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.     

Sol–Gel Synthesis of λ–Na2O·xAl2O3 Films

Na₂O· x Al₂O₃ ( x = 9, 11)films have been obtained by sol–gel method. Crystallization processes during heat treatments have been investigated by X–ray diffraction analysis. A metastable phase with the mullite structure, λ–Na₂O· x Al₂O₃, has been observed starting from 800°C. Films remained stable after a heat treatment at 1000°C for 250 h. Impedance spectroscopy measurements showed that the films of λ-Na₂O· x Al₂O₃ possess a large three–dimensional ionic conductivity at 400°C.     

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.     

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.     

Preparation of Nanometer-Sized α-Alumina Powders by Calcining an Emulsion of Boehmite and Oleic Acid

This study proposes a method to form ultrafine α-Al₂O₃ powders. Oleic acid is mixed with Al(OH)₃ gel. The gel is the precursor of the Al₂O₃. After it is mixed and aged, the mixture is calcined in a depleted oxygen atmosphere between 25° and 1100°C. Oleic acid evaporates and decomposes into carbon during the thermal process. Residual carbon prevents the growth of agglomerates during the formation of α-Al₂O₃. The phase transformation in this process is as follows: emulsion →γ-Al₂O₃→δ-Al₂O₃→θ-Al₂O₃→α-Al₂O₃. This process has no clear θ phase. Aging the mixed sample lowers the formation temperature of α-Al₂O₃ from 1100° to 1000°C. The average crystallite diameter is 60 nm, measured using Scherrer's equation, which is consistent with TEM observations.     

Alumina Dissolution into Silicate Slag

Dissolution of commercial white fused and tabular Al₂O₃ grains into a model silicate slag was investigated after 1 h at 1450° and 1600°C. Formation of CA₆ and hercynitic spinel layers was observed at all Al₂O₃/slag interfaces. The spinel layer was not always continuous, and so, compared with the CA₆ layer, it had a less-significant effect on the dissolution process. The CA₆ layer that formed adjacent to the tabular Al₂O₃ was incomplete at both temperatures, so that its dissolution was not a totally indirect process. These incomplete CA₆ and spinel layers meant that slag penetrated into the tabular Al₂O₃ grains, which, thus, were corroded and disintegrated by the penetrating slag. There was evidence of liquid in the CA₆ layer adjacent to the fused Al₂O₃ after 1 h at 1450°C, which also enabled direct dissolution. After 1 h at 1600°C, fused Al₂O₃ revealed a thick (∼60 μm), continuous and unpene-trated CA₆ layer, indicating fully indirect dissolution at this temperature.     

Sol–Gel Processed Y-PSZ Ceramics with 5 wt% Al2O3

Y-PSZ ceramics with 5 wt% Al₂O₃ were synthesized by a sol–gel route. Experimental results show that powders of metastable tetragonal zirconia with 2.7 mol% Y₂O₃ and 5 wt% Al₂O₃ can be fabricated by decomposing the dry gel powder at 500°C. Materials sintered in an air atmosphere at 1500°C for 3 have high density (5.685 g/cm³), high content of metastable tetragonal zirconia (>96%), and high fracture toughness (8.67 MPa.m^1/2). Compared with the Y-PSZ ceramics, significant toughening was achieved by adding 5 wt% Al₂O₃.     

Formation and Sintering of Yttria-Doped Tetragonal Zirconia with 50 mol% Alumina Prepared by the Hydrazine Method

Al₂O₃/Y₂O₃-doped ZrO₂ composite powders with 50 mol% Al₂O₃ are prepared by the hydrazine method. As-prepared powders are mixtures of AlO(OH) gel and amorphous ZrO₂ solid solutions containing Y₂O₃ and Al₂O₃. The formation process leading to α-Al₂O₃- t -ZrO₂ composite powders is examined. Hot isostatic pressing is performed for 2 h at 1400°C under 196 MPa using θ-Al₂O₃- t -ZrO₂ composite powders. The resulting dense, sintered α-Al₂O₃- t -ZrO₂ composites show excellent mechanical strength.     

