Thermal Expansion of 12CaO°7Al2O3

Literature data for the 12CaO°7Al₂O₃ phase show certain discrepancies in the structure, thermal stability, and mean linear thermal expansion obtained by different techniques. Phase-pure, cubic, polycrystallin I2CaO°7Al₂O₃ was synthesized by annealing a stoichiometric melt in air. Infrared spectrophotometry indicated stabilization by moisture. Differential thermal analysis and thermogravimetric analysis showed the cubic phase to be stable up to at least 1200° C. High-temperature X-ray diffraction analysis of a polycrystalline sample and dilatometric measurement of sintered pellets indicated a linear thermal expansion of 41 × 10^-7 to 43X10^-7/°C in the temperature range 200° to 800°C.     

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.     

Orientation and Grain Boundary Microstructure of Alumina in Al/Al2O3 Composites Produced by Reactive Metal Penetration

The orientation and grain boundary microstructure of alumina in reactive metal penetration Al/Al₂O₃ composites are studied using orientation imaging microscopy and the results are compared with those of sintered polycrystalline Al₂O₃. The interconnected Al₂O₃ in the composite material is separated by Σ3 boundaries (twins) with a 60° rotation around the [0001] direction. A high frequency (∼100%) of Σ3 coincidence boundaries in composite alumina is remarkable since only ∼12% of boundaries in a sintered polycrystalline Al₂O₃ are of special nature. The coincidence boundaries in the in situ alumina grow in a coherent and faceted manner.     

Phase Relations in the Garnet Region of the System Y2O3–Fe2O3–FeO–Al2O3

Liquidus equilibrium relations for the air isobaric section of the system Y₂O₃–Fe₂O₃–FeO–Al₂O₃ are presented. A Complete solid-solution series is found between yttrium iron garnet and yttrium aluminum garnet as well as extensive solid solutions in the spinel, hematite, orthoferrite, and corundum phases. Minimum melting temperatures are raised progressively with the addition of alumina from 1469°C in the system Y–Fe–O to a quaternary isobaric peritectic at 1547°C and composition Y _0.22 Fe _1.08 Al _0.70 O _2.83* Liquidus temperatures increase rapidly with alumina substitutions beyond this point. The thermal stability of the garnet phase is increased with alumina substitution to the extent that above composition Y _0.75 Fe _0.65 Al _0.60 O ₃ garnet melts directly to oxide liquid without the intrusion of the orthoferrite phase. Garnet solid solutions between Y _0.75 Fe _1.25 O ₃ and Y _0.75 Fe _0.32- Al _0.93 O ₃ can be crystallized from oxide liquids at minimum temperatures ranging from 1469° to 1547°C, respectively. During equilibrium crystallization of the garnet phase, large changes in composition occur through reaction with the liquid. Unless care is taken to minimize temperature fluctuations and unless growth proceeds very slowly, the crystals may show extensive compositional variation from core to exterior.     

Sintering and Crystallization of CaO–Al2O3–ZrO2–SiO2 Glasses Containing Different Amount of Al2O3

In this work several complementary techniques have been employed to carefully characterize the sintering and crystallization behavior of CaO–Al₂O₃–ZrO₂–SiO₂ glass powder compacts after different heat treatments. The research started from a new base glass 33.69 CaO–1.00 Al₂O₃–7.68 ZrO₂–55.43SiO₂ (mol%) to which 5 and 10 mol% Al₂O₃ were added. The glasses with higher amounts of alumina sintered at higher temperatures (953°C [lower amount] vs. 987°C [higher amount]). A combination of the linear shrinkage and viscosity data allowed to easily find the viscosity values corresponding to the beginning and the end of the sintering process. Anorthite and wollastonite crystals formed in the sintered samples, especially at lower temperatures. At higher temperatures, a new crystalline phase containing ZrO₂ (2CaO·4SiO₂·ZrO₂) appeared in all studied specimens.     

