Production and characterization of ZrO<Subscript>2</Subscript> ceramics and composites to be used for hip prosthesis

Tetragonal ZrO₂ polycrystalline (TZP) ceramics with varying yttria and ceria content (2–3 mol%) and distribution (coated or co-precipitated), and varying second phase content Al₂O₃ were prepared and investigated by means of microstructural analysis, mechanical properties, and hydrothermal stability, and ZrO₂-based composites with 35–60 vol% of electrical conductive TiN particles were developed. The effects of stabilizer content and means of addition, powder preparation, sintering conditions, and grain size have been systematically investigated. Fully dense Y-TZP ceramics, stabilized with 2–3 mol% Y₂O₃, 2 wt% Al₂O₃ can be achieved by hot pressing at 1,450 °C for 1 h. The hydrothermal stability increased with increasing overall yttria content. The jet-milled TiN powder was used to investigate the ZrO₂–TiN composites as function of the TiN content. The experimental work revealed that fully dense ZrO₂–TiN composites, stabilized with 1.75 mol% Y₂O₃, 0.75 wt% Al₂O₃, and a jet-milled TiN content ranging from 35 to 60 vol% could be achieved by hot pressing at 1,550 °C for 1 h. Transformation toughening was found as the primary toughening mechanism. The decreasing hardness and strength could be attributed to an increasing TiN grain size with increasing TiN content, whereas the decreasing toughness might be due to the decreasing contribution of transformation toughening from the tetragonal to monoclinic ZrO₂ phase transformation. The E modulus increases linearly with increasing TiN content, whereas the hydrothermal stability increases with addition of TiN content.     

Characterization of sol-gel derived TiO2/ZrO2 films and powders by Raman spectroscopy

The effect of zirconium dioxide addition on crystal structure of sol-gel TiO₂ mesoporous films and powders has been investigated by means of Raman spectroscopy, X-Ray diffraction, and Atomic force microscopy. Zirconium incorporation (up to 30 mol%) into TiO₂ lattice resulted in the formation of Ti_1 − xZr_xO₂ solid solution with anatase structure for the binary powders has been proved. Appearance of tetragonal ZrO₂ phase was observed for the samples with high zirconium content.     

Structure and property changes of ZrO2/Al2O3/ZrO2 laminate induced by low-temperature NH3 annealing applicable to metal-insulator-metal capacitor

Phase transformation and morphology evolution of ZrO₂/Al₂O₃/ZrO₂ laminate induced by the post-deposition NH₃ annealing at 480 °C were studied and the effect on the electrical property of the TiN/ZrO₂/Al₂O₃/ZrO₂/TiN capacitor module was evaluated in dynamic random access memory cell. Experimental results indicated N could indeed be incorporated into the dielectric laminate by the low-temperature NH₃ annealing, resulting in tetragonal-to-cubic phase transformation and small crystallites in the ZrO₂ layers. The C residue and Cl impurity in the ZrO₂/Al₂O₃/ZrO₂ laminate, which derived from the dielectric film formation and capping TiN layer deposition, respectively, could also be reduced by the nitridation process. As a result of the better surface morphology and less impurity content, lower dielectric leakage current and longer reliability lifetime were observed for the nitrided ZrO₂/Al₂O₃/ZrO₂ capacitor. This study demonstrates the low-temperature NH₃ annealing on ZrO₂/Al₂O₃/ZrO₂ dielectric can be applicable to the metal-insulator-metal capacitor structure with nitride-based electrode, which brings advantages over mass production-wise property improvements and extends the practical applicability of the ZrO₂/Al₂O₃/ZrO₂ dielectric.     

Microstructure characterization of fibrous HAp-(20 vol.% t-ZrO2)/Al2O3-(25 vol.% m-ZrO2) composites by multi-pass extrusion process

Core-shell structured HAp-(t-ZrO₂)/Al₂O₃-(m-ZrO₂) composites were fabricated using a multi extrusion process. The shell of Al₂O₃-(m-ZrO₂) phases was selected due to their excellent biocompatibility and mechanical properties and the core was designed with t-ZrO₂ dispersed in the HAp matrix. The t-ZrO₂ and m-ZrO₂ particles (< 400 nm) were homogeneously dispersed in the HAp and Al₂O₃ phases, respectively. In the HAp-(t-ZrO₂) core region, a heavy strain field contrast was observed due to the mismatch of their thermal expansion coefficients. The values of relative density, bending strength and Vickers hardness of the third pass fibrous HAp-(t-ZrO₂)/Al₂O₃-(m-ZrO₂) composites, which were sintered at 1400 °C, were about 93%, 169 MPa, and 792 Hv, respectively.     

