Transformation and Densification of Nanocrystalline θ-Alumina during Sinter Forging

The sinter forging behavior of α-Al₂O₃ seeded and unseeded nanocrystalline θ-Al₂O₃ was investigated as a function of temperature, stress, and strain rate. Seeded samples exhibited the highest degree of plastic deformation during the θ- to α-AI₂O₃ phase transformation. As a result, microstructure control, increased densification, and a higher degree of transformation were obtained. A uniform microstructure of 150 nm α-Al₂O₃ grains developed, reaching 57% relative density after sintering 1.5 wt%α-Al₂O₃ seeded samples for 30 min at 1060°C. When sinter forged at 0.25 mm/min to 63 MPa and 1060°C for 30 min large deformations during the phase transformation increased the relative density to 74%. When the stress was increased to 235 MPa (1060°C, 30 min), 99.7% dense α-Al₂O₃ with a grain size of 230 nm was obtained. By increasing the sinter forging temperature to 1150°C, 99.5% relative density was achieved at 190 MPa for 30 min.     

Field-Assisted Densification of Superhard B6O Materials with Y2O3/Al2O3 Addition

B₆O is a possible candidate of superhard materials with a hardness of 45 GPa measured on single crystals. Up to now, densification of these materials was only possible at high pressure. However, recently it was found that Al₂O₃ can be utilized as an effective sintering additive, similar to the addition of Y₂O₃/Al₂O₃ that was used in this work. The densification behavior of the material as a function of applied pressure, its microstructure evolution, and the resulting mechanical properties were investigated. A strong dependence of the densification with increasing pressure was found. The material revealed characteristic triple junctions filled with amorphous residue composed of B₂O₃, Al₂O₃, and Y₂O₃, while no amorphous grain-boundary films were observed along internal interfaces. Mechanical testing revealed on average a hardness of 33 GPa, a fracture toughness of 4 MPa·m^1/2, and a strength value of 520 MPa.     

High Electrical Conductivity and High Fracture Strength of Sc2O3-Doped Zirconia Ceramics with Submicrometer Grains

The microstructure, crystal phase, electrical conductivity, and mechanical strength of less than 7-mol%-Sc₂O₃-doped zirconia ceramics fabricated by comparatively low-temperature sintering at 1200–1300°C for 1 h were investigated. Zirconia ceramics having a uniform microstructure (grain size < 0.5 μm) stabilized with 6 mol% Sc₂O₃ showed high electrical conductivity (0.15 S/cm at 1000°C) and high fracture strength (660 MPa). With the increase of Sc₂O₃ content from 3.5 to 7 mol%, the grain size, fracture strength, and electrical conductivity at 1000°C changed from 0.2 to 0.5 μm, 970 to 440 MPa, and 0.07 to >0.2 S/cm, respectively. Sc₂O₃-doped zirconia polycrystals with high fracture strength and high electrical conductivity are promising candidates for the electrolyte material of solid oxide fuel cells.     

Characterization of Alkoxy-Derived Yttria-Stabilized Hafnia

High-purity submicron HfO₂−Y₂O₃ powders were prepared by the simultaneous hydrolytic decomposition of hafnium and yttrium alkoxides. Compositions of 1 to 7 mol% Y₂O₃ in HfO₂ were studied by high-temperature X-ray diffraction, electron microscopy, BET surface area measurements, emission spectrographic analysis, TGA, and DTA. X-ray diffraction and atomic absorption were used to determine the Y₂O₃ concentration. Hot-pressing or cold-pressing and sintering of the powders resulted in nearly theoretically dense bodies with uniform microstructure containing grains 1 to 5 μm in size. Surface reflection ir spectra were obtained for monoclinic, tetragonal, and cubic specimens. Fully cubic HfO₂ with 7 mol% Y₂O₃ additions was obtained at a relatively low temperature. The hot-pressed specimens, initially slightly oxygen-deficient or gray HfO_{2- x} , were reoxidized at 1000°C with no deleterious effects; thin sections were translucent to incident light.     