Thermal Expansion of Nb2O5

The high-temperature thermal expansion of monoclinic Nb₂O₅ was studied with X-ray and dilatometric techniques. The X-ray axial thermal expansion was anisotropic; the mean coefficients in the a, b , and c directions, respectively, were 5.3, 0, and 5.9×10⁻⁶°C^-1 from room temperature to 1000°C. It is proposed that this anisotropy causes microcrack formation in sintered polycrystalline samples. The bulk linear thermal expansion of both sintered and hot-pressed samples was determined with a dilatometer from room temperature to 1200°C. A hysteresis effect between heating and cooling data observed for sintered samples was attributed to the occurrence and recombination of internal microcracks.     

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.     

Plastic Deformation of Al2O3 During Abrasion

X-ray diffraction line broadening examination of the debris produced by abrasion of polycrystalline Al₂O₃ on a 320-grade diamond-impregnated lap showed that heavy plastic deformation is associated with the abrasive process. Annealing of the debris resulted in an increase in crystallite size at temperatures >800°C but only minor changes in microstrain. This behavior contrasts with the large reduction in microstrain reported for ball-milled Al₂O₃ with similar initial crystallite size. The results are consistent with recovery during formation of the debris particles. A transient temperature of 900° to 1200°C was estimated from the plastic work done, assuming that material is removed by a mechanism similar to that observed in the abrasion of metals.     

Tensile Ductility of Superplastic Al2O3–Y2O3–Si3N4/SiC Composites

Si₃N₄/SiC composites are ceramic materials that exhibit excellent performance for high-temperature applications. Prepared from an ultrafine amorphous Si-C-N powder, sintered materials are constituted mainly of a β -Si₃N₄ matrix with SiC inclusions and have a very small grain size (less than 1 μm). Such a microstructure is propitious for superplastic forming. Superplasticity has been studied in tension, from 1550° to 1650°C, under nitrogen atmosphere. Elongations over 100% have been achieved. In many cases, at the highest temperatures and slowest strain rates, materials are damaged by different processes, including microcracking, cavitation, and chemical decomposition. A map of the most suitable (strain-rate/temperature) domain has been established. It allows the prevention of any structural alteration by selecting carefully the testing conditions. Since specimens suffered considerable strain-induced hardening, sources for this phenomenon are examined. Although the experiments have involved high temperature and extensive strain, neither static nor dynamic grain growth has occurred. Crystallization of the amorphous grain-boundary phase, which is reported in most cases, may be invoked. However, based on microstructural observations, it is not the unique origin for flow hardening.     

Effect of Doping Simultaneously with Iron and Titanium on the Diffusional Creep of Polycrystalline A12O3

The effect of doping simultaneously with iron and titanium was studied in dense, polycrystalline alumina over a range of grain sizes (10 to 100 μm) and temperatures (1250° to 1550°C). In the double-doped system, the titanium concentration was varied between 0.05 and 0.15 cation %, whereas the iron-dopant level was varied between 0.05 and 6 cation %. For iron concentrations below about 2 to 3%, the aluminum vacancy concentration was dominated by the presence of quadrivalent titanium in substitutional solid solution and Nabarro-Herring diffusional creep at 1450°C was rate-limited by aluminum lattice diffusion. As the iron-dopant level was increased, the concentration of divalent iron became comparable to that of quadrivalent titanium, leading to a suppression in the cation lattice diffusivity at an iron-to-titanium ratio of ∼60. These results suggested that, at the dopant levels and temperatures studied, more than 98% of the iron was in the trivalent state. The diffusional creep of polycrystalline alumina doped with a single iron impurity (0.2 to 2%) was reinterpreted in terms of simultaneous contributions of aluminum lattice and grain-boundary diffusion, consistent with a grain-size dependence corresponding to a mixture of Nabarro-Herring and Coble creep. Aluminum grain-boundary diffusion was found to be significantly enhanced by the presence of iron in solid solution. Evidence is presented to suggest that the diffusional creep of polycrystalline Al₂O₃ doped with a single titanium dopant is interface-controlled. Interfacial kinetics can be promoted by several factors, including (1) a small grain size, (2) a high cation lattice diffusivity, (3) slow cation grain-boundary diffusion, and (4) the presence of a grain-boundary second phase.     

