Zircon-Zirconia Ceramics Prepared from Plasma Dissociated Zircon

A ceramic consisting of a dispersion of ZrO₂ particles (∼25%) in zircon was prepared by sintering partially leached plasma dissociated zircon. ZrO₂ particles smaller than ∼150 nm were tetragonal inform; larger particles were monoclinic. The large increase in proportions of tetragonal ZrO₂ after sintering may be ascribed partly to a reduction in particle size by reaction to form zircon, and partly to a matrix effect on the tetragonal to monoclinic transformation.     

Toughening by Monoclinic Zirconia

The toughening induced by monoclinic ZrO₂ in the absence of microcracking was investigated, using ZnO as the host material. Toughness levels K_c in excess of the host toughness K_c^M were achieved, attaining a peak toughness K_c/K_c^M ∼1.7, at monoclinic ZrO₂ volume concentrations 0.2. This toughening is attributed to crack/particle interactions, associated with the deflection and bowing of the crack by the residual strain field around the monoclinic ZrO₂ particles.     

Formation Mechanism of Hydrous-Zirconia Particles Produced by Hydrolysis of ZrOCl2 Solutions: II

The primary and secondary particle sizes of monoclinic hydrous-ZrO₂ particles produced by the hydrolysis of various ZrOCl₂ solutions, with and without the addition of NaCl, CaCl₂, or AlCl₃, were measured using X-ray diffraction and transmission electron microscopy in order to clarify the formation mechanisms of primary and secondary particles. The primary particle size of hydrous ZrO₂, under a constant ZrOCl₂ concentration, decreased monotonously with increasing Cl⁻-ion concentration. On the contrary, the secondary particle size increased monotonously with increasing Cl⁻-ion concentration. The present experimental results revealed that the primary and secondary particle sizes of hydrous ZrO₂ are controlled primarily by the concentrations of H⁺ and Cl⁻ ions produced during hydrolysis, and are independent of the type of added metal ions. The formation mechanisms of the primary and secondary particles of hydrous ZrO₂ were determined on the basis of the present experimental results.     

Measurement of the Crystallographically Transformed Zone Produced by Fracture in Ceramics Containing Tetragonal Zirconia

During fracture of ceramics containing tetragonal zirconia particles, a volume of zirconia material on either side of the crack irreversibly transforms to the monoclinic crystal structure. Transformation zone sizes, measured using Raman microprobe spectroscopy, are presented for three sintered ceramics. In a single-phase ZrO₂−3.5 mol% Y₂O₃ material, an upper bound measurement of 5 μm is obtained for the zone size. In the Al₂O₃/ZrO₂ composites studied, the zone size is deduced to correspond to ∼1 grain in diameter. On the basis of the monoclinic concentrations derived from the Raman spectra it is further concluded that only a fraction of the ZrO₂ grains within the transformation zone transform, providing indirect evidence for the effect of particle size on the propensity for transformation.     

Particle Interactions in Zirconia-Toughened Alumina

In order to determine the effect of the coarse tail of the ZrO₂ size distribution of the monoclinic ZrO₂ content of zirconia-toughened alumina, quantitative hot-stage X-ray measurements were made on (1) A1₂O₃-10% Zr0₂ (submicrometer with a coarse tail >1 μm), (2) A1₂O₃-10% ZrO₂ with the coarse tail of the ZrO₂ carefully removed by centrifugation, and (3) Al₂O₃-10% ZrO₂ in which 10% of Zr0₂(1) and 90% of Zr0₂(2) were used. The monoclinic content of (3) was compared with the weighted average of(1) and (2). A disproportionate amount of monoclinic ZrO₂ was found in (3) and it was concluded that transformation of the coarse particles promotes transformation in finer particles. Microstructural examination supports this conclusion. Results were interpreted as being due both to autocatalytic transformation and to constraint relief from microcracking.     

