Lowering Crystallization Temperatures by Seeding in Structurally Diphasic Al2O3-MgO Xerogels

Thermal reactions in 93% Al₂O₃-7% MgO and 95.8% Al₂O₃-4.2% MgO gels seeded with α-Al₂O₃, MgAl₂O₄, α-Fe₂O₃, and SiO₂, sols were investigated by differential thermal analysis to determine the extent of nucleation catalysis of solid-state reactions. Seeding with α-Al₂O₃ lowered the α-Al₂O₃ crystallization temperature in these xerogels by 100° to 150°C. Spinel seeds have much less effect on the γ-α transition, and α-Fe₂O₃ and SiO₂ seeds do not affect it significantly. Isostructural seeding of gels may therefore permit lower ceramic processing temperatures.     

Conversion from β-Ce2O3·11Al2O3 to α-Al2O3 in Tetragonal ZrO2 Matrix

Composites of β-Ce₂O₃·11Al₂O₃ and tetragonal ZrO₂ were fabricated by a reductive atmosphere sintering of mixed powders of CeO₂, ZrO₂ (2 mol% Y₂O₃), and Al₂O₃. The composites had microstructures composed of elongated grains of β-Ce₂O₃·11Al₂O₃ in a Y-TZP matrix. The β-Ce₂O₃·11Al₂O₃ decomposed to α-Al₂O₃ and CeO₂ by annealing at 1500°C for 1 h in oxygen. The elongated single grain of β-Ce₂O₃·11Al₂O₃ divided into several grains of α-Al₂O₃ and ZrO₂ doped with Y₂O₃ and CeO₂. High-temperature bending strength of the oxygen-annealed α-Al₂O₃ composite was comparable to the β-Ce₂O₃·11Al₂O₃ composite before annealing.     

Microwave Plasma Synthesis of Nanostructured γ-Al2O3 Powders

Nanostructured Al₂O₃ powders have been synthesized by combustion of aluminum powder in a microwave oxygen plasma, and characterized by X-ray diffraction and electron microscopy. The main phase is γ-Al₂O₃, with a small amount of δ-Al₂O₃. The particles are truncated octahedral in shape, with mean particle sizes of 21–24 nm. The effect of reaction chamber pressure on the phase composition and the particle size was studied. The γ-alumina content increases and the mean particle size decreases with decreasing pressure. No α-Al₂O₃ appears in the final particles. Electron microscopy studies find that a particle may contain more than one phase.     

Growth of α-Al2O3 Crystals by Na2O Evaporation

A technique for growing α-Al₂O₃ crystals is described in which Na₂O·11Al₂O₃ is dissolved in a liquid of composition Na₂O·4TiO₂·3Al₂O₃. Alpha Al₂O₃ is precipitated as Na₂O evaporates from the system; Na₂O·11Al₂O₃ serves as a source of Al₂O₃, and Na₂O in the liquid. The content of solids in the mixture is always such that it does not melt completely. The size of the α-Al₂O₃ crystals grown is related to the Na₂O content of the composition. Crystals as large as 4000 by 3000 μm in the α-axis direction and 500 μm in the c -axis direction have been grown.     

Growth of α-AI2O3 Platelets in the HF-γy-AI2O3 System

In the presence of a fluorine mineralizer, highly aggregated, <5 μm α-Al₂O₃ platelet particles form by vapor transport during the thermal transformation of γ-alumina. Platelet aggregation was determined to occur by platelet inter-growth and by edge nucleation on primary α-Al₂0₃ platelets. The addition of 10¹⁰α-alumina seed particles/cm³γ–Al₂O₃ resulted in the development of discrete particles during the initial stage of transformation. Impingement of the growing platelets during the latter stage of transformation, however, resulted in intergrowth, a process which was not changed by seeding. Particle size distribution broadening was observed to increase with increasing HF and H₂O concentrations because vapor reactant supersaturation increases the degree of edge nucleation. When initially low HF and H₂O concentrations were used in seeded systems, however, essentially aggregate-free α-Al₂O₃ platelets of 10–15 μm were obtained.     

Preparation of a Highly Conductive Al2O3/TiN Interlayer Nanocomposite through Selective Matrix Grain Growth

An electroconductive TiN/Al₂O₃ nanocomposite was prepared by a selective matrix grain growth method, using a powder mixture of submicrosized α-Al₂O₃, nanosized γ-Al₂O₃, and TiN nanoparticles synthesized through an in situ nitridation process. During sintering, a self-concentration of TiN nanoparticles at the matrix grain boundary occurred, as a result of the selective growth of large α-Al₂O₃ matrix grains. Under suitable sintering conditions, a typical interlayer nanostructure with a continuous nanosized TiN interlayer was formed along the Al₂O₃ matrix grain boundary, and the electroconducting behavior of the material was significantly improved. Twelve volume percent TiN/Al₂O₃ nanocomposite with such an interlayer nanostructure showed an unprecedentedly low resistivity of 8 × 10⁻³Ω·cm, which was more than two orders lower than the TiN/Al₂O₃ nanocomposite without such an interlayer nanostructure.     