Alumina Sol-Assisted Sintering of SiC—Al2O3 Composites

The composite sol—gel (CSG) technology has been utilized to process SiC—Al₂O₃ ceramic/ceramic particulate reinforced composites with a high content of SiC (up to 50 vol%). Alumina sol, resulting from hydrolysis of aluminum isopropoxide, has been utilized as a dispersant and sintering additive. Microstructures of the composites (investigated using TEM) show the sol-originating phase present at grain boundaries, in particular at triple junctions, irrespective of the type of grain (i.e., SiC or Al₂O₃). It is hypothesized that the alumina film originating from the alumina sol reacts with SiO₂ film on the surface of SiC grains to form mullite or alumina-rich mullite-glass mixed phase. Effectively, SiC particles interconnect through this phase, facilitating formation of a dense body even at very high SiC content. Comparative sinterability studies were performed on similar SiC—Al₂O₃ compositions free of alumina sol. It appears that in these systems the large fraction of directly contacting SiC—SiC grains prevents full densification of the composite. The microhardness of SiC—Al₂O₃ sol—gel composites has been measured as a function of the content of SiC and sintering temperature. The highest microhardness of 22.9 GPa has been obtained for the composition 50 vol% SiC—50 vol% Al₂O₃, sintered at 1850°C.     

Novel Synthesis of Mullite Powder with High Surface Area

Boehmite (AlO(OH)) solid-solution gel, which yields stoichiometric mullite (3Al₂O₃2SiO₂) at high temperatures, has been prepared by the hydrazine method. The formation process leading to 3Al₂O₃2SiO₂ is discussed. The as-prepared powder and powders heated below 1200°C consist of very fine particles showing needlelike morphology, whereas the particles of mullite powder show thin prismatic morphology. The mullite powder after heating at 1300°C has a high surface area (87 m²/g).     

Chemical Vapor Deposition of Polycrystalline Al2O3

Polycrystalline Al₂O₃ was chemically vapor-deposited onto sintered Al₂O₃ substrates by reaction of AlCl₃ with (1) H₂O, (2) CO:H₂, and (3) O₂ at 1000° and 1500°C and 0.5 and 5.0 torr. Although the thermodynamics of all these reactions predict the formation of solid Al₂O₃, the deposition rate of the first reaction was considerably greater than that of the second. The third reaction was so slow that no measurable deposit was formed in 6 h at 1500°C. Formation of dense deposits of α-Al₂O₃ was favored by increasing temperature and decreasing pressure. Microstructural examination of the dense deposits showed long columnar grains, the largest of which extended through the deposit from the substrate to the surface.     

Low-Temperature Synthesis of Calcium Hexa-Aluminate

Calcium hexa-aluminate (CaO·6Al₂O₃) has been prepared from calcium nitrate and aluminum sulfate solutions in the temperature range of 1000°–1400°C. A 0.3 mol/L solution of aluminum sulfate was prepared, and calcium nitrate was dissolved in it in a ratio that produced 6 mol of Al₂(SO₄)₃·16H₂O for each mole of Ca(NO₃)₂·4H₂O. It was dried over a hot magnetic stirrer at ∼70°C and fired at 1000°–1400°C for 30–360 min. The phases formed were determined by XRD. It was observed that CaO·Al₂O₃ and CaO·2Al₂O₃ were also formed as reaction intermediates in the reaction mix of CaO·6Al₂O₃. The kinetics of the formation of CaO·6Al₂O₃ have been studied using the phase-boundary-controlled equation 1 − (1 − x )^1/3= K log t and the Arrhenius plot. The activation energy for the low-temperature synthesis of CaO·6Al₂O₃ was 40 kJ/mol.     

Preparation and Characterization of Aluminum Borate

Aluminum borate, 9Al₂O₃·2B₂O₃ or Al₁₈B₄O₃₃, was synthesized by the reaction of stoichiometric amounts of α-Al₂O₃ and B₂O₃. The Al₁₈B₄O₃₃ material was formed into a dense ceramic by pressureless sintering with CaO, MgO, or CaAl₂B₂O₇ additives. The material was characterized by low bulk density, moderate coefficient of thermal expansion (3 × 10⁻⁶/°C to 5 × 10⁻⁶/°C), moderate strength (210 to 324 MPa), and low dielectric constant.     

Effect of Alumina Content on the Oxidation of Hot-Pressed Silicon Carbide

The oxidation behavior at 1370°C of dense SiC, hot-pressed with the aid of Al₂O₃, has been investigated as a function of Al₂O₃ content. Increasing amounts of the Al₂O₃ hot-pressing aid increased the oxidation rate. Observations of the oxide surface show that a glassy phase (indicating formation of a liquid at the oxidation temperature) containing Si, Al, Fe, and K forms over the residual Al₂O₃ in the hot-pressed material. It is suggested that the oxygen transport through an impure aluminosilicate liquid is faster than that through a pure SiO₂ scale, thus causing an increased oxidation rate.     