Crystallization and Transformation of Zirconia Under Hydrothermal Conditions

During constant-rate heating to 350°C in concentrated NaOH solutions, cubic ZrO₂ crystallized at ∼120°C from hydrated amorphous ZrO₂; these One cubic ZrO₂ particles abruptly changed into needlelike monoclinic ZrO₂ single crystals at 300°C. Crystallization and phase transformation were studied by XRD, TEM, and EPMA. Cubic ZrO₂ appears to crystallize via collapse of the ZrO₂−nH₂O structure and subsequent slight rearrangement of the lattice. The abrupt formation of mono-clinic ZrO₂ was considered to result when the very fine cubic ZrO₂ particles coagulated in a highly oriented fashion.     

Growth of Monoclinic ZrO2 Thin, Flaky Crystals by Hydrothermal Decomposition of Zirconium Oxide Sulfate Crystals

Thin platelike hexagonal crystals of zirconium oxide sulfate (ZOS) with a chemical composition of Zr₃O₅SO₄. n H₂O were previously synthesized by the hydrolysis of an aqueous solution of 2 mol/L ZrOSO₄ at 240°C. The ZOS particles obtained were hydrothermally treated again in dilute sulfuric acid solution (<0.15 mol/L) at 240°C. The decomposition of ZOS and the nucleation and growth morphology of the monoclinic ZrO₂ crystals were automatically controlled with increasing sulfuric acid released by the decomposition of ZOS, and were influenced by the morphology of ZOS as precursors. Anisotropic monoclinic ZrO₂ single crystals, elongated thin and flaky particles (length: >2 (Am; width: about 0.1 μm; thickness:«0.01 μm), could be obtained under some conditions without the coexistence of another type of anisotropic ZrO₂ fibrous twin crystal.     

Stability of ZrO2 Phases in Ultrafine ZrO2-Al2O3 Mixtures

Mixtures of ultrafine monoclinic zirconia and aluminum hydroxide were prepared by adding NH₄OH to hydrolyzed zirconia sols containing varied amounts of aluminum sulfate. The mixtures were heat-treated at 500° to 1300°C. The relative stability of monoclinic and tetragonal ZrO₂ in these ultrafine particles was studied by X-ray diffractometry. Growth of ZrO₂ crystallites at elevated temperatures was strongly inhibited by Al₂O₃ derived from aluminum hydroxide. The monoclinic-to-tetragonal phase transformation temperature was lowered to ∼500°C in the mixture containing 10 vol% Al₂O₃, and the tetragonal phase was retained on cooling to room temperature. This behavior may be explained on the basis of Garvie's hypothesis that the surface free energy of tetragonal ZrO₂ is lower than that of the monoclinic form. With increasing A1₂O₃ content, however, the transformation temperature gradually increased, although the growth of ZrO₂ particles was inhibited; this was found to be affected by water vapor formed from aluminum hydroxide on heating. The presence of atmospheric water vapor elevates the transformation temperature for ultrafine ZrO₂. The reverse tetragonal-to-monoclinic transformation is promoted by water vapor at lower temperatures. Accordingly, it was concluded that the monoclinic phase in fine ZrO₂ particles was stabilized by the presence of water vapor, which probably decreases the surface energy.     

Stability of Ultrafine Tetragonal ZrO2 Coprecipitated with Al2O3 by the Spray-ICP Technique

The transformation of ultrafine powders (particle size, 0.01 to 0.04 μm) of the system ZrO_2–Al₂O₃, prepared by spraying their corresponding nitrate solutions into an inductively coupled plasma (ICP) of ultrahigh temperature, was investigated. The powders were composed of metastable tetragonal ZrO₂ ( mt- ZrO₂) and γ-Al₂O₃. On heating, the mt- ZrO₂ (or tetragonal ZrO₂, t -ZrO₂) was retained up to 1200°C. At 1380°C the transformation to monoclinic ZrO₂ ( m -ZrO₂) occurred and the amount of the m -ZrO₂ decreased with the increase in Al₂O₃ content, thus indicating the stabilization of the t -ZrO₂ by the Al₂O₃, which seems to be explained in terms of the retardation of grain growth.     