Transformation, Microstructure Development, and Densification in α-Fe2O3-Seeded Boehmite-Derived Alumina

Addition of α-Fe₂O₃ seed particles to alkoxide-derived boehmite sols resulted in a 10-fold increase in isothermal rate constants for the transformation of γ- to α-Al₂O₃. Changes in porosity and surface area with sintering temperature showed no effect of seeding on coarsening of the transition alumina gels, but the 200-fold decrease in surface area associated with transformation to α-Al₂O₃ occurred ∼ 100°C lower in seeded gels compared with unseeded materials. As a result of high nucleation frequency and reduced microstructure coarsening, fully transformed seeded alumina retained specific surface areas >22 m²/g and exhibited narrow pore size distributions, permitting development of fully dense, submicrometer α-Al₂O₃ at ∼ 1200°C.     

Microstructure and Electrical Properties of Sc2O3-Doped, Rare-Earth-Oxide-Doped, and Undoped BaTiO3

Polycrystalline BaTiO₃ prepared from alkoxy-derived high-purity submicron powders was studied. Highly dense bodies with uniform grain size were obtained typically by uniaxial cold-pressing at 3000 psi and isostatic pressing at 30,000 psi followed by sintering at 1300° to 1350°C in air for 0.5 to 1 h. Using the same consolidation parameters and intimate mixing of residual concentrations of highly active fine-particulate rare-earth oxides to act as grain-growth inhibitors, nearly theoretically dense bodies with a uniform microstructure and 1 to 1.5 μm grain size were obtained. Typical microstructures with well-defined 90° and 180° domain patterns characteristic of BaTiO₃: were observed. Also, an example of a checkerboard pattern resulting from a 〈111〉 ingrown twin plane in the structure which is independent of the Curie temperature was found. Electrical measurements on the undoped material indicated room-temperature dielectric constant and tan δ values of 5000±500 and 4×10⁻³, respectively. Very high k values and dissipation factors were observed with the La₂O₃- and Nd₂O₃-doped samples.     

Al2O3─SiC Composites from Aluminosilicate Precursors

Al₂O₃ and SiC composite materials have been produced from mixtures of aluminosilicates (both natural minerals and synthetic) and carbon as precursor materials. These composites are produced by heating a mixture of kaolinite (or synthetic aluminosilicates) and carbon in stoichiometric proportion above 1550°C, so that only Al₂O₃ and SiC remain as the major phases. A similar process has also been used for synthesizing other composite powders having mixtures of Al₂O₃, SiC, TiC, and ZrO₂ in different proportions (all compounds together or selective mixtures of some of them), as desired. The microstructure of hot-pressed dense compacts, produced from these powders, revealed that the SiC phase is distributed very homogeneously, even occasionally within Al₂O₃ grains on a nanosize scale. The homogeneous distribution of SiC particles within the system produced high fracture toughness of the hot-pressed material (K_IC∼ 7.0 MPa · m^1/2) and having Vicker's hardness values greater than 2000 kgf/mm².     

Synthesis of Novel Niobium Aluminide-Based Composites

A reactive sintering process has been used to produce almost fully dense composites with interpenetrating networks of NbAl₃ and Al₂O₃. The process involves the reaction synthesis of niobium aluminides and Al₂O₃ from compacts of intensively milled aluminum and Nb₂O₅ powder mixtures. During carefully controlled heating under an inert atmosphere, the oxide reduction by aluminum to form niobium aluminides and Al₂O₃ proceeds at temperatures below the melting point of aluminum. At temperatures of >1000°C, the reaction-formed niobium aluminides and Al₂O₃ sinter. The present paper discusses processing parameters, such as attrition milling, the heating cycle, and the metal:ceramic ratio in the starting mixture, that control microstructure development and mechanical properties.     

