Synthesis and Characterization of MgAl2O4 Spinel Precursor from a Heterogeneous Alkoxide Solution Containing Fine MgO Powder

A precursor was synthesized from a heterogeneous alkoxide solution that contained fine MgO powder, which allowed the preparation of MgAl₂O₄ spinel powder with high sinterability characteristics. The precursor consisted of a mixture of boehmite (AlO(OH)) and a mixed hydroxide (Mg₄Al₂(OH)₁₄· 3H₂O). The spinel phase formed through two steps: (i) decomposition of the mixed hydroxide at low temperature and (ii) solid-state reaction between MgO and γ-Al₂O₃ at higher temperatures. Dense polycrystalline spinel could be obtained from the calcined powders at sintering temperatures as low as 1400°C.     

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.     

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.     

Electrochemical Determination of the Gibbs Energy of Formation of MgAl2O4

The standard Gibbs energy of formation of the spinel MgAl₂O₄ from component oxides, MgO and α-Al₂O₃, has been determined in the temperature range 900 to 1250 K using a solid-state cell incorporating single-crystal CaF₂ as the solid electrolyte. The cell can be represented as—Pt,O₂,MgO+MgF₂|CaF₂|MgF₂+MgAl₂O₄+α-Al₂O₃,O₂,Pt—The standard Gibbs energy of formation from binary oxides, computed from the reversible emf, can be represented by the expression—capdelta G °_f,ox=−23600 − 5.91 T (±150) J/mol—The 'second-law' enthalpy of formation of MgAl₂O₄ obtained in this study is in good agreement with high-temperature solution calorimetric studies reported in the literature.     

Mechanical Properties of Hot Isostatically Pressed Zirconia-Toughened Alumina Ceramics Prepared from Coprecipitated Powders

Amorphous Al₂O₃–ZrO₂ composite powders with 5–30 mol% ZrO₂ have been prepared by adding aqueous ammonia to the mixed solution of aqueous aluminum sulfate and zirconium alkoxide containing 2-propanol. Simultaneous crystallization of γ-Al₂O₃ and t -ZrO₂ occurs at 870°–980°C. The γ-Al₂O₃ transforms to α-Al₂O₃ at 1160°–1220°C. Hot isostatic pressing has been performed for 1 h at 1400°C under 196 MPa using α-Al₂O₃– t -ZrO₂ composite powders. Dense ZrO₂-toughened Al₂O₃ (ZTA) ceramics with homogeneous-dispersed ZrO₂ particles show excellent mechanical properties. The toughening mechanism is discussed. The microstructures and t / m ratios of ZTA are examined, with emphasis on the relation between strength and fracture toughness.     

Estimation of Hamaker Constants of Ceramic Materials from Optical Data Using Lifshitz Theory

The Hamaker constants of eight different ceramic materials, 6H-SiC, tetragonal, partially stabilized ZrO₂ (3% Y₂O₃), β-Si₃N₄, α-Al₂O₃, Y₂O₃, sapphire (single-crystal α-Al₂O₃), MgO, MgAl₂O₄, and fused silica, across air, water, and n -dodecane at room temperature and across silica at 2000 K have been calculated from optical data using the Lifshitz theory. Spectroscopic ellipsometry was used to measure the photon energy dependence of the refractive index, n , and the extinction coefficient, k , in the visible and near-UV range on several important ceramic materials. This relatively simple, nondestructive technique has proved to yield reliable optical data on sintered, polycrystalline materials such as Si₃N₄, SiC, ZrO₂, Al₂O₃, and ZnO. For the other materials, Y₂O₃, sapphire, MgO, MgAl₂O₄, and fused silica, optical data from the literature were used to calculate the Hamaker constants. The calculated Hamaker constants were estimated to be accurate within ±10%.     

Mechanical-Activation-Triggered Gibbsite-to-Boehmite Transition and Activation-Derived Alumina Powders

Mechanical activation of monoclinic gibbsite (Al(OH)₃) in nitrogen led to the formation of nanocrystalline orthorhombic boehmite (AlOOH) at room temperature. The boehmite phase formed after merely 3 h of mechanical activation and developed steadily as the mechanical-activation time increased. Forty hours of mechanical activation resulted in essentially single-phase boehmite, together with α-alumina (α-Al₂O₃) nanocrystallites 2–3 nm in size. The sequence of phase transitions in the activation-derived boehmite was as follows: boehmite to γ-Al₂O₃ and then to α-Al₂O₃ when flash-calcined at a heating rate of 10°C/min in air. γ-Al₂O₃ formed at 520°C, and flash calcination to 1100°C led to the formation of an α-Al₂O₃ phase, which exhibited a refined particle size in the range of 100–200 nm. In contrast, the gibbsite-to-boehmite transition in the unactivated gibbsite occurred over the temperature range of 220°–330°C. A flash-calcination temperature of 1400°C was required to complete the conversion to α-Al₂O₃ phase, with both δ-Al₂O₃ and θ-Al₂O₃ as the transitional phases. The resulting alumina powder consisted of irregularly shaped particles 0.4–0.8 μm in size, together with an extensive degree of particle agglomeration.     

