Enthalpies of formation in the scandia‐zirconia system

The scandia‐zirconia (ScZ) solid solutions have been attracting attention from the communities interested in solid‐oxide fuel cells because they possess the highest ionic conductivity among zirconia‐based materials. However, this system shows a relatively large number of polymorphs with lack of thermodynamic data to enable comprehensive phase control for property optimization. In this work, the enthalpy of formation of the ScZ system within the range 0–20 mol% Sc₂O₃ is determined by combining the surface energy values with enthalpy of drop solution data obtained from high‐temperature oxide melt solution calorimetry. The heats of formation, a key data for understanding phase stability, for five polymorphs: monoclinic (m), tetragonal (t), cubic (c), and rhombohedral (β and γ) are reported for the first time.     

Phase Stability in Nanocrystals: A Predictive Diagram for Yttria–Zirconia

Predicting the polymorphic stability of nanocrystals entails taking into account the thermodynamic effects from solid–vapor interfaces. With recent advances in microcalorimetry, it is finally possible to obtain reliable surface energy data which allow building of predictive diagrams, such as the usual phase diagrams for bulk crystals, for nanocrystals. Yttria doped zirconia (YZ) is currently utilized in a variety of applications; making it one of the most studied oxide systems to date. However, the polymorphism of nanocrystalline YZ (nYZ) is much less understood as compared to its bulk counterpart, and the stability conditions of cubic, tetragonal, monoclinic, and amorphous polymorphs at the nanoscale is so far only empirically defined. In this work, we present a new predictive nanoscale phase diagram for nYZ using unprecedented data on surface energies and bulk enthalpies acquired by microcalorimetry. The phase diagram shows the stable zirconia polymorph as a function of the composition and size. This is a useful tool and an important and novel advancement to relatively untouched bulk phase diagrams, which holds the key for reliable materials' design.     

Energy Crossovers in Nanocrystalline Zirconia

The synthesis of nanocrystalline powders of zirconia often produces the tetragonal phase, which for coarse-grained powders is stable only at high temperatures and transforms into the monoclinic form on cooling. This stability reversal has been suggested to be due to differences in the surface energies of the monoclinic and tetragonal polymorphs. In the present study, we have used high-temperature oxide melt solution calorimetry to test this hypothesis directly. We measured the excess enthalpies of nanocrystalline tetragonal, monoclinic, and amorphous zirconia. Monoclinic ZrO₂ was found to have the largest surface enthalpy and amorphous zirconia the smallest. Stability crossovers with increasing surface area between monoclinic, tetragonal, and amorphous zirconia were confirmed. The surface enthalpy of amorphous zirconia was estimated to be 0.5 J/m². The linear fit of excess enthalpies for nanocrystalline zirconia, as a function of area from nitrogen adsorption (BET) gave apparent surface enthalpies of 6.4 and 2.1 J/m², for the monoclinic and tetragonal polymorphs, respectively. Due to aggregation, the surface areas calculated from crystallite size are larger than those measured by BET. The fit of enthalpy versus calculated total interface/surface area gave surface enthalpies of 4.2 J/m² for the monoclinic form and 0.9 J/m² for the tetragonal polymorph. From solution calorimetry, the enthalpy of the monoclinic to tetragonal phase transition for ZrO₂ was estimated to be 10±1 kJ/mol and amorphization enthalpy to be 34±2 kJ/mol.     

Crystallite and Grain-Size-Dependent Phase Transformations in Yttria-Doped Zirconia

In pure zirconia, ultrafine powders are often observed to take on the high-temperature tetragonal phase instead of the "equilibrium" monoclinic phase. The present experiments and analysis show that this observation is one manifestation of a much more general phenomenon in which phase transformation temperatures shift with crystallite/grain size. In the present study, the effect of crystallite (for powders) and grain (for solids) size on the tetragonal → monoclinic phase transformation is examined more broadly across the yttria–zirconia system. Using dilatometry and high-temperature differential scanning calorimetry on zirconia samples with varying crystallite/grain sizes and yttria content, we are able to show that the tetragonal → monoclinic phase transformation temperature varies linearly with inverse crystallite/grain size. This experimental behavior is consistent with thermodynamic predictions that incorporate a surface energy difference term in the calculation of free-energy equilibrium between two phases.     