Development and Characterization of Y2O3-Stabilized ZrO2 (Y-TZP) Composites with TiB2, TiN, TiC, and TiC0.5N0.5

Up to 50 vol% of TiB₂, TiC_0.5N_0.5, TiN, or TiC was added to Y₂O₃-stabilized tetragonal ZrO₂ polycrystals (Y-TZP) and hot pressed under vacuum. The influence of the type of secondary phase on the microstructure and mechanical properties was studied, as a function of the hot-pressing temperature. The influence of the secondary-phase content on the mechanical properties was studied by varying the TiB₂ content up to 50 vol%. Fully dense Y-TZP-based composites with very high toughness (up to 10 MPa·m^1/2), excellent bending strength (up to 1237 MPa), and increased hardness, with respect to ZrO₂ (Vickers hardness up to 1450 kg/mm²), were obtained.     

Sr3LaNb3O12: A New Low Loss and Temperature Stable A4B3O12-Type Microwave Dielectric Ceramic

The microwave dielectric properties of dense ceramics of a new A₄B₃O₁₂ type cation-deficient hexagonal perovskite Sr₃LaNb₃O₁₂ are reported. Single-phase powders can be obtained from the mixed-oxide route at 1320°C and dense ceramics (>96% of the theoretical X-ray density) with uniform microstructures (5–12 um) can be obtained by sintering in air at 1430°C. The ceramic exhibits a moderate dielectric constant ɛ_r∼36, a high quality factor Q × f ∼45 327 GHz, and a low temperature coefficient of resonant frequency τ _f of −9 ppm/°C.     

Effect of Aqueous Processing Conditions on the Microstructure and Transformation Behavior in Al2O3─ZrO2(CeO2) Composites

Aqueous processing of Al₂O₃─ZrO₂ (123 mol% CeO₂) composites, combined with sintering conditions, was used to control the microstructure and its influence on the martensitic transformation temperature of t -ZrO₂ and the transformation-toughening contribution at room temperature. The resultant ZrO₂ grain sizes in the dense composites were related to the transformation-toughening behavior of t -ZrO₂. The data show that (1) the best processing conditions exist when the electrophoretic mobilities of the two solids are positive, adequately high to ensure colloidal stability, efficient packing,and uniform ZrO₂ distribution but differ greatly in magnitude, (2) the colloidal stability of ZrO₂ controls the overall stability and the rheological and processing behavior of this mixture, (3) the grain size distribution in dense pieces sintered for 1 h at 1500°C is comparable to the particle size distribution of the powders, (4) the martensite start temperature for the tetragonal to-monoclinic transformation in Al₂O₃ containing 20 and 40 vol% ZrO₂ increases and can approach 0°C with increasing average ZrO₂ grain size, and as a result, (5) the fracture toughness values at room temperature are raised from 4–5 MPa.m^1/2 to 9–12 MPa.m^1/2 for these two compositions.     

Oxidation Protection of MgO–C Refractories by Means of Al8B4C7

The effect of Al₈B₄C₇ used as an antioxidant in MgO–C refractories and the behavior of Al₈B₄C₇ in CO gas were investigated in the present study. Al₈B₄C₇ was found to react with CO gas, to form Al₂O₃( s ), B₂O₃( l ), and C( s ), at temperatures >1100°C. The Al₂O₃ reacts with MgO to form MgAl₂O₄ near the surface of the material. At the same time, B₂O₃( l ) evaporates and reacts with MgO, to form a liquid phase, at >1333°C, the eutectic point between 3MgO·B₂O₃ and MgO. The coexistence of the liquid and MgAl₂O₄ makes the protective layer more dense, thus inhibiting oxidation of the refractory. At >1333°C, the process apparently is controlled by oxygen diffusion, whereas it is controlled by chemical reaction when the temperature is <1333°C.     