Synthesis of AlN Nanopowder from γ-Al2O3 by Reduction–Nitridation in a Mixture of NH3–C3H8

Aluminum nitride (AlN) powders were synthesized by gas reduction–nitridation of γ-Al₂O₃ using NH₃ and C₃H₈ as the reactant gases. AlN was identified in the products synthesized at 1100°–1400°C for 120 min in the NH₃–C₃H₈ gas flow confirming that AlN can be formed by the gas reduction–nitridation of γ-Al₂O₃. The products synthesized at 1100°C for 120 min contained unreacted γ-Al₂O₃. The ²⁷A1 MAS NMR spectra show that Al–N bonding in the product increases with increasing reaction temperature, the tetrahedral AlO₄ resonance decreasing prior to the disappearance of the octahedral AlO₆ resonance. This suggests that the tetrahedral AlO₄ sites of the γ-Al₂O₃ are preferentially nitrided than the AlO₆ sites. AlN nanoparticles were directly formed from γ-Al₂O₃ at low temperature because of this preferred nitridation of AlO₄ sites in the reactant. AlN nanoparticles are formed by gas reduction–nitridation of γ-Al₂O₃ not only because the reaction temperature is sufficiently low to restrict grain growth, but also because γ-Al₂O₃ contains both AlO₄ and AlO₆ sites, by contrast with α-Al₂O₃ which contains only AlO₆.     

Formation of Al2O3/Metal Composites by the Directed Oxidation of Molten Aluminum-Magnesium-Silicon Alloys: Part I, Microstructural Development

The growth of α-Al₂O₃/metal composites by the directed oxidation of molten Al-Mg-Si alloys proceeds through four distinct stages. The first stage encompasses the early heating of the alloy ingot, melting, and continued heating to between 1123 and 1173 K. In this latter temperature range, the molten alloy surface rapidly oxidizes to form a MgO-covered MgAl₂O₄ layer. During further heating and initial soak at the composite growth temperature (1373 to 1573 K), the duplex layer slowly thickens (second stage). The start of the third stage, growth initiation, is marked by the spread of a metal-rich zone over the duplex layer; this metal-rich zone is believed to be connected to the molten alloy through microcracks in the thickened MgO/MgAl₂O₄ layer. Small nodules of the oxide/metal composite nucleate from the metal-rich layer. During the final rapid growth stage, the small composite nodules grow and coalesce to form a macroscopically planar growth front, which persists until growth is complete. Throughout the growth process, the external surface of the α-Al₂O₃/metal composite is covered by a thin MgO layer. Immediately under this external layer and separating it from the α-Al₂O₃ is a thin layer of molten metal.     

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.     

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.     

Formation of Zirconia Solid Solutions Containing Alumina Prepared by New Preparation Method

In the system ZrO₂–Al₂O₃, a new method for preparing ZrO₂ solid solutions from ZrCl₄ and AlCl₃ using hydrazine monohydrate is investigated. c -ZrO₂ solid solutions containing up to ∼40 mol% Al₂O₃ crystallize at low temperatures from amorphous materials. The formation mechanism is discussed from IR spectral data. The values of the lattice parameter α increase linearly from 0.5072 to 0.5105 nm with increasing Al₂O₃ content. At higher temperatures, transformation of the solid solutions proceeds as follows: c ( SS ) → t ( ss ) → t ( ss ) +α-Al₂O₃→ m +α-Al₂O₃. m -ZrO₂–α-Al₂O₃ composite ceramics are fabricated by hot isostatic pressing for 2 h at 1250°C and 196 MPa. Microstructures and mechanical properties are examined, in connection with increasing Al₂O₃ content.     

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.     

Seeding with γ-Alumina for Transformation and Microstructure Control in Boehmite-Derived α-Alumina

The dehydration, transformation, and densification of boehmite (γ-AlOOH) are enhanced by addition of γ-Al₂O₃ seed particles. α-Al₂O₃ microstructures with uniform 1- to 2-μm grain size and sintered densities 98% of theoretical are achieved at 1300°C Thermal analysis shows that γ-Al₂O₃ seed particles transform to α-Al₂O₃ before the matrix, thus controllably nucleating the transformation of θ-AI₂O₃ to α-Al₂O₃.     

