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The skull crucible process was developed at the Lebedev Physical Institute in Moscow to manufacture cubic zirconia. [1] It was invented to solve the problem of cubic zirconia's melting-point being too high for even platinum crucibles.
In essence, by heating only the center of a volume of cubic zirconia, the material forms its own "crucible" from its cooler outer layers. The term "skull" refers to these outer layers forming a shell enclosing the molten volume. Zirconium oxide powder is heated then gradually allowed to cool. Heating is accomplished by radio frequency induction using a coil wrapped around the apparatus. The outside of the device is water-cooled in order to keep the radio frequency coil from melting and also to cool the outside of the zirconium oxide and thus maintain the shape of the zirconium powder.
Since zirconium oxide in its solid state does not conduct electricity, a piece of zirconium metal is placed inside the gob of zirconium oxide. As the zirconium melts it oxidizes and blends with the now molten zirconium oxide, a conductor, and is heated by radio frequency induction.
When the zirconium oxide is melted on the inside (but not completely, since the outside needs to remain solid) the amplitude of the RF induction coil is gradually reduced and crystals form as the material cools. Normally this would form a monoclinic crystal system of zirconium oxide.
In order to maintain a cubic crystal system a stabilizer is added, magnesium oxide, calcium oxide or yttrium oxide as well as any material to color the crystal. After the mixture cools the outer shell is broken off and the interior of the gob is then used to manufacture gemstones.
Zirconium is a chemical element with the symbol Zr and atomic number 40. The name zirconium is derived from the name of the mineral zircon, the most important source of zirconium. The word is related to Persian zargun. It is a lustrous, grey-white, strong transition metal that closely resembles hafnium and, to a lesser extent, titanium. Zirconium is mainly used as a refractory and opacifier, although small amounts are used as an alloying agent for its strong resistance to corrosion. Zirconium forms a variety of inorganic and organometallic compounds such as zirconium dioxide and zirconocene dichloride, respectively. Five isotopes occur naturally, four of which are stable. Zirconium compounds have no known biological role.
Cubic zirconia (abbreviated CZ) is the cubic crystalline form of zirconium dioxide (ZrO2). The synthesized material is hard and usually colorless, but may be made in a variety of different colors. It should not be confused with zircon, which is a zirconium silicate (ZrSiO4). It is sometimes erroneously called cubic zirconium.
Zirconium dioxide is a white crystalline oxide of zirconium. Its most naturally occurring form, with a monoclinic crystalline structure, is the mineral baddeleyite. A dopant stabilized cubic structured zirconia, cubic zirconia, is synthesized in various colours for use as a gemstone and a diamond simulant.
A crucible is a ceramic or metal container in which metals or other substances may be melted or subjected to very high temperatures. Although crucibles have historically tended to be made out of clay, they can be made from any material that withstands temperatures high enough to melt or otherwise alter its contents.
Induction heating is the process of heating electrically conductive materials, namely metals or semi-conductors, by electromagnetic induction, through heat transfer passing through an inductor that creates an electromagnetic field within the coil to heat up and possibly melt steel, copper, brass, graphite, gold, silver, aluminum, or carbide.
A getter is a deposit of reactive material that is placed inside a vacuum system to complete and maintain the vacuum. When gas molecules strike the getter material, they combine with it chemically or by absorption. Thus the getter removes small amounts of gas from the evacuated space. The getter is usually a coating applied to a surface within the evacuated chamber.
In materials science, a refractory is a material that is resistant to decomposition by heat or chemical attack that retains its strength and rigidity at high temperatures. They are inorganic, non-metallic compounds that may be porous or non-porous, and their crystallinity varies widely: they may be crystalline, polycrystalline, amorphous, or composite. They are typically composed of oxides, carbides or nitrides of the following elements: silicon, aluminium, magnesium, calcium, boron, chromium and zirconium. Many refractories are ceramics, but some such as graphite are not, and some ceramics such as clay pottery are not considered refractory. Refractories are distinguished from the refractory metals, which are elemental metals and their alloys that have high melting temperatures.
A diamond simulant, diamond imitation or imitation diamond is an object or material with gemological characteristics similar to those of a diamond. Simulants are distinct from synthetic diamonds, which are actual diamonds exhibiting the same material properties as natural diamonds. Enhanced diamonds are also excluded from this definition. A diamond simulant may be artificial, natural, or in some cases a combination thereof. While their material properties depart markedly from those of diamond, simulants have certain desired characteristics—such as dispersion and hardness—which lend themselves to imitation. Trained gemologists with appropriate equipment are able to distinguish natural and synthetic diamonds from all diamond simulants, primarily by visual inspection.