An Unusual Twin Structure in Transformed Precipitates in Y-PSZ Single Crystals

Mosaic-like monoclinic ZrO₂ particles form in TEM thin foils in 3.4-mol%-Y₂O₃-partially-stabiIized ZrO₂ (Y-PSZ) single crystals aged for 150 h at 1600°C. These particles transformed martensitically during TEM foil preparation; the parent phase existed as internally twinned tetragonal ZrO₂ precipitates which had formed during aging. These monoclinic particles contain (100)_m and {110}_m transformation twins, and the twin variants have uniform thickness. The origin of this transformation microstructure, the lattice correspondences, and the applicability of the invariant plane strain model of martensitic transformations are discussed.     

Formation of Ultrafine Tetragonal ZrO2 Powder Under Hydrothermal Conditions

Ultrafine tetragonal ZrO₂ powder was prepared by hydrothermal treatment at 100 MPa of amorphous hydrous zirconia with distilled water and LiCl and KBr solutions. The resulting powder consisted of well-crystallized particles; at 200°C, the particle size was 16 nm and at 500°C, 30 nm. Under hydrothermal conditions tetragonal ZrO₂ appears to crystallize topotactically on nuclei in the amorphous hydrous zirconia.     

Characterization and Stabilization of Metastable Tetragonal ZrO2

Fine single-domain and polydomain particles of tetragonal ZrO₂ were prepared by hydrothermal and heat treatment of ZrO₂· n H₂O. The particles were characterized by X-ray diffraction, electron microscopy, NMR, mass spectrometry, and ir spectroscopy. The main impurity in the samples was 1 to 2 wt% OH⁻ ions, most of which were concentrated on the particle surfaces or at domain boundaries; some were also distributed in the lattice. Fine single-domain tetragonal particles were strain-free, but polydomain particles had large strains. The single-domain tetragonal particles were transformed much more easily than the polydomain particles by mechanical treatment. The stablization of metastable tetragonal ZrO₂ cannot be explained adequately by the surface-energy theory. An explanation based on the concept of a martensitic transformation may be more reasonable.     

Preparation of Ultrafine Zirconia Particles

Ultrafine ZrO₂ particles have been prepared via a new sol-gel process. This process involves the addition of excess C₂H₄O into the aqueous ZrOCl₂ solution and reacting the mixture at room temperature; a glassy ZrO(OH)₂ gel is formed moments later. An ultrafine ZrO₂ powder is obtained after the gel is dried and calcined; the powder is monoclinic. The average particle size is ∼12 nm, and its specific surface area is 55.1 m²/g. In addition, partially stabilized ZrO₂ can be prepared in the same manner, yielding a good result.     

Fracture Toughness of Al2O3 with an Unstabilized ZrO2Dispersed Phase

The fracture toughness of Al₂O₃ is considerably increased by the incorporation of fine monoclinic ZrO₂ particles. Hot-pressed composites containing 15 vol % ZrO₂ yield K_lcvalues of ∼ 10 MN/m^3/2, twice that of the A1₂O₃ matrix. It is hypothesized that this increase results from a high density of small matrix microcracks absorbing energy by slow propagation. The microcracks are formed by the expansion of ZrO₂during the tetragonal → monoclinic transformation. Since extremely high tensile stresses develop in the matrix, very small ZrO2 particles can act as crack formers, thus limiting the critical flaw size to small values.     

Ultrafine-Grained Dense Monoclinic and Tetragonal Zirconia

Nanoparticles of ZrO₂ with diameters ranging from 4 to 8 nm were synthesized by gas condensation. As-prepared n -ZrO₂ particles have a monoclinic and a high-pressure tetragonal structure depending on size. Pure ZrO₂ was sintered to full density under vacuum at 04 T _m within the monoclinic phase field. Final grain sizes in theoretically dense pellets are below 60 nm. By sintering below the monoclinic–tetragonal transition temperature, microcracking was completely avoided. Tetragonal ZrO₂ stabilized with 3 mol% Y₂O₃ was prepared by interdiffusion of nanoparticles and sintered to near-theoretical density.     