Low-Temperature Processing and Mechanical Properties of Zirconia and Zirconia–Alumina Nanoceramics

The 1.5- to 3-mol%-Y₂O₃-stabilized tetragonal ZrO₂ (Y-TZP) and Al₂O₃/Y-TZP nanocomposite ceramics with 1 to 5 wt% of alumina were produced by a colloidal technique and low-temperature sintering. The influence of the ceramic processing conditions, resulting density, microstructure, and the alumina content on the hardness and toughness were determined. The densification of the zirconia (Y-TZP) ceramic at low temperatures was possible only when a highly uniform packing of the nanoaggregates was achieved in the green compacts. The bulk nanostructured 3-mol%-yttria-stabilized zirconia ceramic with an average grain size of 112 nm was shown to reach a hardness of 12.2 GPa and a fracture toughness of 9.3 MPa·m^1/2. The addition of alumina allowed the sintering process to be intensified. A nanograined bulk alumina/zirconia composite ceramic with an average grain size of 94 nm was obtained, and the hardness increased to 16.2 GPa. Nanograined tetragonal zirconia ceramics with a reduced yttria-stabilizer content were shown to reach fracture toughnesses between 12.6–14.8 MPa·m^1/2 (2Y-TZP) and 11.9–13.9 MPa·m^1/2 (1.5Y-TZP).     

Prominent Nanocrystallization of 25K2O·25Nb2O5·50GeO2 Glass

Some K₂O-Nb₂O₅-GeO₂ glasses are prepared, and their crystallization behaviors are examined. 25K₂O·25Nb₂O₅·50GeO₂ glass with the glass transition temperature T _g= 622°3C and crystallization onset temperature T _x= 668°3C shows a prominent nanocrystallization. The crystalline phase is K_3,8Nb₅Ge₃O_20,4 with an orthorhombic structure. The sizes of crystals in the crystallized glasses heat-treated at 630° and 720°3C for 1 h are °10 and 20–30 nm, respectively, and the crystallized glasses obtained by heat treatments at 620°-850°3C for 1 h maintain good transparency. The density of crystallized glasses increases gradually with increasing heat-treatment temperature, and the volume fraction of crystals in the sample heat-treated at 630°3C for 1 h is estimated to be ∼35%. The usual Vickers hardness and Martens hardness (estimated by nanoindentation) of 25K₂O·25Nb₂O₅·50GeO₂ glass change steeply by heat treatment at T _g, i.e., at around 35% volume fraction of nanocrystals. The present study demonstrates that the composite of nanocrystals and the glassy phase has a strong resistance against deformation during Vickers indenter loading in crystallized glasses.     

Densification of Cr2O3-ZrO2 Ceramics by Sintering

Cr₂O₃ and ZrO₂ were mixed in various ratios and pressed to form compacts, which were then sintered in carbon powder. Compacts with >30 wt% Cr₂O₃ were sintered to densities >98% of true density at 1500°C. This method of sintering in carbon powder can be used to prepare very dense Cr₂O₃-ZrO₂ ceramics at a relatively low temperature, (∼1500°C) without additives.     

Thermal Evolution and Sintering Behavior of a 2:1 Mullite Gel

The thermal evolution of a mullite gel of composition 2Al₂O₃·SiO₂ has been investigated. The gel crystallized at 1300°C into an alumina-rich mullite and corundum, instead of single-phase 2Al₂O₃·SiO₂ mullite. The amount of Al₂O₃ that dissolved in the mullite structure has been determined in the 1300–1780°C temperature range by measuring the mullite lattice parameters. A maximum limit for the amount of Al₂O₃ in solid solution has been observed. Densification of the gel powders has been analyzed up to temperatures of 1780°C. The microstructure of dense materials always showed the presence of residual Al₂O₃ particles.     

Solid-State Reactive Sintering of Transparent Polycrystalline Nd:YAG Ceramics

Transparent polycrystalline Nd:YAG ceramics were fabricated by solid-state reactive sintering a mixture of commercial Al₂O₃, Y₂O₃, and Nd₂O₃ powders. The powders were mixed in methanol and doped with 0.5 wt% tetraethoxysilane (TEOS), dried, and pressed. Pressed samples were sintered from 1700° to 1850°C in vacuum without calcination. Transparent fully dense samples with average grain sizes of ∼50 μm were obtained at 1800°C for all Nd₂O₃ levels studied (0, 1, 3, and 5 at.%). The sintering temperature was little affected by Nd concentration, but SiO₂ doping lowered the sintering temperature by ∼100°C. Abnormal grain growth was frequently observed in samples sintered at 1850°C. The Nd concentration was determined by energy-dispersive spectroscopy to be uniform throughout the samples. The in-line transmittance was >80% in the 350–900 nm range regardless of the Nd concentration. The best 1 at.% Nd:YAG ceramics (2 mm thick) achieved 84% transmittance, which is equivalent to 0.9 at.% Nd:YAG single crystals grown by the Czochralski method.     