UV Raman spectroscopic study on the surface phase of ZrO2 modified with Nd2O3

The Nd₂O₃ modified ZrO₂ was synthesized using two methods of co-precipitation (Nd-ZrO₂) and wet impregnation (Nd/ZrO₂). The surface and bulk crystalline phases of Nd₂O₃ modified ZrO₂ were investigated by using UV Raman spectroscopy, visible Raman spectroscopy, and X-ray diffraction (XRD). It is observed that the tetragonal phase in the surface region of Nd-ZrO₂ was not effectively stabilized by Nd₂O₃, as Nd₂O₃ is mainly present in the bulk of Nd-ZrO₂. However, in Nd/ZrO₂, it is found that with the impregnation of 0.5 mol% Nd₂O₃ on ZrO₂, the surface tetragonal phase of Nd/ZrO₂ can be stabilized even after calcination at 700 °C. The UV Raman results indicate that a disordered structure, or intermediate structure, which is involved in the transition from the tetragonal to the cubic phase, is formed at the surface region of Nd/ZrO₂. The formation of the aforementioned intermediate structure inhibits the phase transition from tetragonal to monoclinic in the surface region of Nd/ZrO₂. Furthermore, it is observed that the mixed tetragonal and monoclinic phases in the surface region of ZrO₂ which has been impregnated with Nd₂O₃ can also be stabilized after calcination at 700 °C. This work provides a simple method for controlling the surface phase of ZrO₂ at high temperatures.     

Thermal behavior of the amorphous precursors of the ZrO2-SnO2 system

Thermal behavior of the amorphous precursors of the ZrO₂-SnO₂ system on the ZrO₂-rich side of the concentration range, prepared by co-precipitation from aqueous solutions of the corresponding salts, was monitored using differential thermal analysis, X-ray powder diffraction, Raman spectroscopy, field emission scanning electron microscopy (FE-SEM) and energy dispersive X-ray spectrometry (EDS). The crystallization temperature of the amorphous precursors increased with an increase in the SnO₂ content, from 405 °C (0 mol% SnO₂) to 500 °C (40 mol% SnO₂). Maximum solubility of Sn⁴⁺ ions in the ZrO₂ lattice (∼25 mol%) occurred in the metastable products obtained upon crystallization of the amorphous precursors. A precise determination of unit-cell parameters, using both Rietveld and Le Bail refinements of the powder diffraction patterns, shows that the incorporation of Sn⁴⁺ ions causes an asymmetric distortion of the monoclinic ZrO₂ lattice. The results of phase analysis indicate that the incorporation of Sn⁴⁺ ions has no influence on the stabilization of cubic ZrO₂ and negligible influence on the stabilization of tetragonal ZrO₂. Partial stabilization of tetragonal ZrO₂ in products having a tin content above its solid-solubility limit was attributed to the influence of ZrO₂-SnO₂ surface interactions. In addition to phases closely structurally related to cassiterite, monoclinic ZrO₂ and tetragonal ZrO₂, a small amount of metastable ZrSnO₄ phase appeared in the crystallization products of samples with 40 and 50 mol% of SnO₂ calcined at 1000 °C. Further temperature treatments caused a decrease in and disappearance of metastable phases. The results of the micro-structural analysis show that the sinterability of the crystallization products significantly decreases with an increase in the SnO₂ content.     

Preparation of slaking resistant CaO aggregate from lightweight CaCO3 with oxide addition

CaO aggregate was sintered from reagent-grade lightweight CaCO₃ powder by the addition of 0-20% (molar ratio) MgO and ZrO₂, respectively. The results showed that the CaO derived from lightweight CaCO₃ was highly sinterable and compact CaO aggregate with relative density above 96% was obtained after sintering at 1400 °C for 2 h, but further increase of compactness was restrained due to the occurrence of abnormal grain growth. The densification of the aggregate was promoted due to the behavior of oxide addition on restraining the grain growth of CaO. With increasing the amount of oxide addition, the microstructure of CaO aggregate underwent a restructuration process. Homogeneous microstructure, with well growing MgO grains occupying most of the boundary triple points of CaO grain, formed by the addition of 20% MgO. Especially when 20% ZrO₂ was added, CaZrO₃ layer formed around CaO grains. The slaking resistance of the aggregate was appreciably improved due to the promotion of densification, the formation of CaO solid solution (while MgO added) and the modification of microstructure.     

