. Doping with a
fluoride ion flux can lower the peak processing
temperature without significantly altering the
crystallizing path.High strength can be achieved
through this process (σF >500 MPa).
5.5 Cordierite thick films A more recent but highly promising application
of cordierite is the synthesis of cordierite thick
films. Mei et al. [57] prepared thick films of
cordierite-based glass ceramics by aqueous tape
casting from suspensions containing
cordierite/glass mass-% of 70/30 to 30/70. The
suspensions with 50–60 mass-% glass showed
the lowest viscosity values, while the green tape
containing 30 mass-% glass showed a homoge-
neous microstructure at both the top and bot-
tom surfaces. The green densities increased with
the glass content. The sintered tapes (1150 °C,
2 h) containing 50–60 mass-% glass showed the
lowest values for the dielectric constant (simi-
lar to 5.2) and dielectric loss (similar to 0.002)
at 1 MHz. Cho et al. [58] developed a cordierite
based thick film on an oxidized copper layer
where the authors found evidence of copper dif-
fusion as it was incorporated into the cordierite
and the remaining Cu was precipitated, which
ultimately lowered the densification and crys-
tallization temperature. The authors also stud-
ied the microstructure, crystallization kinetics
and properties of nonstoichiometric cordierite
(2.4 MgO, 2Al2O3, 5SiO2, containing 3 mass-%
P2O5 and 3 mass-% PbO) based thick film di-
electrics. A stable glass ceramic thick film mi-
crostructure that was formed in a 96 % alumi-
na substrate was observed after firing at a tem-
perature of 915 °C for 30 min in nitrogen at-
mosphere. The activation energy for
crystallization of the thick film was determined
to be ~83 kcal/mol (~350 kJ/mol). In the case
of the 3 mass-% PbO sample fired in a nitrogen
atmosphere at 950 °C for 30 min, the remaining
glass was estimated using the parallel mixing
rule, to have a dielectric constant of 15.3 at
1 MHz. The estimated coefficient of thermal ex-
pansion of the remaining glass for the 3 mass-%
PbO sample was 19 � 10–6 / K.
5.6 Cordierite filters Cordierite has been successfully tried in a num-
ber of industrial day-to-day applica-tions. Ne-
gro et al. [59] studied the mechanical behaviour
of cordierite ceramic filters for automotive emis-
sion control in a fired condition after thermal
shock and thermal ageing. Park et al. [60] inves-
tigated the feasibility of porous cordierite in
foam type structures such as filters for dust col-
lection.Various shaped porous cordierites with
different pore sizes and with constant porosity
of 80 % were prepared by the conventional me-
chanical foaming method combined with gel
casting using water-soluble polymers. Gas per-
meability of the membrane layers of 150 µm was
above 200 � 10–13 m2. In the dust collection
test, the removal efficiency for particulates fin-
er than 10 µm was above 99.99 %. Montanaro
[61] studied the interactions of sodium sulphite,
iron oxide and cerium oxide from fuel additives
with a cordierite monolith filter in the operat-
ing temperature range of a diesel soot filter. He
concluded that the said oxides do not react sig-
nificantly with the filter, but sodium sulphite
leads to a diffuse etching starting from low op-
erating temperatures. However, the total poros-
ity and pore size distribution were not affected
by these interactions. Park et al. [62] developed
a new trap to reduce the particulate matter emis-
sion from diesel engines and to control the com-
bustion rate of the particulate matter filtered in
the trap. Cordierite is a major component of the
trap as it is susceptible to thermal shock.
5.7 Cordierite substratesReznik et al. [63] utilized cordierite as substrate
material and produced pyrolytic carbon de-
posits by the CVD technique on a planar
cordierite substrate using methane as a source
gas. The surface morphology was characterized
by a cell structure induced by grains elongated
perpendicular to the substrate surface. The ma-
terial located at the interface was more amor-
phous compared to the graphite-like materials
101Vol. 56 (2007) [2]
> > >
located within the cells. Chen et al. [64] studied
the potential of burying inductors in multilay-
er ceramic substrates by inserting a ferrite lay-
er into a low-temperature cofired cordierite sub-
strate. Bi2O3 was doped to lower the sintering
temperature and increase the permeability of
Ni-Zn-Cu ferrite. Sohn et al. [65] investigated
the suitability of glass-ceramics containing
cordierite as a crystal phase for application to
magnetic disk substrates to achieve higher stor-
age capacity. Parent glasses were prepared with
a CeO2 addition as flux, and α-cordierite was
precipitated after heat treatment. The optimum
properties for the magnetic memory disk sub-
strates are as follows: Bending strength - 192 MPa,
Vickers hardness - 642.1 kg/mm., CTE -
39 � 10–7 / K, and surface roughness - 2.7 nm.
