Spark-Plasma-Sintering Condition Optimization for Producing Transparent MgAl2O4 Spinel Polycrystal

By controlling the heating rate at <10°C/min during spark-plasma-sintering (SPS) processing, transparent polycrystalline spinel with an in-line transmission of 50% and 70% in the visible- and infrared-wavelengths, respectively, can be successfully fabricated for only a 20-min soak at 1300°C. The high transmission can be attained by reducing the residual porosity and pore size, which was achieved by the low-heating rate. At high heating rates, many closed pores are formed due to the high densification rate during the heating process and remain as large pores around grain junctions. At temperatures >1300°C, the coalescence of the residual pores and the precipitation of second phases, which are caused by rapid grain growth, degrade the transparency. The present study demonstrates that although the high heating rates have been regarded as a primary advantage for the SPS processing, the low heating rate is highly effective in attaining a high transparency in the spinel even at low temperatures and for short sintering times.     

Fine-grained transparent MgAl2O4 spinel obtained by spark plasma sintering of commercially available nanopowders

A high transmittance/small grain size combination for pure spinel ceramics from commercially available nanopowders without sintering aids can be obtained by SPS sintering. By using a low heating rate ≤10 °C/min and a sintering temperature ≤1300 °C, a transparent polycrystalline MgAl₂O₄ spinel was fabricated by SPS with an in-line transmission of 74% and 84% for 550 nm (visible) and 2000 nm (NIR) wavelengths respectively. A small average grain size of about 250 nm was obtained and the pores located at the multiple grain junctions have a mean size of about 20 nm. The high in-line transmission is linked not only to the low residual porosity but particularly to the very small size of pores.     

Spark Plasma Sintering of Sol–Gel Derived Amorphous ZrW2O8 Nanopowder

Dense ZrW₂O₈ was prepared by spark plasma sintering (SPS), using amorphous ZrW₂O₈ nanopowder as a raw material, at 873 K for 10 min. We investigated the effects of SPS conditions, such as sintering temperature, heating rate, and the discharge power that is expressed as the product of pulsed direct current and voltage, on the densification process of ZrW₂O₈. The relative density and microstructure of ZrW₂O₈ prepared by SPS were compared with those of ZrW₂O₈ prepared by hot pressing (HP). The relative density of ZrW₂O₈ prepared by HP at 873 K for 1 h was 63.1%. On the contrary, the relative density of ZrW₂O₈ prepared by SPS at 873 K for 10 min at a heating rate of 50 K/min was 98.6%. These results show that the discharge pressure that is proportional to discharge power enhances the densification and grain growth of ZrW₂O₈ in the SPS process.     

Development of WC–ZrO2 Nanocomposites by Spark Plasma Sintering

In the present work, we report the processing of ultrahard tungsten carbide (WC) nanocomposites with 6 wt% zirconia additions. The densification is conducted by the spark plasma sintering (SPS) technique in a vacuum. Fully dense materials are obtained after SPS at 1300°C for 5 min. The sinterability and mechanical properties of the WC–6 wt% ZrO₂ materials are compared with the conventional WC–6 wt% Co materials. Because of the high heating rate, lower sintering temperature, and short holding time involved in SPS, extremely fine zirconia particles (∼100 nm) and submicrometer WC grains are retained in the WC–ZrO₂ nanostructured composites. Independent of the processing route (SPS or pressureless sintering in a vacuum), superior hardness (21–24 GPa) is obtained with the newly developed WC–ZrO₂ materials compared with that of the WC–Co materials (15–17 GPa). This extremely high hardness of the novel WC–ZrO₂ composites is expected to lead to significantly higher abrasive-wear resistance.     

Pulse Electric Current Sintering of Al2O3/3 vol% ZrO2 with Constrained Grains and High Strength

The pulse electric current sintering technique (PECS) was demonstrated to be effective in rapid densification of fine-grained Al₂O₃/3Y-ZrO₂ using available commercial powders. The composites attained full densification (>99% of TD) at 1450°C in less than 5 min. The composites sintered at a high heating rate had a fine microstructure. The incorporation of 3 vol% 3Y-ZrO₂ substantially increased the average fracture strength and the toughness of alumina to as high as 827 MPa and 6.1 MPa·m^1/2, respectively. A variation in the heating rate during the PECS process influenced grain size, microstructure, and strength, though there was little or no variation in the fracture toughness.     