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
An induction furnace is an electrical furnace in which the heat is applied by induction heating of metal. Induction furnace capacities range from less than one kilogram to one hundred tons, and are used to melt iron and steel, copper, aluminum, and precious metals.
Spray forming, also known as spray casting, spray deposition and in-situ compaction, is a method of casting near net shape metal components with homogeneous microstructures via the deposition of semi-solid sprayed droplets onto a shaped substrate. In spray forming an alloy is melted, normally in an induction furnace, then the molten metal is slowly poured through a conical tundish into a small-bore ceramic nozzle. The molten metal exits the furnace as a thin free-falling stream and is broken up into droplets by an annular array of gas jets, and these droplets then proceed downwards, accelerated by the gas jets to impact onto a substrate. The process is arranged such that the droplets strike the substrate whilst in the semi-solid condition, this provides sufficient liquid fraction to 'stick' the solid fraction together. Deposition continues, gradually building up a spray formed billet of metal on the substrate.
Induction hardening is a type of surface hardening in which a metal part is induction-heated and then quenched. The quenched metal undergoes a martensitic transformation, increasing the hardness and brittleness of the part. Induction hardening is used to selectively harden areas of a part or assembly without affecting the properties of the part as a whole.
This page describes how uranium dioxide nuclear fuel behaves during both normal nuclear reactor operation and under reactor accident conditions, such as overheating. Work in this area is often very expensive to conduct, and so has often been performed on a collaborative basis between groups of countries, usually under the aegis of the Organisation for Economic Co-operation and Development's Committee on the Safety of Nuclear Installations (CSNI).
Glass-to-metal seals are a type of mechanical seal which joins glass and metal surfaces. They are very important elements in the construction of vacuum tubes, electric discharge tubes, incandescent light bulbs, glass-encapsulated semiconductor diodes, reed switches, glass windows in metal cases, and metal or ceramic packages of electronic components.
Ultrasonic soldering is a flux-less soldering process that uses ultrasonic energy, without the need for chemicals to solder materials, such as glass, ceramics, and composites, hard to solder metals and other sensitive components which cannot be soldered using conventional means.
The micro-pulling-down (μ-PD) method is a crystal growth technique based on continuous transport of the melted substance through micro-channel(s) made in a crucible bottom. Continuous solidification of the melt is progressed on a liquid/solid interface positioned under the crucible. In a steady state, both the melt and the crystal are pulled-down with a constant velocity.
Induction plasma, also called inductively coupled plasma, is a type of high temperature plasma generated by electromagnetic induction, usually coupled with argon gas. The magnetic field induces an electric current within the gas which creates the plasma. The plasma can reach temperatures up to 10,000 Kelvin. Inductive plasma technology is used in fields such as powder spheroidisation and nano-material synthesis. The technology is applied via an Induction plasma torch, which consists of three basic elements: the induction coil, a confinement chamber, and a torch head, or gas distributor. The main benefit of this technology is the elimination of electrodes, which can deteriorate and introduce contamination.
Corium, also called fuel-containing material (FCM) or lava-like fuel-containing material (LFCM), is a material that is created in a nuclear reactor core during a nuclear meltdown accident. Resembling lava in consistency, it consists of a mixture of nuclear fuel, fission products, control rods, structural materials from the affected parts of the reactor, products of their chemical reaction with air, water, steam, and, in the event that the reactor vessel is breached, molten concrete from the floor of the reactor room.
Implant induction welding is a joining method used in plastic manufacturing. The welding process uses an induction coil to excite and heat electromagnetically susceptible material at the joint interface and melt the thermoplastic. The susceptible material can be contained in a gasket placed between the welding surface, or within the actual components of a composite material. Its usage is common for large, unusually shaped, or delicate parts that would be difficult to weld through other methods.
Hafnium compounds are compounds containing the element hafnium (Hf). Due to the lanthanide contraction, the ionic radius of hafnium(IV) (0.78 ångström) is almost the same as that of zirconium(IV) (0.79 angstroms). Consequently, compounds of hafnium(IV) and zirconium(IV) have very similar chemical and physical properties. Hafnium and zirconium tend to occur together in nature and the similarity of their ionic radii makes their chemical separation rather difficult. Hafnium tends to form inorganic compounds in the oxidation state of +4. Halogens react with it to form hafnium tetrahalides. At higher temperatures, hafnium reacts with oxygen, nitrogen, carbon, boron, sulfur, and silicon. Some compounds of hafnium in lower oxidation states are known.