Superplastic Alumina Ceramics with Grain Growth Inhibitors

Superplastic deformation of alumina ceramics was studied at 1400° to 1450°C and at a strain rate of 4 × 10⁻⁵ to 5 × 10⁻⁴ s⁻¹. MgO and ZrO₂ were introduced to suppress dynamic grain growth. The latter was especially effective; grain growth was minimal in 10-vol%-ZrO₂-containing material. Both materials were superplastically stretched under biaxial tension to 100% engineering strain with good surface finishing, demonstrating the feasibility of superplastic forming for alumina ceramics.     

Microstructure and High-Temperature Corrosion Behavior of a Cr–Al–C Composite

A Cr–Al–C composite was successfully synthesized by a hot-pressing method using Cr, Al, and graphite as starting materials. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that the composite contained Cr₂AlC, AlCr₂, Al₈Cr₅, and Cr₇C₃. The orientation relationships and atomic-scale interfacial microstructures among Cr₂AlC, AlCr₂, and Al₈Cr₅ are presented. This composite displays both excellent high-temperature oxidation resistance in air and hot-corrosion resistance against molten Na₂SO₄ salt. The parabolic rate constants for the oxidation in air at 1000°, 1100°, and 1200°C are 3.0 × 10⁻¹², 6.2 × 10⁻¹¹, and 6.2 × 10⁻¹⁰ kg² (m⁴·s)⁻¹, respectively, while the linear weight gain rates for the hot corrosion of Na₂SO₄-coated samples at 900° and 1000°C are, respectively, 1.2 × 10⁻³ and 4.4 × 10⁻³ mg (cm²·h)⁻¹. The mechanism of the excellent high-temperature corrosion resistance can be attributed to the formation of a protectively alumina-rich scale.     

Sintering and Properties of Monazite-Type CePO4

Monazite-type CePO₄ powder (average grain size 0.3 μm) was dry-pressed to disks or bars. The green compacts began to sinter above 950°C. Relative density ≧ 99% and apparent porosity <1% were achieved when the specimens were sintered at 1500°C for 1 h in air. The linear thermal expansion coefficient and thermal conductivity of the CePO₄ ceramics were 9 × 10⁻⁶/°C to 11 × 10⁻⁶/°C (200° to 1300°C) and 1.81 W/(m · K) (500°C), respectively. Bending strength of the ceramics (average grain size 4 μm) was 174 ± 28 MPa (room temperature). The CePO₄ ceramics were cracked or decomposed by acidic or alkaline aqueous solutions at high temperatures.     

Simple and Inexpensive Flash Technique for Determining Thermal Diffusivity of Ceramics

A simple technique for determining the thermal diffusivity of ceramics at room temperature is presented. The technique is a variant of the well-known flash technique, but uses an inexpensive photo flash as the energy source, a fast-response paste-on thermocouple, and a precision digital voltmeter to measure the temperature rise. A data analysis technique, which does not need any knowledge of either the initial or the maximum sample temperature, is presented. Good agreement with the laser-flash technique for ceramics with thermal diffusivities in the range 0.5 × 10⁻⁶ to 75 × 10⁻⁶ m²· s⁻¹ is obtained. Measurements of thermal diffusivity of stainless steel and graphite (standard reference materials) indicate that the method is accurate to within 3%.     

Mechanical Properties and Failure Analysis of Alumina-Glass Dental Composites

Strength measurements and fractography were used to investigate the failure of alumina-glass dental composites containing 75 vol% alumina and 25 vol% glass. Alumina compacts were prepared by slip casting and sintering at 1100°C for 2 h. Dense composites were made by infiltrating partially sintered alumina with glass at 1150°C for 8 h. Young's modulus and the hardness of the composites were 270 GPa and 12 GPa, respectively. The mean strength (460 MPa) and fracture toughness (4.0 MPa·m^1/2) of the composites were insensitive to the glass thermal expansion coefficient (α_glass= 5.9 × 10⁻⁶ to 7.8 × 10⁻⁶°C⁻¹). Typical flaws were pores and cracklike voids formed by poor particle packing and differential sintering near agglomerates of alumina in the composite. Crack deflection and crack bridging were observed in indentation cracks. Fracture toughness was single-valued because the alumina particle size was small (∼3 μm). Alumina-glass composites are promising new ceramics for dental crown and bridge applications, because their strength and fracture toughness are ∼2 times greater than those of current dental ceramics.     