Densification and Grain Growth of Al2O3 Nanoceramics During Pressureless Sintering

α - Al₂O₃ nanopowders with mean particle sizes of 10, 15, 48, and 80 nm synthesized by the doped α-Al₂O₃ seed polyacrylamide gel method were used to sinter bulk Al₂O₃ nanoceramics. The relative density of the Al₂O₃ nanoceramics increases with increasing compaction pressure on the green compacts and decreasing mean particle size of the starting α-Al₂O₃ nanopowders. The densification and fast grain growth of the Al₂O₃ nanoceramics occur in different temperature ranges. The Al₂O₃ nanoceramics with an average grain size of 70 nm and a relative density of 95% were obtained by a two-step sintering method. The densification and the suppression of the grain growth are achieved by exploiting the difference in kinetics between grain-boundary diffusion and grain-boundary migration. The densification was realized by the slower grain-boundary diffusion without promoting grain growth in second-step sintering.     

Influence of Cr and Fe on Formation of α-Al2O3 from γ-Al2O3

The effect of Cr and Fe in solid solution in γ-Al₂O₃ on its rate of conversion to α-Al₂O₃ at 1100°C was studied by X-ray diffraction. The δ form of Al₂O₃ was the principal intermediate phase produced from both pure γ-Al₂O₃ and that containing Fe³⁺ in solid solution, although addition of Fe greatly reduced crystallinity. Reflectance spectra and magnetic susceptibilities showed that Cr exists as Cr⁶⁺ in γ-Al₂O₃ and as Cr³⁺ in α-Al₂O₃, with θ-Al₂O₃ as the intermediate phase. The intermediates formed rapidly, and the rates of their conversion to α-Al₂O₃ were increased by 2 and 5 wt% additions of Fe and decreased by 2 and 4 wt% additions of Cr. An approximately linear relation observed between α-Al₂O₃ formation and decrease in specific surface area was only slightly affected by the added ions. This relation can be explained by a mechanism in which the sintering of δ- or θ-Al₂O₃, within the aggregates of their crystallites, is closely coupled with conversion of cubic to hexagonal close packing of O^2- ions by synchro-shear.     

Fabrication of Nano-Scaled α-Al2O3 Crystallites Through Heterogeneous Precipitation of Boehmite in a Well-Dispersed θ-Al2O3-Suspension

The possibility of eliminating finger or vermicular growth of α-Al₂O₃ particles obtained by calcination of boehmite was examined. Heterogeneous precipitation of boehmite in a well-dispersed θ-Al₂O₃ suspension was first prepared, in which the mass ratio of boehmite to θ-crystallite was evaluated to form agglomerates of similar sizes that will form α-Al₂O₃ crystallites of <100 nm in diameter. θ- to α-phase transformation of alumina experiences a nucleation and growth mechanism, with the critical size of nucleation being ∼25 nm for θ-Al₂O₃ and the size for accomplishment of transformation followed by finger growth being ∼100 nm. Hence, fabricating agglomerates that would form α-Al₂O₃ crystallites with sizes <100 nm accompanied with appropriate thermal treatments can be a method for obtaining α-Al₂O₃ crystallites free of finger growth. It is found that proper preparation of the agglomerate with appropriate size may initiate a simultaneous and lower temperature θ- to α-Al₂O₃ phase transformation for such powder systems, substantially limiting the mass transfer among the newly formed α-Al₂O₃ particles. Moreover, α-Al₂O₃ crystallites free of finger growth can be obtained.     

Growth of Tabular α-Al2O3 Grains on Porous Alumina Substrate

Gradient, porous alumina ceramics were prepared with the characteristics of microsized tabular α-Al₂O₃ grains grown on a surface with a fine interlocking feature. The samples were formed by spin-coating diphasic aluminosilicate sol on porous alumina substrates. The sol consisted of nano-sized pseudo-boehmite (AlOOH) and hydrolyzed tetraethyl orthosilicate [Si(OC₂H₅)₄]. After drying and sintering at 1150°–1450°C, the crystallographic and chemical properties of the porous structures were investigated by analytical electron microscopy. The results show that the formation of tabular α-Al₂O₃ grains is controlled by the dissolution of fine Al₂O₃ in the diphasic material at the interface. The nucleation and growth of tabular α-Al₂O₃ grains proceeds heterogeneously at the Al₂O₃/glass interface by ripening nano-sized Al₂O₃ particles.     