A Screening Design Approach for the Understanding of Spark Plasma Sintering Parameters: A Case of Translucent Polycrystalline Undoped Alumina

An experimental screening design was used to evaluate the effects of spark plasma sintering (SPS) parameters such as heating rate, sintering temperature, dwell duration, and green-shaping processing on the relative density, grain size, and the optical properties of polycrystalline alumina (PCA). It is shown that heating rate and sintering temperature are the most critical factors for the densification of PCA during SPS. Green-shaping processing could prevent grain growth at low SPS sintering temperatures. No predominant SPS parameters are observed on the optical properties. Hence, the optical properties of PCA are controlled by microstructural evolution during the SPS process.     

Crack Healing and Stress Relaxation in Al2O3 SiC "Nanocomposites"

The crack-healing behavior of A1₂O₃ and Al₂O₃-SiC nanocomposite was studied using Vickers indentations to generate precracks. After annealing in argon for 2 h at 1300°C, radial cracks in the nanocomposite healed: The cracks closed and there was a small degree of rebonding in the vicinity of the crack tip. In contrast, radial cracks in alumina grew when exposed to the same annealing treatment. The different responses are attributed to the fracture mode and toughening mechanism in each material: In the nanocomposite, the cracks close as the residual stresses surrounding the indentations relax. Radial cracks open and grow in A1₂O₃ because microstructural toughening is diminished during heating to the annealing temperature. An implication is that strength-limiting machining flaws in these materials behave similarly, thereby accounting for the strengthening effect of annealing in this "nanocomposite" system.     

Densification of alumina by SPS and HP: A comparative study

In this study, the densification of alumina by spark plasma sintering (SPS) was investigated and compared to conventional hot pressing. It was shown that SPS is very effective in the sintering of alumina leading to higher densities and allows to work at lower temperatures and with shorter sintering cycles. The effect of the heating rate is dependent on the heating mode (SPS or HP). The identification of active sintering mechanisms was attempted by an isothermal and an anisothermal methods, showing that other mechanisms probably related to electrical effects enhance the densification. We suggest the higher contribution of surface diffusion mainly during the initial stage of sintering and an influence of the presence of impurities segregated at the grain boundaries. They could create conductive layers and also introduce ions with a lower valence than Al³⁺; defects are created in the surface layers and the diffusion of the species is increased.     

Effect of TiO2 on Initial Sintering of Al2O3

Alpha alumina with additions of TiO₂ sintered more rapidly than "pure" alumina. The rate of initial sintering increased approximately exponentially with titania concentration up to a percentage beyond which the rate of sintering remained approximately constant or decreased slightly with additional titania. The concentration which produces the maximum rate of sintering is thought to be the solubility limit of TiO₂ in Al₂O₃. For alumina particles larger than about 2 μm, the kinetic process was mainly grain-boundary diffusion. With smaller particles, volume diffusion increased. The "solubility limit" increased with decreasing particle size, indicating an excess surface concentration of TiO₂. The data may be interpreted in terms of a region of enhanced diffusion at the grain boundary that increases with TiO₂ concentration. With small alumina particles, this region is large enough to become a significant portion of the volume of the particle, and the small particles appear to sinter by volume diffusion kinetics, but the diffusion coefficient corresponds to an enhanced diffusion coefficient.     

Influence of Stress and Chemical Homogeneity on Dielectric Properties of BaTi0.9Zr0.1O3

The influence of mechanical stress and chemical homogeneity on the permittivity of BaTi_0.9Zr_0.1O₃ ceramics prepared from mixed-oxide and hydrothermal powders was studied. To reduce stress, liquid-phase sintering was applied in conjunction with a low heating rate to stimulate the formation of large grains. The influence of chemical homogeneity was studied by variations in sintering temperatures and times. For both types of ceramics, the dielectric constant at the Curie temperature was influenced by both factors, but to a different extent. In the mixed oxide ceramic, chemical homogeneity played a more prominent role, while internal stress appeared to exert a larger influence in the hydrothermal ceramics. The dielectric constant at the Curie temperature could be increased by 5%–10% by an annealing treatment at 200°C, followed by slow cooling.     

Effects of heating rate on microstructure and transparency of spark-plasma-sintered alumina

Commercial alumina powder was densified by spark plasma sintering (SPS) at 1150 °C. During SPS processing, the effects of the heating rate were examined on microstructure and transparency. With decreasing heating rate, the grain size and the residual porosity decreased, while the transparency increased. At a heating rate of 2 °C/min, the grain size was 0.29 μm, and the in-line transmission was 46% for a wavelength of 640 nm. The mechanisms for the fine microstructure and low porosity at slow heating, which are conflicting with some existing results, were explained by considering the role of defect concentration and grain-boundary diffusion during densification.     