5.8 Cordierite supports Recent advances have been made in research on
cordierite monolithic catalyst supports, partic-
ularly on honeycombs and ceramic foams. Car-
ty and Lednor [66] reported that honeycombs
are used as catalyst supports for the removal of
gaseous or particulate emissions from combus-
tion engines and for reducing nitrogen oxide
emissions from power plants. They also noted
that ceramic foams are attracting attention as
catalyst supports due to their high thermal sta-
bility, high porosity and increased tortuosity
with respect to honeycombs.Yamuna et al. [67]
prepared honeycomb and pellet type carriers
from kaolin-based cordierite composition, and
their efficiency in pollution monitoring was
studied in two-stroke vehicles. The convention-
ally prepared kaolin based cordierite system re-
moved 78 % of the CO and 82 % of the hydro-
carbons from the exhaust gases under idling
conditions. Cordierite honeycombs are used as
catalyst supports and must be coated with
porous alumina to increase their specific sur-
face area. Hua et al. [68] tried to prepare porous
alumina with a large surface area on the inter-
nal surface of cordierite honeycombs through
in-situ and dip-coating methods of loading
γ-Al2O3 prior to its hydrolysis during the prepa-
ration of alumina sol. Seijger et al. [69] studied
the in situ synthesis of binderless ferrierite coat-
ings on 300 si cordierite honeycomb supports.
The silica-to-alumina ratio of the synthesis mix-
ture and the development of the ferrierite coat-
ing as a function of time were also investigated.
Schneider et al. [70] studied the catalytic behav-
iour of perovskite (LaMnO3, LaCoO3, etc.)
supported on cordierite monoliths in the total
oxidation of chlorinated hydrocarbons. In the
case of monolith supported LaCoO3 perovskite,
an irreversible catalyst deactivation was ob-
served. Orlandi et al. [71] investigated the bio-
compatibility of two cordierite ceramics (DF
and Cord 1014) with similar chemical compo-
sition and different porosity, as a potential sup-
port for cell growth in a continuous-flow, sol-
id-bed reactor. They concluded that Cord 1014
could be a promising support for growing CHO
(Chinese hamster ovary) cells in great numbers
and producing recombinant hepatitis B surface
antigens.
5.9 Optical applications Park and Shin [72] prepared glass-ceramics con-
taining cordierite and a small amount of rutile
as the major crystalline phases for application
as IR reflectors. Nucleation occurred at 750 °C
for 3 h and crystal growth at 1100 °C for 5 h.
This material showed over 90 % reflectance in
the spectral range of 570 to 2500 nm.
5.10 Electrical and electronic applications Cordierite electric ceramics have an important
role in modern technology.They have been used
in electrothermics for the production of elec-
tric heater supports. Nowadays, due to its elec-
trical, electromechanical and thermal proper-
ties, this ceramic finds its applications in elec-
tronics for the production of microelectronic
components and in the machine-building in-
dustry for the manufacture of internal combus-
tion components.Acimovic et al. [73] prepared
cordierite ceramics based on sepiolite and ex-
amined their applications in foundries, defin-
ing the technological parameters for the pro-
duction of refractory coatings for sand moulds
and cores, and of refractory linings for use in
the lost loam process. Ting et al. [74] studied the
interactions between ruthenia-based resistors
and cordierite-glass substrates in low-temper-
ature co-fired ceramics which are composed of
a RuO2-based resistor and a cordierite-glass
substrate that are sintered at temperatures of
850 °C and 900 °C. X-ray diffractometry re-
vealed that the lead ruthenate pyrochlore
(Pb2Ru2O6.5) in peak-fired thick-film resistors
(TFR) disappears and the co-fired samples con-
tain only RuO2 in the resistor film when sintered
at 900 °C. The overall resistance of the LTCC re-
sistors is increased by a factor of ~3 when the
temperature is raised from 850 to 900 °C. The
increase in the resistance of the LTCC resistors
is attributed to the interruption of the conduc-
tion path by platelike anorthite crystals that are
produced in the resistor-substrate interface dur-
ing co-firing.
5.11 Electrochemical applications Domenech-Carbo et al. [75] studied the elec-
trochemistry of α-, β-, and µ-cobalt containing
cordierites (Co2Al4Si5O18) attached to paraffin-
impregnated graphite electrodes by linear scan
and cyclic voltametries in HCl + NaCl and
NaOH electrolytes. Cordierite-modified elec-
trodes display a significant site-dependent cat-
alytic effect on the electrochemical oxidation of
mannitol in 0.1 (M) NaOH.