Homogeneous ZrO2–Al2O3 Composite Prepared by Nano-ZrO2 Particle Multilayer-Coated Al2O3 Particles

ZrO₂–Al₂O₃ nanocomposite particles were synthesized by coating nano-ZrO₂ particles on the surface of Al₂O₃ particles via the layer-by-layer (LBL) method. Polyacrylic acid (PAA) adsorption successfully modified the Al₂O₃ surface charge. Multilayer coating was successfully implemented, which was characterized by ξ potential, particle size. X-ray diffraction patterns showed that the content of ZrO₂ in the final powders could be well controlled by the LBL method. The powders coated with three layers of nano-ZrO₂ particles, which contained about 12 wt% ZrO₂, were compacted by dry press and cold isostatically pressed methods. After sintering the compact at 1450°C for 2 h under atmosphere, a sintered body with a low pore microstructure was obtained. Scanning electron microscopy micrographs of the sintered body indicated that ZrO₂ was well dispersed in the Al₂O₃ matrix.     

Twinning and Microcracking Associated with Monoclinic Zirconia in the Eutectic System Zirconia–Mullite

Crystallography and morphology of twins and microcracks in the eutectic system mullite–zirconia are discussed in view of the tetragonal-to-monoclinic transformation and associated toughening mechanisms. Specific twin relationships were observed in monoclinic ZrO₂. Highly symmetric and crystallographically well-defined microcracks were observed at the mullite–ZrO₂ interface. Microdiffraction revealed closely related crystallography of monnoclinic twins and microcracks. The number of twin variants depend on the monoclinic ZrO₂ particle size. A method to calculate twinning shear strain using microcrack morphology is suggested. This parameter is essential in several fracture-mechanics calculations.     

Crystallization of MgO-Al2O3-SiO2-ZrO2 Glasses

The crystallization of MgO-Al₂O₃-SiO₂-ZrO₂ glasses at 1000°C was studied. Isothermal heat treatments of a cordierite-based glass (2MgO.2Al₂O₃.5SiO₂= Mg₂Al₄Si₅O₁₈) with 7 wt% ZrO₂ produced surface crystallization of α-cordierite and tetragonal ZrO₂ ( t -ZrO₂). These phases advanced into the glass by cocrystallization of t -ZrO₂ rods in an α-cordierite matrix with a well-defined orientation relation. The t -ZrO₂ rods were unstable with respect to diffusional breakup (a Rayleigh instability) and decomposed into rows of aligned ellipsoidal and spheroidal particles. The t -ZrO₂ was very resistant to transformation to monoclinic symmetry. With a similar glass containing 15 wt% ZrO₂, surface crystallization of α-cordierite and t -ZrO₂ was accompanied by internal crystallization of t -ZrO₂ dendrites. Transformation of the dendrites to mono-clinic symmetry was observed under some conditions.     

Infrared Absorption Spectroscopy in Zirconia Research

Infrared absorption spectra are shown for monoclinic ZrO₂ and for cubic stabilized ZrO₂. Nine bands are reported in monoclinic ZrO₂ in the region 800 to 200 cm^−l, whereas only one broad band is observed in cubic ZrO₂ over the same frequency range.     

Microstructural Studies in Alkoxide-Derived Mullite/Zirconia/Silicon Carbide-Whisker Composites

Mullite composites toughened with ZrO₂ (with or without a MgO or Y₂O₃ stabilizer) and/or SiC whiskers (SiC( w )) were fabricated by hot-pressing powders prepared from Al, Si, Zr, and Mg(Y) alkoxide precursors by a sol–gel process. Micro-structures were studied by using XRD. SEM, and analytical STEM. Pure mullite samples contained prismatic, preferentially oriented mullite grains. However, the addition of ZrO₂, as well as the hot-pressing temperature, affected the morphology and grain size in the composites; a fine, uniform, equiaxed microstructure was obtained. The effect of SiC( W ) was less pronounced than that of ZrO₂. Glassy phases were present in mullite and mullite/SiC( W ) composites, but were rarely observed in Al₂O₃-rich or ZrO₂-containing samples. The formation of zircon due to the reaction between ZrO₂ and SiO₂ and the considerable solid solution of SiO₂ in ZrO₂ prevented the formation of the glassy phase, whereas the reaction between Al₂O₃ and MgO in MgO-containing samples formed a spinel phase and also deprived the ZrO₂ phase of the stabilizer. Intergranular ZrO₂ particles were either monoclinic or tetragonal, depending on size and stabilizer content; small intragranular ZrO₂ inclusions were usually tetragonal in structure.