Microstructure and Properties of Spark Plasma-Sintered ZrO2–ZrB2 Nanoceramic Composites

In a recent work, ¹ we have reported the optimization of the spark plasma sintering (SPS) parameters to obtain dense nanostructured 3Y-TZP ceramics. Following this, the present work attempts to answer some specific issues: (a) whether ZrO₂-based composites with ZrB₂ reinforcements can be densified under the optimal SPS conditions for TZP matrix densification (b) whether improved hardness can be obtained in the composites, when 30 vol% ZrB₂ is incorporated and (c) whether the toughness can be tailored by varying the ZrO₂–matrix stabilization as well as retaining finer ZrO₂ grains. In the present contribution, the SPS experiments are carried out at 1200°C for 5 min under vacuum at a heating rate of 600 K/min. The SPS processing route enables retaining of the finer t -ZrO₂ grains (100–300 nm) and the ZrO₂–ZrB₂ composite developed exhibits optimum hardness up to 14 GPa. Careful analysis of the indentation data provides a range of toughness values in the composites (up to 11 MPa·m^1/2), based on Y₂O₃ stabilization in the ZrO₂ matrix. The influence of varying yttria content, t -ZrO₂ transformability, and microstructure on the properties obtained is discussed. In addition to active contribution from the transformation-toughening mechanism, crack deflection by hard second phase brings about appreciable increment in the toughness of the nanocomposites.     

Effect of heating rate on properties of transparent aluminum oxynitride sintered by spark plasma sintering

High heating rates ranging from 50 to 250°C/min are selected to rapidly sinter transparent aluminum oxynitride (AlON) ceramics by spark plasma sintering (SPS) at 1600°C under 60 MPa using a bimodal AlON powder synthesized by the carbothermal reduction and nitridation method. With 1 minute holding time before cooling, all the specimens show high density and high transparence. The maximum transmittance is up to 74.5%-80.6%, where the maximum transmittance is positively correlated with the heating rate. Further analysis reveals that faster heating rates enable the decrease in the amount of the AlON phase decomposed into the α-Al₂O₃ and AlN phases during heating. These α-Al₂O₃ and AlN phases have to be converted back to AlON at the final stage of sintering, which indicates that a decrease in the amount of the α-Al₂O₃ and AlN phases via the boosted heating leads to the higher transmittance of the AlON ceramics. The high heating rates and short holding duration of the SPS utilized in this study result in the fine grain size of the obtained ceramics (1-6 μm) compared to that of the AlON ceramics fabricated by the conventional sintering method. This effect of high heating rates is confirmed by the coupled densification-grain growth modeling. In turn, the obtained AlON specimens exhibit a Vickers hardness of 15.87-16.62 GPa.     

Grain Growth Control in NaNbO3–SrTiO3 Ceramics by Mechanosynthesis and Spark Plasma Sintering

The combination of non-conventional methods of synthesis (mechanosynthesis) and sintering (spark plasma sintering, SPS) has been used for the first time to process dense, fine-grained ceramics of the (1− x )NaNbO₃– x SrTiO₃ system. Dielectric properties have been measured across main phase transitions in the system for the submicrometer-structured ceramic materials processed by SPS, and are comparable with those of ceramics prepared by conventional sintering. This approach thus allows grain growth to be controlled while retaining properties, and provides the possibility of processing ceramics of alkaline niobate-based perovskite solid solutions with a homogeneous, fine-grained microstructure and good functionality.     

Preparation of Dense Lead Magnesium Niobate–Lead Titanate (Pb(Mg1/3Nb2/3)O3–PbTiO3) Ceramics by Spark Plasma Sintering

The effect of spark plasma sintering (SPS) on the densification behavior of Pb(Mg_1/3Nb_2/3)O₃–PbTiO₃ ceramics has been investigated. Specimens with a density of >99% of the theoretical density (TD) were obtained using SPS treatment at 900°C. Through normal sintering at 1200°C, however, the density of the specimen was only ∼92% of TD.     

Sintering of Nanophase γ-Al2O3 Powder

The sintering of ultrafine γ-Al₂O₃ powder (particle size ∼10–20 nm) prepared by an inert gas condensation technique was investigated in air at a constant heating rate of 10°C/min. Qualitatively, the kinetics followed those of transition aluminas prepared by other methods. Measurable shrinkage commenced at ∼ 1000°C and showed a region of rapid sintering between ∼1125° and 1175°C followed by a transition to a much reduced sintering rate at higher temperatures. Starting from an initial density of ∼0.60 relative to the theoretical value, the powder compact reached a relative density of 0.82 after sintering to 1350°C. Compared to compacts prepared from the as-received powder, dispersion of the powder in water prior to compaction produced a drastic change in the microstructural evolution and a significant reduction in the densification rate during sintering. The incorporation of a step involving the rapid heating of the loose powder to ∼1300°C prior to compaction (which resulted in the transformation to α-Al₂O₃) provided a method for significantly increasing the density during sintering.     