Effect of Monovalent Cation Additives on the γ-Al2O3-to-α-Al2O3 Phase Transition

The effect of monovalent cation addition on the γ-Al₂O₃-to-α-Al₂O₃ phase transition was investigated by differential thermal analysis, powder X-ray diffractometry, and specific-surface-area measurements. The cations Li⁺, Na⁺, Ag⁺, K⁺, Rb⁺, and Cs⁺ were added by an impregnation method, using the appropriate nitrate solution. β-Al₂O₃ was the crystalline aluminate phase that formed by reaction between these additives and Al₂O₃ in the vicinity of the γ-to-α-Al₂O₃ transition temperature, with the exception of Li⁺. The transition temperature increased as the ionic radii of the additive increased. The change in specific surface area of these samples after heat treatment showed a trend similar to that of the phase-transition temperature. Thus, Cs⁺ was concluded to be the most effective of the present monovalent additives for enhancing the thermal stability of γ-Al₂O₃. Because the order of the phase-transition temperature coincided with that of the formation temperature of β-Al₂O₃ in these samples, suppression of ionic diffusion in γ-Al₂O₃ by the amorphous phase containing the added cations must have played an important role in retarding the transition to α-Al₂O₃. Larger cations suppressed the diffusion reaction more effectively.     

Effect of Physical Nature of Powders and Firing Atmosphere on ZnAI2O4 Formation

The rate of ZnA1₂O₄ formation for binary powder mixtures of ZnO and α-Al₂O₃ (dense coarse particles and weak agglomerates of fine powder) fired in air or O₂ atmospheres was measured and the microstructures of those systems were observed by scanning electron microscopy. With dispersed dense particles of α-Al₂O₃, the Al₂O₃ surfaces were covered with ZnO and the spinel grew into the particles maintaining essentially a constant reaction interface area. Calculations based on geometric measurements and use of Jander's equation gave a similar high activation energy, 354 kJ/mol, which corresponds to the activation energy of volume diffusion of Zn²⁺ in ZnAl₂O₄. An oxygen atmosphere had no effect. With a matrix of fine α-Al₂O₃ powder and dispersed granules of ZnO, a higher reaction rate occurred because of an increase in reaction interface area due to penetration of the powder compact matrix by ZnO vapor, which was enhanced by an O₂ atmosphere. The reaction layer grew into the alumina matrix adjoining the ZnO granules with a parabolic rate law. Apparent activation energies below ∼200 kJ/mol were calculated.     

Effects of Amorphous and Crystalline SiO2 Additives on γ-Al2O3-to-alpha-Al2O3 Phase Transitions

This paper focused on the effects of various phases of SiO₂ additives on the γ-Al₂O₃-to-α-Al₂O₃ phase transition. In the differential thermal analysis, the exothermic peak temperature that corresponded to the theta-to-α phase transition was elevated by adding amorphous SiO₂, such as fumed silica and silica gel obtained from the hydrolysis of tetraethyl orthosilicate. In contrast, the peak temperature was reduced by adding crystalline SiO₂, such as quartz and cristobalite. Amorphous SiO₂ was considered to retard the γ-to-α phase transition by preventing γ-Al₂O₃ particles from coming into contact and suppressing heterogeneous nucleation on the γ-Al₂O₃ surface. On the other hand, crystalline SiO₂ accelerated the α-Al₂O₃ transition; thus, this SiO₂ may be considered to act as heterogeneous nucleation sites. The structural difference among the various SiO₂ additives, especially amorphous and crystalline phases, largely influenced the temperature of γ-Al₂O₃-to-α-Al₂O₃ phase transition.     

Formation and Transformation of Cubic ZrO2 Solid Solutions in the System ZrO2—Al2O3

In the system ZrO₂-Al₂O₃, cubic ZrO₂ solid solutions containing up to 40 mol% Al₂O₃ crystallize at low temperatures from amorphous materials prepared by the simultaneous hydrolysis of zirconium and aluminum alkoxides. The values of the lattice parameter, a, increase linearly from 0.5095 to 0.5129 nm with increasing Al₂O₃ content. At higher temperatures, the solid solutions transform into tetragonal ZrO₂ and α-Al₂O₃. Pure ZrO₂ crystallizes in the tetragonal form at 415° to 440°C.     