Phase stability and microstructure evolution of MgO-ZrO2 and MgO-6YSZ ceramic fibers

In this work, MgO-ZrO₂ and MgO-6YSZ ceramic fibers were prepared with sol-gel method via electrospinning. Polymorph stability and microstructure evolution of zirconia fibers were fully characterized by X-ray diffraction, Raman spectra, X-ray photoelectron spectroscopy, and Scanning electron microscope. The results indicated that tetragonal zirconia for MgO-ZrO₂ was obtained and cubic zirconia could be fully stabilized for MgO-6YSZ with MgO molar fractions varying from 0.1 to 0.5 at 800°C. Monoclinic phase appeared with MgO molar fractions even up to 0.5 for MgO-ZrO₂ system and partially or fully stabilized zirconia could be achieved for MgO-6YSZ at 1000°C and 1200°C. Grain size was gradually decreased with increasing of MgO content at 800°C both for MgO-ZrO₂ and MgO-6YSZ ceramic fibers. The grain size of both systems increased with MgO molar fractions varying from 0.1 to 0.2 and then decreased at higher contents at 1000°C and 1200°C. A discussion on relationship among MgO state and the phase stability and grain size was presented. This work shows surface excess and solid solution of MgO predominantly controlled the phase stability and microstructure evolution of zirconia fibers.     

Effect of valeric acid on the agglomeration of zirconia particles and effects of the sintering temperature on the strut wall thickness of particle-stabilized foam

Highly porous zirconia ceramics were prepared utilizing a particle-stabilized direct foaming technique in which the hydrophilic characteristic of zirconia particles was altered by the in situ adsorption of valeric acid on its surface. These surface modified zirconia particles are irreversibility adsorbed at the air/water interface and create an armor coating around the bubbles to stabilize them. In this study, the foamability and stability of zirconia foam were investigated by varying the valeric acid concentration, and zirconia foam with a foam volume of approximately four times the colloidal system volume was successfully prepared. The sintered foam has cell size ranging from 50 to 150 μm and the pore structure was characterized by mercury porosimetry. The effects of the sintering temperature on the grain size, strut wall thickness, and tetragonal phase were studied and correlated with an increase in the mechanical strength to 3.5 MPa with porosity of more than 90%.     

High‐Temperature Aging of Plasma Sprayed Quasi‐Eutectoid LaYbZr2O7–Part II: Microstructure & Thermal Conductivity

LaYbZr₂O₇ ceramic thermal barrier coatings (TBC) of meta‐stable structure were prepared by an air plasma spraying process. Their microstructure and associated thermal transport properties evolution during high‐temperature annealing at 1300°C were characterized. The as‐sprayed LaYbZr₂O₇ TBCs underwent a fast crystallization and a quasi‐eutectoid transformation during annealing, resulting in a biphase composite consisting of La‐rich pyrochlore phase and Yb₂Zr₂O₇ fluorite phase with coherent phase boundaries. Due to the diffusion barriers between the two phases as well as the low interface energy of the coherent boundaries, sintering and grain growth of materials was significantly refrained. Therefore, a final thermal dynamically stable microstructure with a grain size of ~300 nm and a total porosity about 5% could be maintained even after long‐term aging at a high temperature of 1300°C. Resulting from this stable microstructure, an ultralow thermal conductivity of 1.3 W·(m·K)^?1 could be obtained even after 216 h high‐temperature aging, which is much lower than that of the state‐of‐art 7 wt% yttria‐stabilized zirconia TBCs. Both the high phase and microstructure stability and the extremely low thermal conductivities could be particularly beneficial for TBC material in gas turbine applications.     