Effects of Preparation Conditions on the Structural and Optical Properties of Spark Plasma-Sintered PLZT (8/65/35) Ceramics

Transparent lanthanum-doped lead zirconate titanate (PLZT) ceramics with high density were fabricated using spark plasma sintering (SPS), a recently developed hot-pressing method. A wet–dry combination method was used to prepare the fine PLZT powders. The average grain size of the PLZT ceramics was less than 1 μm, because of a relatively low sintering temperature and a very short sintering time. The transmittance of PLZT ceramics increased with an increase of calcination temperature up to 700°C and then it slightly decreased with further increase of calcination temperature. The transmittance strongly depended on the SPS temperature and heat-treatment temperature. The pellet sintered at 900°C for 10 min and heat treated at 800°C for 1 h with a thickness of 0.5 mm showed a transmittance of 31% at a wavelength of 700 nm. The relationships between the transmittance and the microstructure were investigated.     

Ambient-Temperature Mechanochemical Formation of Titanium Nitride-Alumina Composites from TiO2 and FeTiO3

The fabrication of a homogeneous submicrometer-sized powder composed of nanocrystalline (<10 nm) alumina and titanium nitride during high-energy ball-milling is reported in this paper. The starting materials were rutile (TiO₂) and aluminum powder. A similar composite with iron was also produced using the mineral ilmenite (FeTiO₃) as the starting material. The powders were ball-milled together under a nitrogen atmosphere for 100 h in a laboratory-scale mill and subjected to thermal analysis and isothermal annealing at up to 1200°C. X-ray diffraction showed that all of the phases formed within the milling step and underwent grain growth on annealing. Differential thermal analysis indicated no residual elemental aluminum, confirming that the reaction was completed during the milling operation.     

Kinetics of the β"-to-β Transformation in the System Na2O-A12O3

Mixtures of α-A1₂O₃ and NaAlO₂ corresponding to the eutectic composition 65 mot % A1₂O ₃ were heated in sealed platinum crucibles above the eutectic temperature (measured to be 1572°C in this study). Once melting was complete, the liquid was quenched and the resultant solid examined by X-ray diffraction. Sodium aluminate, beta alumina, and beta" alumina were detected in all cases. However, the relative amounts of beta and beta" present were a function of the cooling rate, with the amount of beta" increasing with a decreasing cooling rate. Subsequent annealing (in platinum envelopes) of the solidified eutectic at 1400° and 1530°C showed that the amount of beta" present decreased with increasing annealing time. Based on this observation, it is apparent that, in the temperature range studied, beta"-is metastable. Analysis of the time-transformation data shows that the reaction kinetics are consistent with the diffusion-controlled growth of the beta phase at the expense of the beta"-phase.     

Translucent Yttria‐ and Silica‐Doped Mullite Ceramics with Anisotropic Grains Produced by Spark Plasma Sintering

Translucent, high‐performance, mullite ceramics with anisotropic grains were prepared by the spark plasma sintering (SPS) of a powder mixture consisting of commercial mullite powder, which already contained small amounts of alumina (θ and α) and silica (cristobalite) (≤3 wt% in total), to which 2 and 1 wt% of yttria and amorphous silica was admixed, respectively. The combination of low‐viscosity Y₂O₃–Al₂O₃–SiO₂ transient liquid formation and SPS sintering provided enhanced densification, also provoking anisotropic grain growth (which became exaggerated after 20 min of SPS dwell time), at a relatively low sintering temperature of 1370°C. In this way, it was possible to meet the conflicting demands for obtaining a dense mullite ceramic with anisotropic grains, ensuring good mechanical properties, while preserving a noticeable light transmittance. In terms of mechanical and optical properties, the best results were obtained when SPS dwell times of 5 and 10 min were employed. The as‐sintered samples possessed densities in the range 3.16–3.18 g/cm³, anisotropic grains with an aspect ratio (AR) of 7 and a grain thickness of approximately 0.45 μm, a flexural strength between 350 and 420 MPa, a Vickers indentation toughness and a hardness of approximately 2.45 MPa·m^1/2 and 15 GPa, respectively, and an optical transmittance of between 30% and almost 50% in the IR range.