Preparation and Properties of Porous α-Al2O3 Membrane Supports

Strong and permeable macro-porous α-Al₂O₃ membrane supports are made by colloidal filtration of 20 vol% dispersions of α-Al₂O₃ with an average particle size of 600 nm. Intact compacts with very good surface quality were obtained at an optimum pH of 9.5 and dosage of 0.2 wt% ammonium aurintricarboxylate (Aluminon), based on dry alumina. The colloidal stability of the aluminon-stabilized slurries is confirmed by ξ potential measurements. Slight sintering of dense-packed α-Al₂O₃ compacts was found to result in >67% packing density and a bimodal pore-size distribution as derived from shrinkage behavior and gas adsorption studies. Non-stationary single gas permeation measurements showed improved gas permeability, compared with α-Al₂O₃ compacts prepared using powder with a smaller particle size (300 nm). The strength of the disk-shaped alumina compacts within the porosity range of 30%–20% increased from 100 to 300 MPa with a standard deviation of 20 and 50 MPa, respectively.     

Reinvestigation of Al–Si Spinel Phase in Diphasic Al2O3–SiO2 Gel

Mechanical mixture of γ-Al₂O₃ and amorphous SiO₂, and diphasic Al₂O₃/SiO₂ gels of three different compositions were synthesized. They were subjected to heat treatment to various temperatures in the range 900°–1600°C. Qualitative X-ray diffraction data show that these diphasic gels do not crystallize to a combined mixture of θ-Al₂O₃ and α-Al₂O₃ polymorphs at the intermediate stage, prior to mullite formation. Estimated mullite formation data show that the course of its formation from mixed oxides was different from that of diphasic gels. Results are compared with previous findings and the concept of Al–Si spinel formation in the phase transformation of stoichiometric diphasic gel system is substantiated.     

Characterization of Interfacial Reactions Between β-Al2O3 and Y2O3-Partially-Stabilized ZrO2

The interfacial reaction between Y₂O₃-partially-stabilized ZrO₂ and α-Al₂O₃ was studied. It was noted that α-Al₂O₃ forms inside the periphery of the β-Al₂O₃ grains; its formation suggests the loss of Na₂O from the p-Al₂O₃, either by evaporation or by dissolution in the ZrO₂ matrix. The presence of Na₂ZrO₃ is suspected.     

Formation and Transformation of TiO2 (Anatase) Solid Solution in the System TiO2—Al2O3

In the system TiO₂—Al₂O₃, TiO₂ (anatase, tetragonal) solid solutions crystallize at low temperatures (with up to ∼ 22 mol% Al₂O₃) from amorphous materials prepared by the simultaneous hydrolysis of titanium and aluminum alkoxides. The lattice parameter a is relatively constant regardless of composition, whereas parameter c decreases linearly with increasing Al₂O₃. At higher temperatures, anatase solid solutions transform into TiO₂ (rutile) with the formation of α-Al₂O₃. Powder characterization is studied. Pure anatase crystallizes at 220° to 360°C, and the anatase-to-rutile phase transformation occurs at 770° to 850°C.     

Analytical Electron Microscope Analysis of the Formation of BaO · 6Al2O3

The formation process of barium hexaaluminate (BaO 6Al₂O₃) from BaCO₃/γ-Al₂O₃ powders or hydrolyzed alkoxides was studied by analytical electron microscopy. Barium hexaaluminate is produced by a two-step solid-state reaction from BaCO₃ and Al₂O₃ via formation of BaO·Al₂O₃. Marked grain growth and inclusion of nonequilibrium phase were inevitable in this powder mixture process. However, in an alkoxide-derived precursor, homogeneous mixing of components is attained and hence the formation of BaO·6Al₂O₃ proceeds readily. Powders obtained by this latter route consisted of fine planar particles with a uniform size and retained a large surface area (20.2 m²/g) even after heating at 1300°C. Electron diffraction results implied that suppression of crystal growth along the c axis is the reason for the large surface area of BaO·6Al₂O₃.     

Growth of Single-Crystal and Polycrystalline Thin Films of MgAl2O4 and MgFe2O4

Single-crystal and polycrystalline films of Mg-Al₂O₄ and MgFe₂O₄ were formed by two methods on cleavage surfaces of MgO single crystals. In one procedure, aluminum was deposited on MgO by vacuum evaporation. Subsequent heating in air at about 510°C formed a polycrystalline γ-Al₂O₈ film. Above 540°C, the γ-Al₂O, and MgO reacted to form a single-crystal MgAl₂O₄ film with {001} MgAl₂O₄‖{001} MgO. Above 590°C, an additional layer of MgAl₂O₄, which is polycrystalline, formed between the γ-Al₂O₃ and the single-crystal spinel. Polycrystalline Mg-Al₂O₄ formed only when diffusion of Mg²⁺ ions proceeded into the polycrystalline γ-Al₂O₃ region. Corresponding results were obtained for Mg-Fe₂O₄. MgAl₂O₄ films were also formed on cleaved MgO single-crystal substrates by direct evaporation, using an Al₂O₃ crucible as a source. Very slow deposition rates were used with source temperatures of ∼1350°C and substrate temperatures of ∼800°C. Departures from single-crystal character in the films may arise through temperature gradients in the substrate.