Effect of ZrO2 addition on crystallization behaviour, porosity and chemical-mechanical properties of a CaO-TiO2-P2O5 microporous glass ceramic

2-6 mol% ZrO₂ was added to a base glass composition of P₂O₅ 31.25, CaO 43.75, TiO₂ 25 (mol%) at the expense of TiO₂. The prepared glasses were crystallized to bulk glass ceramics containing the major phases of β-Ca₃(PO₄)₂ and CaTi₄(PO₄)₆. DTA was utilized to determine the appropriate phase separation-nucleation and crystallization temperatures. The crystalline products and resulting microstructures were examined by XRD and SEM. The β-Ca₃(PO₄)₂ phase was dissolved out by leaching the resulting glass ceramics in HCl, leaving a porous skeleton of CaTi₄(PO₄)₆. It was shown that ZrO₂ addition resulted in reduction of volume porosity and mean pore diameter while the specific surface area was increased. The smallest median pore diameter and largest surface area were 8.6 nm and 32 m² g⁻¹ respectively obtained for the specimen containing 6 mol% ZrO₂. The ZrO₂ addition also improved the chemical durability and bending strength of porous glass ceramics.     

Disintegration process of yttria-stabilized zirconia ceramics using hydrothermal conditions

Capability of the recycling of high strength and high fracture toughness yttria-stabilized tetragonal zirconia polycrystalline (Y-TZP) sintered body utilizing “low-temperature annealing degradation” phenomenon was investigated. Hydrothermal treatment was employed to induce the phase transformation from tetragonal to monoclinic zirconia and to disintegrate the Y-TZP sintered body. 3 mol% Y₂O₃–ZrO₂ specimens sintered at 1,550 °C and more were disintegrated without leaving the original appearances when the treatment temperature was between 200 °C and 400 °C. The size of the disintegrated fragments of Y-TZP sintered body was much affected by hydrothermal treatment conditions. Only with hydrothermal treatment and simple ball milling, the sintered body was pulverized into the primary particle level. This technique is expected to apply to a sustainable recycling system for the zirconia ceramics, which restrains an energy consumption compared to crushing zirconia using mechanical procedures.     

Structural, thermal and optical characterization of TiO2:ZrO2 thin films prepared by sol-gel method

We have studied the structural and optical properties of thin films of TiO₂, doped with 5% ZrO₂ and deposited on glass substrate (by the sol-gel method). The dip-coated thin films have been examined at different annealing temperatures (350 to 450 °C) and for various layer thicknesses (63-286 nm). Refractive index and porosity were calculated from the measured transmittance spectrum. The values of the index of refraction are in the range of 1.62-2.29 and the porosity is in the range of 0.21-0.70. The coefficient of transmission varies from 50 to 90%. In the case of the powder of TiO₂, doped with 5% ZrO₂, and aged for 3 months in ambient temperature, we have noticed the formation of the anatase phase (tetragonal structure with 14.8 nm grains). However, the undoped TiO₂ exhibits an amorphous phase. After heat treatments of thin films, titanium oxide starts to crystallize at the annealing temperature 350 °C. The obtained structures are anatase and brookite. The calculated grain size, depending on the annealing temperature and the layer thickness, is in the range (8.58-20.56 nm).     

Microstructure and mechanical behaviour of 3Y-TZP/Mo nanocomposites possessing a novel interpenetrated intragranular microstructure

Yttria stabilized tetragonal zirconia polycrystal (Y-TZP)/0-100 vol % molybdenum (Mo) composites were fabricated by hot-pressing a mixture of Y-TZP powder containing 3 mol % yttria (Y₂O₃) and a fine Mo powder in vacuum. This composite system possessed a novel microstructural feature composed of an interpenetrated intragranular nanostructure, in which either nanometer sized Mo particles or equivalent sized zirconia (ZrO₂) particles located within the ZrO₂ grains or Mo grains, respectively. The strength and toughness were both greatly enhanced with increasing Mo content for the 3Y-TZP/Mo composites thus breaking through the strength-toughness tradeoff relation in transformation toughened ZrO₂ and its composite materials. They exhibited a maximum strength of 2100 MPa and a toughness of 11.4 MPa·m^1/2 for the composite containing 70 vol % Mo. These simultaneous improvements in strength and toughness were determined to be the result of a decrease in flaw size associated with the interpenetrated intragranular nanostructure, and a stress shielding effect created in the crack tip by the elongated Mo polycrystals bridging the crack tip in addition to the stress induced phase transformation.     