Influence of the Y2O3 Content and Temperature on the Mechanical Properties of Melt-Grown Al2O3–ZrO2 Eutectics

The effect of Y₂O₃ content on the flexure strength of melt-grown Al₂O₃–ZrO₂ eutectics was studied in a temperature range of 25°–1427°C. The processing conditions were carefully controlled to obtain a constant microstructure independent of Y₂O₃ content. The rod microstructure was made up of alternating bands of fine and coarse dispersions of irregular ZrO₂ platelets oriented along the growth axis and embedded in the continuous Al₂O₃ matrix. The highest flexure strength at ambient temperature was found in the material with 3 mol% Y₂O₃ in relation to ZrO₂(Y₂O₃). Higher Y₂O₃ content did not substantially modify the mechanical response; however, materials with 0.5 mol% presented a significant degradation in the flexure strength because of the presence of large defects. They were nucleated at the Al₂O₃–ZrO₂ interface during the martensitic transformation of ZrO₂ on cooling and propagated into the Al₂O₃ matrix driven by the tensile residual stresses generated by the transformation. The material with 3 mol% Y₂O₃ retained 80% of the flexure strength at 1427°C, whereas the mechanical properties of the eutectic with 0.5 mol% Y₂O₃ dropped rapidly with temperature as a result of extensive microcracking.     

Synthesis of Porous Si3N4 Ceramics with Rod-Shaped Pore Structure

Porous Si₃N₄ ceramics were synthesized by pressureless sintering of green compacts prepared using slip casting of slurries containing Si₃N₄, 5 wt% Y₂O₃+2 wt% Al₂O₃, and 0–60% organic whiskers composed of phenol–formaldehyde resin with solids loading up to 60 wt%. Rheological properties of slurries were optimized to achieve a high degree of dispersion with a high solid-volume fraction. Samples were heated at 800°C in air and sintered at 1850°C in a N₂ atmosphere. Porosities ranging from 0% to 45% were obtained by the whisker contents (corresponding to 0–60 vol% whisker). Samples exhibited a uniform pore distribution. Their rod-shaped pore morphology originated from burnout of whiskers, and an extremely dense Si₃N₄ matrix.     

Equilibrium Amorphous Silicon–Calcium–Oxygen Films at Interfaces in Copper–Alumina Composites Prepared by Melt Infiltration

The microstructure of copper–alumina (Cu-Al₂O₃) composites that have been prepared via the melt infiltration of liquid copper into porous alumina preforms was studied in detail, using various transmission electron microscopy (TEM) techniques. Two different samples—with open pore diameters of 0.2 and 0.8 μm—were investigated. For both specimens, a single crystalline copper network that extended throughout the open porosity of the alumina preform was observed. An amorphous glass phase that contained silicon and calcium was observed at the Al₂O₃/Cu/Al₂O₃ triple junctions. The diameters of these amorphous pockets, which were strongly faceted along the Al₂O₃ grains, were up to 20 and 100 nm for the initial pore sizes of 0.2 and 0.8 μm, respectively. A glass phase that contained silicon and calcium also was present at the Cu/Al₂O₃ interfaces, whereas the Al₂O₃ boundaries remained dry. Detailed high-resolution transmission electron microscopy investigations have shown that the interfacial glass phase at the Cu/Al₂O₃ interfaces exhibited a uniform equilibrium film thickness along the interface region. However, the interfacial film thickness was dependent on the orientation of the Al₂O₃ grain, and its value varied from 0.4 nm for Al₂O₃ rhombohedral-plane termination ((1¯012)) up to 1 nm for Al₂O₃ basal-plane termination ((0001)).