Stability of rare‐earth‐doped spherical yttria‐stabilized zirconia synthesized by ultrasonic spray pyrolysis

Phase stability is one of the crucial requirements for any material that can be used at elevated temperature applications such as thermal barrier coating (TBC). The most traditional TBC material, partially stabilized zirconia, limits the operating temperature due to its phase transformation. Conversely, the low thermal conductivity of fully stabilized zirconia (YSZ) may enable effective reduction in the surface temperature on the coated component, while avoiding deleterious phase transitions, although still being subjected to sintering and grain growth. It has been reported that addition of rare‐earths as dopants to YSZ can significantly increase resistance to grain growth at high temperature. Keeping this under consideration, this work investigates the role of rare‐earths (lanthanum and gadolinium) in increasing thermal stability of YSZ microspheres, the building blocks for high‐temperature photonics for reflective TBC. The spheres were produced by ultrasonic spray pyrolysis, and the doping led to significant improvement of stability by significant inhibition of grain growth. While the individual dopants showed significant growth and sintering inhibition up to 900°C, co‐doping with 4% (in mol) of each (Gd and La) led to coarsening resistance up to 1000°C for 3 hours, when particles retained reasonable spherical features with nanometric crystallite sizes.     

Size driven thermodynamic crossovers in phase stability in zirconia and hafnia

Hafnia (HfO₂) and zirconia (ZrO₂) are of great interest in the quest for replacing silicon oxide in semiconductor field effect transistors because of their high permittivity. Both exhibit extensive polymorphism and understanding the energetics of their transitions is of major fundamental and practical importance. In this study, we present a systematic thermodynamic summary of the influence of particle size on thermodynamic phase stability in hafnia and zirconia using recently measured enthalpy data from the literature. The amorphous phase is found to be the most energetically stable above 165 and 363 m²/g of surface area for HfO₂ and ZrO₂, respectively. Below 16 and 20.3 m²/g of surface area, respectively, the monoclinic phase is the most energetically stable for HfO₂ and ZrO₂. At intermediate sizes there are closely balanced energetics among monoclinic, tetragonal, and cubic phases. The energy crossovers reflect decreasing surface enthalpy in the order monoclinic, tetragonal, cubic and amorphous for both hafnia and zirconia.     

The Low‐Temperature High‐Pressure Phase Diagram of Energetic Materials: I. Hexahydro‐1,3,5‐Trinitro‐s‐Triazine

The reaction phase diagram of hexahydro‐1,3,5‐trinitro‐s‐triazine (RDX) has been studied as a function of temperature and pressure by Raman spectroscopy to 29 GPa and temperatures ranging from 4 to 298 K. Three stable phases (α, γ, and δ) have been found and their phase stabilities have been investigated. Phase boundaries were studied as a function of pressure and temperature, permitting a delineation of the various polymorph stability fields. A pressure–temperature reaction/phase diagram is constructed from the results of this study and compared to previous high temperature work.     

Phase Stability in Calcia‐Doped Zirconia Nanocrystals

Calcia‐doped zirconia exhibits all of the polymorphism seen in the yttria‐doped zirconia ceramics, but can be produced at lowered costs and in greater abundance due to the accessibility of Calcium precursors in comparison to Yttrium. Although with great challenges, there exists an opportunity to replace yttria with calcia in applications such as ionic conductors where phase stability is critical. There is a dearth of surface characterization to enable design and prediction of the polymorphism in nanoparticulate calcia–zirconia. With recent advances in water adsorption microcalorimetry, one can accurately probe surface energies of the four zirconia polymorphs: monoclinic, tetragonal, cubic, and amorphous. The surface energies can then be coupled with bulk enthalpies extracted from oxide melt drop solution calorimetry to create a nanocrystalline phase stability diagram similar to its bulk counterpart. We report here the surface and bulk thermodynamic data on polymorphs of calcia–zirconia with composition ranging from 0 to 20 mol% calcia and use it to build a nanophase diagram for this system. The effect of the humidity in the phase stability diagram trends is also addressed and demonstrated to minimize the effect of the surface energies in the overall polymorphism trends.     