Effect of the addition of t-ZrO2 on the material properties of β-TCP/PCL composites

Using poly-methyl methacrylate as a pore-forming agent, porous β-tricalcium phosphate (β-TCP)/t-ZrO₂ composites were fabricated depending on the volume percentages (vol.%) of t-ZrO₂ powder. In the porous sintered bodies, hybrid pores, about 20 and 200 μm in diameter, were homogenously dispersed in the β-TCP/t-ZrO₂ matrix and showed good interconnection. On the other hand, β-TCP-(t-ZrO₂)/polycaprolactone (PCL) composites were fabricated by the melt infiltration process using porous β-TCP/t-ZrO₂ bodies. The relative density of the β-TCP-(t-ZrO₂)/PCL composites increased as the vol.% of t-ZrO₂ increased and its maximum value was about 98.6%. However, the hardness, bending strength and elastic modulus of β-TCP-(t-ZrO₂)/PCL composites decreased due to the low densification of porous β-TCP/t-ZrO₂ bodies as the volume percentages of t-ZrO₂ content increased. The values (using 20 vol.% of t-ZrO₂) were 11.4 Hv, 25.5 MPa and 17.2 GPa, respectively.     

Electrical and microstructural properties of CaTiO3-doped K1/2Na1/2NbO3-lead free ceramics

Microstructure, electrical properties and dielectric behaviour of K_1/2Na_1/2NbO₃ (KNN) and CaTiO₃-modified K_1/2Na_1/2NbO₃ (CTO-KNN) systems, were investigated. Discs doped with 0 to 0·55% mol of CaTiO₃ (CTO) were sintered at 1125°C for 2 h. Although minority phases were found in doped samples, CaTiO₃ was not detected. It was also observed that CTO changed the microstructure and grain size of KNN drastically. Also, the Curie temperature and permittivity values decreased. Addition of CTO between 0·15 and 0·45 mol% decreases the density and dielectric values. Samples prepared with higher content of CTO than 0·45 mol% showed better electrical properties.     

Synthesis of nano-particles of anatase-TiO2 and preparation of its optically transparent film in PVA

Anatase-TiO₂ nano-particles have been synthesized by using long-carbon chain carboxylic acid and titanium tetrachloride (TiCl₄). As-prepared powder has been calcined at 500 °C to obtain highly crystalline TiO₂. Broad X-ray diffraction (XRD) pattern of as-prepared as well as calcined powder showed all prominent peaks for tetragonal crystal structure representing anatase-TiO₂. The particle diameter by applying Scherrer formula was found to be about 20 nm. It was possible to load as-prepared particles in poly vinyl alcohol (PVA) for optical studies. Optically transparent film showed sharp absorption band for TiO₂ nano-particles at ∼ 300 nm. Photoluminescence (PL) studies of the solution showed emission wavelength at about 330 nm. Transmission electron microscopy (TEM) and selected area electron diffraction (SAED) revealed that the particles in the film have uniform distribution and even for the powder no agglomeration was observed. Thermal analysis (TGA) showed that the stability of host polymer is enhanced. FTIR spectra showed presence of carboxylate functional group in the powder.     

Efficient way of precipitation to synthesize Ni-ion stabilized tetragonal zirconia nanopowders

Nickel ions (Ni²⁺) stabilized tetragonal zirconia (t-ZrO₂) nanopowders have been synthesized at constant pH as well as increasing (direct process) and decreasing (reverse process) the pH of the precursor solution step by step, using hydrazine hydrate (N₂H₅OH) as a precipitating agent. The constant pH (at 10) process has a promising effect on the stability of t-ZrO₂ over the direct and reverse processes. The maximum solubility limit of Ni²⁺ in ZrO₂ is less than 20 mol%. XRD results of the Ni²⁺-ZrO₂ systems revealed that the minimum concentrations of Ni²⁺ for stabilizing t-ZrO₂ at 700 °C and 800 °C are 10 mol% and 20 mol%, respectively. Decrease in cell volume and crystallite size lead to higher strain with the incorporation of Ni²⁺ ions that causes the stabilization of t-ZrO₂ up to 800 °C while synthesized using constant pH process.     