5.12 Electromagnetic applications Wang et al. [76] synthesized cordierite by sol-
gel processing with the aim of using it as MLCI
material. It has a low dielectric coefficient (3.5)
at high frequency (1.8 GHz). The sintering tem-
perature decreased with increasing Bi2O3 and
B2O3 additions. Luo et al. [77] also synthesized
a sol-gel derived cordierite ceramic that had a
low dielectric constant and a low dissipation fac-
tor and could be co-fired with highly conduc-
tive metals such as Au,Ag, Pd, and Cu paste be-
low 1000 °C, suggesting that it would be a prom-
ising material for high frequency MLCIs.Wang
et al. [78] developed cordierite-based ceramics
by sintering at 950 °C a glass selected from the
MgO–Al2O3–SiO2 system with a small amount
of B2O3 and P2O5 with the aim of using the ma-
terial in high frequency chip inductors. Crys-
talline phases in this sintered sample are most-
ly α-cordierite (hexagonal high cordierite) with
trace amounts of µ-cordierite. It achieved 99 %
of theoretical density, a dielectric constant of
5.5, a dielectric loss of 0.001 and a thermal ex-
pansion coefficient of 26.7 � 10–7/K. It has a
uniformly dense microstructure with granular
crystals.Yue et al. [79] prepared a series of nov-
el composites of NiCuZn ferrite and cordierite
crystallites by sintering the mixtures of nano-
sized NiCuZn ferrite particles and MgO-Al2O3-
SiO2 glass powder to be used for MLCIs. These
composite materials have tuneable electromag-
netic properties with high resonance frequen-
cies. In another work, Yue et al. [80] fabricated
ferrite-glass-cordierite nanocomposites by mix-
ing and sintering NiCuZn ferrite nanopowder
and MgO-Al2O3-SiO2 gel powder prepared by
Ceramics in Asia
102 Vol. 56 (2007) [2]
��the sol-gel process. The composites have tune-
able electric and magnetic properties with res-
onant frequencies higher than 2 GHz.
In addition to the traditional application of
cordierite in kiln furniture, its use as compos-
ite material has been discussed. Among these,
ceria-cordierite composites show an oxygen
storage capacity (OSC), which is helpful for en-
hancing the efficiency of catalytic converters in
automobile engines. The application of crys-
talline cordierite as a coating and joining mate-
rial between two SiC substrates has a promis-
ing future. Cordierite material proved effective
in the filtration of the automotive emissions, es-
pecially in a foam structure. The potential use
of ceramic substrates in capacitor and magnet-
ic disks for higher memory storage capacity has
been discussed.Honeycomb and pellet type car-
riers from kaolin-based cordierite composition
and their efficiency in pollution monitoring have
been described for two-stroke vehicles.The con-
ventionally prepared kaolin based cordierite
system removes 78 % of CO and 82 % of hydro-
carbons under idling conditions. The catalytic
behaviour of perovskite (LaMnO3,LaCoO3,etc.)
supported on cordierite monoliths in the total
oxidation of chlorinated hydrocarbons has al-
so been discussed in this paper. It was shown
that the biocompatibility of two cordierite ce-
ramics could be a promising support for grow-
ing CHO (Chinese hamster ovary) cells in great
numbers and producing recombinant hepatitis
B surface antigens. Cordierite ceramics can al-
so be used in optical applications such as IR re-
flectors with glass-ceramics containing
cordierite and a small amount of rutile as the
main crystalline phases. Nowadays, this ceram-
ic finds its applications in electronics for the pro-
duction of microelectronic components and in
the machine-building industry for the manu-
facture of internal combustion components.The
use of cordierite materials in electrochemical
applications and in electromagnetic applica-
tions in MLCIs and high frequency chip induc-
tors has gained increased importance in recent
years.
6 Summary and conclusion
Cordierite can be synthesized both by conven-
tional techniques using solid state reaction, em-
ploying relatively cheap raw materials, and by
using solution techniques using synthetic ma-
terials such as different organic and inorganic
salts. Some novel synthesis techniques have al-
so been reported in this field. Different addi-
tives were observed to exert profound influences
on the synthesis techniques and the property
(particularly, mechanical and electrical) devel-
opment of cordierite ceramics.Apart from var-
ious traditional applications, several new appli-
cations of cordierite either in the single state or
in the form of composites, exploiting its differ-
ent advantageous properties, have been report-
ed. More research is required to improve upon
its properties and to explore its newer applica-
tions.
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