Size-induced grain boundary energy increase may cause softening of nanocrystalline yttria-stabilized zirconia

An increase in hardness with reducing grain sizes is commonly observed in oxide ceramics in particular for grain sizes below 100 nm. The inverse behavior, meaning a decrease in hardness below a critically small grain size, may also exist consistently with observations in metal alloys, but the causing mechanisms in ceramics are still under debate. Here we report direct thermodynamic data on grain boundary energies as a function of grain size that suggest that the inverse relation is intimately related to a size-induced increase in the excess energies. Microcalorimetry combined with nano and microstructural analyses reveal an increase in grain boundary excess energy in yttria-stabilized zirconia (10YSZ) when grain sizes are below 36 nm. The onset of the energy increase coincides with the observed decrease in Vickers indentation hardness. Since grain boundary energy is an excess energy related to boundary strength/stability, the results suggest that softening is driven by the activation of grain boundary mediated processes facilitated by the relatively weakened boundaries at the ultra-fine nanoscale which ultimately induce the formation of an energy dissipating subsurface crack network during indentation.     

Transition metals increase hydrothermal stability of yttria-tetragonal zirconia polycrystals (3Y-TZP)

In this paper, the influence of transition metals on phase stability of zirconia in 3?mol% Y₂O₃ doped tetragonal zirconia polycrystals (3Y-TZP) in hydrothermal environments was reported. 3Y-TZP with and without stainless-steel or CoCr metal stains on the sample surface were subjected to different isothermal treatments in water vapor, and their respective monoclinic fractions were quantified by confocal Raman spectroscopy. The outputs of these spectroscopic experiments revealed transition metals conspicuously could stabilize the tetragonal zirconia polymorph in the monolithic zirconia, possibly due to the occurrence of off-stoichiometric chemistry in the presence of metal stains.     

Thermal stability and sintering behavior of plasma sprayed nanostructured 7YSZ, 15YSZ and 5.5SYSZ coatings at elevated temperatures

Nanostructured scandia, yttria doped zirconia (5.5SYSZ), 7 wt% yttria stabilized zirconia (7YSZ) and 15YSZ thermal barrier coatings (TBCs) were produced by plasma spraying on nickel-based superalloy substrates with NiCrAlY as the bond coat. The thermal stability and sintering behavior of the three as-sprayed TBCs at 1480 °C were investigated. The results indicated that the thermal stability of SYSZ and TBCs was longer than the 7YSZ TBCs due to higher amount of tetragonal phase. Furthermore, the results demonstrated that the nanostructured 7YSZ coating exhibits higher sintering resistance than 5.5SYSZ TBC.     

Ceria‐doped scandia‐stabilized zirconia (10Sc2O3·1CeO2·89ZrO2) as electrolyte for SOFCs: Sintering and ionic conductivity of thin,flat sheets

In this study, thin, flat sheets, about 90 μm thick, were prepared from ceria‐doped scandia‐stabilized zirconia with molecular formula 10Sc₂O₃·1CeO₂·89 ZrO₂ (10Sc1CeSZ) by tape casting and subsequent sintering at different thermal cycles. A sintering thermal cycle was selected that yielded defect‐free flat sheets, with practically negligible porosity (between 0.35% and 0.10%) and average grain diameters ranging from 1.32 to 6.30 μm. Ionic conductivity at 600°C was as high as 21 mS/cm. Ionic conductivity increased with average grain diameters up to 2.7 μm. At higher average grain diameters, conductivity remained practically constant.     

Effects of sintering on the mechanical and ionic properties of ceria-doped scandia stabilized zirconia ceramic