Influence of rare-earth addition on microstructure and dielectric behavior of Ba0.6Sr0.4TiO3 ceramics

Ba_0.6Sr_0.4TiO₃ (BST) ceramics with 0.5 mol% various trivalent rare-earth additions prepared by a solid-state route are investigated. A strong correlation is observed between the microstructure, dielectric properties and rare-earth element dopant. The results display that comparing with the lattice constants of undoped and doped rare-earth BST, the structure transforms from cubic to tetragonal structure. In addition, the dopant improves the tetragonal distortion with the ionic radius of rare earth decreasing, and then deteriorates it with further decreasing. Large ions rare-earth additions effectively suppress the grain growth of BST. It is found that the temperature-permittivity characteristics for the BSTR (R, namely, rare earth) system could be controlled using various rare-earth elements. Especially, such as Sm, Eu, Gd dopants are effective to satisfy the tunable microwave devices application due to the decrease of permittivity and the improvement of dissipation factors of BST ceramic with the accompanying high-tunability.     

Fabrication of photocatalytic heat-mirror with TiO2/TiN/TiO2 stacked layers

The photocatalytic heat-mirror based on TiO₂/TiN/TiO₂ stacked layers is prepared by reactive magnetron sputtering on quartz substrates under substrate-heating condition. We find that the addition of a thin Ti interlayer between the TiN and the outer TiO₂ layers drastically improves the heat-insulating performance. This type of stacked layer also exhibits higher photocatalytic activity for decomposition of acetaldehyde gas, compared with a TiO₂ single layer. The optical property of the TiN in TiO₂/TiN/TiO₂ stacked layers is the key not only revealing excellent heat-insulating effect but also improving the photocatalytic performance of the outer TiO₂ layers in the stacked layers.     

Acrylamide assisted polymeric citrate route for the synthesis of nanocrystalline ZrO2 powder

Nanocrystalline ZrO₂ powders have been prepared using acrylamide assisted polymeric citrate combustion (autoignition) route. Process parameters (i.e., total metal ions to citric acid ratio) were varied for the formation of polymeric resin in order to obtain the final product with desired properties (organic free, smaller crystallite size, etc.). The effect of three different citric acid amounts in the formation of nanocrystalline ZrO₂ powder was investigated using FTIR, XRD, TG/DTA and SEM-EDS, respectively, to identify the structural coordination, phase, thermal behavior and microstructure of the polymeric intermediates as well as the final ZrO₂ powders. Organic free ZrO₂ powder with two different phases of metastable t-ZrO₂ and m-ZrO₂ were prepared by calcining the polymeric intermediates at 600 °C. The lowest crystallite was found to be 18 and 16 nm, respectively, for the t-ZrO₂ and m-ZrO₂ phases prepared with total metal ions to citric acid ratio of 1:3.     

Photocatalytic properties of porous TiO2/Ag thin films

In this study, nanocrystalline TiO₂/Ag composite thin films were prepared by a sol-gel spin-coating technique. By introducing polystyrene (PS) spheres into the precursor solution, porous TiO₂/Ag thin films were prepared after calcination at a temperature of 500 °C for 4 h. Three different sizes (50, 200, and 400 nm) of PS spheres were used to prepare porous TiO₂ films. The as-prepared TiO₂ and TiO₂/Ag thin films were characterized by X-ray diffractometry (XRD) and by scanning electron microscopy to reveal structural and morphological differences. In addition, the photocatalytic properties of these films were investigated by degrading methylene blue under UV irradiation.When PS spheres of different sizes were introduced after calcination, the as-prepared TiO₂ films exhibited different porous structures. XRD results showed that all TiO₂/Ag films exhibited a major anatase phase. The photodegradation of porous TiO₂ thin films prepared with 200 nm PS spheres and doped with 1 mol% Ag exhibited the best photocatalytic efficiency where ∼ 100% methylene blue was decomposed within 8 h under UV exposure.     

Microstructure and mechanical properties of hot pressed ZrB2-SiCp-ZrO2 composites

The present paper investigated the microstructure and mechanical properties of ZrB₂-10 vol.%SiC_p-10 vol.%ZrO₂ composites hot pressed at three temperatures. Phase transformability from t-ZrO₂ to m-ZrO₂ during fracture was analyzed through calculating the volume fractions of m-ZrO₂ and t-ZrO₂ on polished and fracture surfaces. The densification temperature was found to have a significant effect on the microstructure, phase transformation and the properties of the composites. When the composite was hot pressed at 1950 °C, the average grain size was 9.5 µm, and the fracture toughness was 4.5 MPa·m^1/2. Comparatively, when the composite was hot pressed at 1750 °C, the average grain size was 3.4 µm, and the fracture toughness increased by ~ 50% to 6.8 MPa·m^1/2.