Low-Temperature Sintering of Seeded Sol—Gel-Derived, ZrO2-Toughened Al2O3 Composites

Seeding a mixture of boehmite (AIOOH) and colloidal ZrO₂ with α-alumina particles and sintering at 1400°C for 100 min results in 98% density. The low sintering temperature, relative to conventional powder processing, is a result of the small alumina particle size (∼0.3 μm) obtained during the θ-to α-alumina transformation, homogeneous mixing, and the uniform structure of the sol-gel system. Complete retention of pure ZrO₂ in the tetragonal phase was obtained to 14 vol% ZTA because of the low-temperature sintering. The critical grain size for tetragonal ZrO₂ was determined to be ∼0.4 μm for the 14 vol% ZrO₂—Al₂O₃ composite. From these results it is proposed that seeded boehmite gels offer significant advantages for process control and alumina matrix composite fabrication.     

Some Observations on the Wetting of Al2O3, by Aluminum

The contact angle of liquid aluminum with recrystallized alumina and with sapphire, respectively, was measured using the sessile-drop technique, The variation in contact angle with time was determined at temperatures of the order of 1200°C. in vacuo at 10-⁴ mm. Hg. A significant difference in spreading behavior was observed for aluminum on the respective aluminas. In the case of aluminum on recrystallized Al₂O₃ the contact angle attained a steady value, whereas on sapphire the drop was observed to spread and contract repeatedly. The contact angle assumed after each contraction was essentially constant. The observations are discussed and an explanation is proposed for the effect in terms of changes in the interfacial geometry between liquid aluminum and the alumina due to dissolution.     

Optically Transparent Polycrystalline Al2O3 Produced by Spark Plasma Sintering

The spark plasma sintering (SPS) technique was used to produce mid-infrared (IR) transparent alumina with the desired transmittance. An excellent transmittance of 85% has been obtained in a sample sintered at 1300°C for 5 min. The heating rate, sintering time, and annealing have a significant influence on IR transmittance. The improvement in transmission may be attributed to the progressive elimination of residual porosity when applying a slower heating rate, longer sintering time during SPS, and postsinter annealing. It is suggested that localized residual strain/stress at grain boundaries and oxygen vacancy concentration are other factors influencing the optical properties of the SPS-sintered alumina.     

Transformation Strengthening of β"Al2O3 with Tetragonal ZrO2

The solid sodium electrolyte β"-Al₂O₃ (Li-stabilized) was strengthened with additions of tetragonal ZrO₂ (15 vol%). The conductivity of this composite material, measured in an Na/Na cell, was 7.7 Ω· at 300°C. Average values of strength and the critical stress intensity factor were 350 MPa and 4.5 MPa·m_1/2, respectively, for the sintered composite material.     

SiC-Whisker-Reinforced Al2O3 Composites by Free Sintering of Coated Powders

SiC whiskers were coated with a thick cladding of finegrained Al₂O₃ powder by controlled heterogeneous precipitation in a concentrated suspension of whiskers. After calcination, the coated whiskers were compacted by cold isostatic pressing and sintered at a constant heating rate of 5°C/min in a helium atmosphere. The parameters which control the coating process and the sintering characteristics of the consolidated powders are reported. Starting with an initial matrix density of 40–45% of the theoretical, composites containing up to ≅20 vol% whiskers (aspect ratio ≅15) were sintered freely to nearly theoretical density below 1800°C. By comparison, a similar composite formed by mechanical mixing of the whiskers and the precipitated Al₂O₃ powder reached a density of only 68% of the theoretical after sintering under identical conditions. For a fixed whisker content, the sinterability of the composites formed from the coated whiskers shows a fairly strong dependence on the whisker aspect ratio.     