The effect of conventional sintering from 1300 to 1550 °C on the properties of 1 mol% ceria-doped scandia stabilized zirconia was investigated. In addition, the influence of rapid sintering via microwave technique at low temperature regimes of 1300 °C and 1350 °C for 15 min on the properties of this zirconia was evaluated. It was found that both sintering methods yielded highly dense samples with minimum relative density of 97.5%. Phase analysis by X-ray diffraction revealed the presences of only cubic phase in all sintered samples. All sintered pellets possessed high Vickers hardness (13–14.6 GPa) and fracture toughness (~3 MPam^1/2). Microstructural examination by using the scanning electron microscope revealed that the grain size varied from 2.9 to 9.8 µm for the conventional-sintered samples. In comparison, the grain size of the microwave-sintered zirconia was maintained below 2 µm. Electrochemical Impedance Spectroscopy study showed that both the bulk and grain boundary resistivity of the zirconia decreases with increasing test temperature regardless of sintering methods. However, the grain boundary resistivity of the microwave-sintered samples was higher than the conventional-sintered ceramic at 600 °C and reduced significantly at 800 °C thus resulting in the enhancement of electrical conduction.     

96Zr diffusion in polycrystalline scandia stabilized zirconia

Diffusion of the stable tracer isotope ⁹⁶Zr in 12 mol% polycrystalline scandia stabilized zirconia was studied in air in the temperature range from 1200 to 1600 °C. Secondary ion mass spectroscopy (SIMS) was used to record the tracer diffusion profiles. The activation enthalpies for bulk and grain boundary diffusion were determined to be (5.0 ± 0.4) eV and (3.9 ± 0.5) eV, respectively, with the latter being six to seven orders in magnitude faster than the first. Using XRD, it was proved that the diffusion occurs only in the cubic phase.     

Crystal structure and morphology of CeO2 doped stabilized zirconia ceramics under high-frequency microwave field sintering

Under high-frequency microwave irradiation, zirconia ceramics were prepared by sintering nano-CeO₂ (Ce = 7 mol%) doped zirconia powder. The different effects of temperature environment on the phase structure transformation, surface functional groups, microstructure, growth process, and density of doped zirconia were analyzed, and the optimized microwave sintering process for zirconia was determined. The experimental results reveal that the tetragonal phase of zirconia is positively correlated with the temperature when the temperature reaches about 1100 °C in the studied range. The reason is that the grain grows with the increase of sintering temperature, and the surface energy of grain decreases, which leads to the fluctuation of tetragonal phase content. The density of zirconia reaches 98.03% at 1300 °C, and the growth activation energy is 27.40 kJ/mol. There is no abnormal growth of zirconia particles, and the phase transition temperature decreases, which is attributed to the efficient heating of microwave and the incorporation of nano-ceria stabilizer.     

Synthesis of Al2O3/SiO2 nano‐nano composite ceramics under high pressure and its inverse Hall–Petch behavior

We report the synthesis of alumina/stishovite nano‐nano composite ceramics through a pressure‐induced dissociation in Al₂SiO₅ at a pressure of 15.6 GPa and temperatures of 1300°C‐1900°C. Stishovite is a high‐pressure polymorph of silica and the hardest known oxide at ambient conditions. The grain size of the composites increases with synthesis temperature from ~15 to ~750 nm. The composite is harder than alumina and the hardness increases with reducing grain size down to ~80 nm following a Hall–Petch relation. The maximum hardness with grain size of 81 nm is 23 ± 1 GPa. A softening with reducing grain size was observed below this grain size down to ~15 nm, which is known as inverse Hall–Petch behavior. The grain size dependence of the hardness might be explained by a composite model with a softer grain‐boundary phase.     

Thermal Stability of Silica-Zirconia Membranes

The thermal stability, phase transformation, surface morphology, pore size distribution and permeation of the defect-free silica-zirconia membrane were investigated by using X-ray diffraction （XRD）, atomic force microscopy （AFM）, gas adsorption analyzer （BET）, and gas permeation apparatus, respectively. Using silica as the stabilizing agent, the defect-free membrane was much more stable than pure zirconia. The crystal transformation of zirconia in the silica-stabilized membrane could be prohibited by the interaction between silica and zireonia. ZrO2 crystals were kept tetragonal below 900℃, the size of which did not change with temperature between 700℃ and 900℃. It was further verified by the AFM observation, pore size analysis and permeation study. This thermal stability makes the silica-zirconia membrane a good choice as the intermediate layer for zeolite and Pd-based membranes.