Thermochemistry of MgAl2O4-Al8/3O4 Defect Spinels

Solution calorimetry of MgAl₂O₄-Al_8/3O₄ solid solutions was performed in a molten 2PbO · B₂O₃ solvent at 975 K. The results indicate small negative heats of mixing, relative to spinel standard states for both end-members. These data were combined with information on the energetics of the α-γ transition in Al₂O₃ and on the MgAl₂O₄-Al_8/3O₄ (MgO-Al₂O₃) subsolidus phase relations to estimate the partial molar entropy of mixing of γ-Al_8/3O₄ in the solid solution. This entropy is much less positive than that calculated from several models for the configurational entropy of mixing of magnesium, aluminum, and vacancies on octahedral and/or tetrahedral sites. The data suggest a good deal of local order to be present in the solid solutions, consistent with negative enthalpies of mixing and entropies of mixing far less than ideal configurational values.     

Preparation and Properties of Hydrothermally Stable γ-Alumina Membranes

Supported mesoporous γ-Al₂O₃ membranes deteriorate and blister in steam-containing environments at high temperatures. This deterioration led us to the development of a new type of supported γ-Al₂O₃ membrane with significantly improved stability under hostile conditions. Two measures were taken to achieve this result. First, the γ-Al₂O₃ itself was stabilized by an addition of 6 mol% La₂O₃ to suppress pore growth of the mesoporous structure. Second, the adherence of the γ-Al₂O₃ membrane to the α-Al₂O₃ support was significantly improved by application of phosphate bonding between the membrane layer and the support, using an Al(H₂PO₄)₃ precursor solution. Membranes applied without phosphate bonding were separated from the α-Al₂O₃ support during high-temperature steam treatment, resulting in complete loss of separative properties. The newly developed membranes could be operated for 100 h at 600°C in H₂O/CH₄= 3/1 (by volume) at 2.5 MPa total pressure with no delamination or cracking in the membrane–support interface and with no significant pore growth in the γ-Al₂O₃ membrane.     

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.     

Synthesis of α-Alumina Hexagonal Platelets Using a Mixture of Boehmite and Potassium Sulfate

Single-crystal α-alumina (Al₂O₃) hexagonal platelets with a diameter of about 200 nm and 25 nm in thickness were synthesized by heating a mixture of boehmite and potassium sulfate at 1000°C for 2 h and washing with water. The potassium sulfate addition effects on the Al₂O₃ phase and morphology were investigated using differential thermal analysis (DTA), X-ray diffraction (XRD), and transmission electron microscopy (TEM). It was found that potassium sulfate addition helps in the formation of single-crystal α-Al₂O₃ hexagonal platelets and promotes phase transformation from intermediate γ-Al₂O₃ to α-Al₂O₃.     

Liquid-Phase-Assisted Transformation of Seeded γ-Alumina

α-Al₂O₃-seeded, boehmite-derived γ-Al₂O₃ was transformed in the presence of V₂O₅, resulting in a 205°C decrease in the α-Al₂O₃ transformation temperature and a 74% reduction in the apparent activation energy for the γ- to α-Al₂O₃ transformation at temperatures greater than 850°C. These changes are attributed to the lowered energy barrier for nucleation by seeding and the lowered activation energy for material transport through the liquid relative to the unseeded, solid-state transformation. Growth of the transforming alumina yielded fine-grained α-Al₂O₃ particles which exhibited a highly faceted morphology. It is proposed that the combined control of both nucleation and growth during liquid-phase-assisted transformation provides a potentially powerful technique for tailoring powder characteristics in many material systems which undergo nucleation and growth processes.     

Analysis of Phase Distribution for Ceramic Coatings Formed by Microarc Oxidation on Aluminum Alloy

The phase distribution for ceramic coatings formed by microarc oxidation (MAO) on 2024 aluminum alloy was investigated using X-ray diffraction. The results showed that the ceramic coatings mainly consisted of α-Al₂O₃ and γ-Al₂O₃ phases. The percentage of α-Al₂O₃ gradually increased from the external surface to the interface between the coating and the substrate of samples. The surface layer of coatings mainly contained the γ-Al₂O₃ phase, and its fraction of the composition remained almost constant with oxidation time. It is believed that the difference in the amounts of α-Al₂O₃ and γ-Al₂O₃ phases in the different layers of coatings was caused by the various cooling rates of molten Al₂O₃, which temporarily existed in the microarc zone.