The Al2O3-Nd2O3 Phase Diagram

A tentative phase diagram for the system Al₂0₃-Nd₂O₃ is presented. Three compounds were obtained: a β -A1₂O₃-type compound, the perovskite NdAlO₃, and Nd₄Al₂O₉. The perovskite melts congruently (mp 2090°C), and the two other compounds exhibit incongruent melting behavior: β -Nd/Al₂O₃, mp 1900°C; Nd₄Al₂O₉, mp 1905°C. Two eutectics exist with the following compositions and melting points: 80 mol% Al₂O₃, 1750°C; 23 mol% Al₂O₃,1800°C. Nd₄Al₂O9 decomposes in the solid state at 1780°C.     

Synthesis, Densification, and Phase Evolution Studies of Al2O3–Al2TiO5–TiO2 Nanocomposites and Measurement of Their Electrical Properties

Alumina–aluminum titanate–titania (Al₂O₃–Al₂TiO₅–TiO₂) nanocomposites were synthesized using alkoxide precursor solutions. Thermal analysis provided information on phase evolution from the as-synthesized gel with an increase in temperature. Calcination at 700°C led to the formation of an Al₂O₃–TiO₂ nanocomposite, while at a higher temperature (1300°C) an Al₂O₃–Al₂TiO₅–TiO₂ nanocomposite was formed. The nanocomposites were uniaxially compacted and sintered in a pressureless environment in air to study the densification behavior, grain growth, and phase evolution. The effects of nanosize particles on the crystal structure and densification of the nanocomposite have been discussed. The sintered nanocomposite structures were also characterized for dielectric properties.     

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.     

Hot Extrusion of Ceramics

Two dense ceramics, Bi₂Sr₂CaCu₂O_{8+ X} and 2Y-TZP: 10 wt% Al₂O₃, were hot-extruded through conical dies under a wide range of conditions. Extrusion of Bi₂Sr₂CaCu₂O_{8+ X} was performed at 775° to 825°C and speeds of 0.0005 to 0.2 mm/s, with the die semi-angles from 30° to 60° and extrusion ratios from 4 to 9. Extrusion of 2Y-TZP:10 wt% Al₂O₃ was performed at 1650°C and 0.017 mm/s. During hot extrusion of Bi₂Sr₂CaCu₂O_{8+ X} , a strong texture was developed with the basal plane aligned along the extrusion direction, whereas the zirconia/alumina composite underwent grain growth which resulted in strain hardening. A simple analytical extrusion model for strain-rate-sensitive materials has been developed using a combined slab method and upper-bound method and a power-law material flow equation. The model predictions are in good agreement with the experimental results and they further serve to delineate the limitation of the extrusion technique for ceramic applications.     

Tensile Ductility in Zirconia-Dispersed Alumina at High Temperatures

High-temperature plastic flow in Al₂O₃-10 wt% ZrO₂ (2.5 mol% Y₂O₃) has been examined at temperatures between 1400° and 1500°C. Al₂O₃-10 wt% ZrO₂ (2.5 mol% Y₂O₃) exhibits much higher flow stress and smaller tensile elongation below about 1450°C than 0.1 wt% MgO-doped single-phase Al₂O₃. The suppression of grain growth with ZrO₂ dispersion into Al₂O₃ is not effective for improving the tensile ductility. The limited ductility in Al₂O₃-10 wt% ZrO₂ (2.5 mol% Y₂O₃) is associated with the increment of flow stress caused by ZrO₂. The ZrO₂ dispersion or segregation in Al₂O₃/Al₂O₃ boundaries suppresses the grain boundary sliding and hence results in the increased flow stress at high temperatures.     

Fabrication of Mullite Ceramics With Ultrahigh Porosity by Gel Freeze Drying

Porous mullite (3Al₂O₃·2SiO₂) ceramics with an open porosity up to 92.9% were fabricated by a gel freeze-drying process. An alumina (Al₂O₃) gel mixed with ultrafine silica (SiO₂) was frozen and sublimation of ice crystals was carried out by drying the frozen body under a low pressure. Porous mullite ceramics were prepared in air at 1400°–1600°C due to the mullitization between Al₂O₃ and SiO₂. A complex and porous microstructure was formed, where large dentritic pores with a pore size of ∼100 μm contained small cellular pores of 1–10 μm on their internal walls. Owing to the complete mullitization, a relatively high-compressive strength of 1.52 MPa was obtained at an open porosity of 88.6%.