Oxygen-Enhanced Crystallization of Solution-Derived 12CaO·7Al2O3

12CaO·7Al₂O₃ (C12A7) composed of nanosize cage structure can clathrate oxygen radicals (O⁻) and has a high potential to application of strong oxidizing catalysis. In the present report, we demonstrate a fabrication route to C12A7 fine powders by Chemical Solution Deposition method in order to enhance the catalytic reactivity. Aluminum sec-butoxide, calcium nitrate tetrahydrate, acetylacetone, 2-methoxyethanol, and nitric acid were used as raw materials. Precursor solution was dried and annealed at 800°–900°C in air or O₂ atmosphere. Crystalline C12A7 powders were obtained by annealing at 900°C in O₂ atmosphere. Scanning electron microscope and transmission electron microscope images of the obtained powders revealed C12A7 particles were sintered and formed several micrometer particles with many pores. BET specific surface area of the powders was 4.2 m²/g. Possibility for synthesizing C12A7 powder with higher specific surface area by the solution process was indicated.     

Reactions Between Aluminum Oxide and Carbon The Al2O3—Al4C3 Phase Diagram

A phase diagram of the system A1₂O₃-A1₄C₃ is proposed. Two intermediate oxycarbides, A1₄O₄C and A1₂OC, were established. Eutectic melting between alumina and A1₄O₄C occurred at 1840° C. No other low melting was observed. The alumina phase was not corundum but was similar to delta-alumina. Because of the high reactivity of aluminum carbide and all the intermediate compounds with moisture and oxygen, use of refractories based on the system A1₂O₃-A1₄C₃ must be limited to applications where these agents are excluded. The behavior of high-alumina refractories in the presence of carbon is explained.     

Effect of Moisture on the High-Temperature Stability of Unidirectionally Solidified Al2O3/YAG Eutectic Composites

The corrosion resistance of a unidirectionally solidified alumina/yttrium aluminum garnet (Al₂O₃/YAG) eutectic mixture was investigated at high temperature. Samples were exposed to high temperature (1200°–1800°C) in different atmospheres, which included argon, argon/water vapor, air, and air/water vapor. The most important microstructural changes occurred at the interface between the YAG and the Al₂O₃. Those changes consisted of localized thermal grooving, especially when the corrosive atmosphere contained water vapor. The samples exhibited significant weight loss at high temperature (1800°C) after 20 h of exposure. The calculated volume gain that was induced by the increased surface relief was low and limited, except when the corrosive atmosphere contained air, which indicated that the presence of air (particularly oxygen) induced a more-active corrosion process. On the other hand, no change in the flexural strength was observed, even after 100 h at 1800°C in a humid atmosphere, because of the cross-linked structure of the composite, which limited propagation of the groove.     

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.     

Anisotropic Calcium Segregation to the Surface of Al2O3

The surface enrichment of Ca on various crystalloraphic planes of CaO-doped sapphire has been measured as a function of annealing temperature using Auger electron spectroscopy (AES). Strong Ca enrichment was found on the (10 1 0) prism plane at ≥1300°C, whereas no evidence or Ca segregation could be observed on the (0001) basal plane up to 1500°C. The surface enrichment factor estimated at 1300°C was at least 3 × 10³ for the prism plane, while that for the basal plane was below 50, which corresponds to the detectability limit of AES. The Ca segregation to the prism plane was uniform and limited to the surface monolayer; an apparent heat of segregation determined in the range of 1300° to 1500°C was–169 kJ/mol. Low-energy electron diffraction studies of annealed surfaces revealed that Ca segregation was concurrent with a two-dimensional surface phase transition. The anisotropic segregation behavior of Ca may explain why CaO is not an effective additive for alumina sintering.