Effect of Microstructure on the Tribological and Mechanical Properties of CuO-Doped 3Y-TZP Ceramics

Dense 8 mol% CuO-doped 3Y-TZP ceramics were prepared by pressureless sintering for 8 h at 1500° and 1550°C, respectively. Transmission electron spectroscopy revealed that the ceramic sintered at 1500°C exhibits grain boundaries free of any amorphous phase, while crystalline copper-oxide grains were found in the zirconia matrix, whereas the sample sintered at 1550°C contains a Cu-rich amorphous grain boundary layer. The tribological behavior of these materials was tested under dry-sliding conditions using a pin-on-disk tribometer. The material sintered at 1500°C showed self-lubrication resulting in a low coefficient of friction ( f ) of 0.2–0.3 and a low specific wear rate ( k ) ≪ 10⁻⁶ mm³·(N·m)⁻¹. In contrast, the material sintered at 1550°C showed poor tribological behavior ( f =0.8–0.9; k ≫ 10⁻⁶ mm³·(N·m)⁻¹ under the same conditions. The difference in the tribological behavior of these two materials was interpreted on the basis of mechanical properties and microstructural characteristics.     

Pyroelectric and Dielectric Properties of Mn Modified 0.82Bi0.5Na0.5TiO3–0.18Bi0.5K0.5TiO3 Lead-Free Thick Films

MnO-doped 0.82Bi_0.5Na_0.5TiO₃–0.18Bi_0.5K_0.5TiO₃(NBT–KBT) thick films with thickness about 40 μm have been prepared using screen printing on Pt electroded alumina substrates. The strong pyroelectric coefficient of 3.8 × 10⁻⁴ C·(m²·°C)^–1 was observed in 1.0 mol% MnO-doped-thick films, and the calculated detectivity figure of merit as high as 1.1 × 10⁻⁵ Pa^−0.5, which can be comparable to that of the commonly used lead based materials. The enhancement of the pyroelectric performances is attributed to the reductions in dielectric constant and loss and the improvements in the pyroelectric coefficient, which can be ascribed to the Mn acts as a hard dopant in the NBT–KBT lattice, creating oxygen vacancies and pinning the residual domains.     

Mechanical and Thermal Properties of Antiperovskite Ti3AlC Prepared by an In Situ Reaction/Hot-Pressing Route

Bulk Ti₃AlC ceramic containing 2.68 wt% TiC was prepared by an in situ reaction/hot-pressing route. The reaction path, microstructure, mechanical and thermal properties were systematically investigated. At room temperature Vickers hardness of Ti₃AlC ceramic is 7.8 GPa. The flexural strength, compressive strength, and fracture toughness are 182, 708 MPa, and 2.6 MPa·m^1/2, respectively. Its apparent Young's modulus, shear modulus, bulk modulus and Possion's ratio are 208.9, 83.4, 140.4 GPa, and 0.25 at room temperature. Apparent Young's modulus decreases slowly with the increasing temperature, and at 1210°C the modulus is 170 GPa. The average coefficient of thermal expansion of Ti₃AlC ceramic is about 10.1 × 10⁻⁶ K⁻¹ in the temperature range of 150°–1200°C. Both the molar heat capacity and thermal conductivity increase with an increase in the temperature. At 300 and 1373 K, the molar heat capacities are 87 and 143·J·(mol·K)⁻¹, while the thermal conductivities are 8.19 and 15.6 W·(m·K)⁻¹, respectively.     

In Situ Reaction Synthesis, Electrical and Thermal, and Mechanical Properties of Nb4AlC3

In this work, a bulk Nb₄AlC₃ ceramic was prepared by an in situ reaction/hot pressing method using Nb, Al, and C as the starting materials. The reaction path, microstructure, physical, and mechanical properties of Nb₄AlC₃ were systematically investigated. The thermal expansion coefficient was determined as 7.2 × 10⁻⁶ K⁻¹ in the temperature range of 200°–1100°C. The thermal conductivity of Nb₄AlC₃ increased from 13.5 W·(m·K)⁻¹ at room temperature to 21.2 W·(m·K)⁻¹ at 1227°C, and the electrical conductivity decreased from 3.35 × 10⁶ to 1.13 × 10⁶Ω⁻¹·m⁻¹ in a temperature range of 5–300 K. Nb₄AlC₃ possessed a low hardness of 2.6 GPa, high flexural strength of 346 MPa, and high fracture toughness of 7.1 MPa·m^1/2. Most significantly, Nb₄AlC₃ could retain high modulus and strength up to very high temperatures. The Young's modulus at 1580°C was 241 GPa (79% of that at room temperature), and the flexural strength could retain the ambient strength value without any degradation up to the maximum measured temperature of 1400°C.     

Tribological Behavior of Ti2SC at Ambient and Elevated Temperatures

The tribological properties of Ti₂SC were investigated at ambient temperatures and 550°C against Ni-based superalloys Inconel 718 (Inc718) and alumina (Al₂O₃) counterparts. The tests were performed using a tab-on-disk method at 1 m/s and 3N (≈0.08 MPa). At room temperature, against the superalloy, the coefficient of friction, μ, was ∼0.6, and at ∼8 × 10⁻⁴ mm³·(N·m)⁻¹ the specific wear rate (SWRs), was high. However, against Al₂O₃, at ∼5 × 10⁻⁵ mm³·(N·m)⁻¹ and ∼0.3, the SWRs and μ were significantly lower, which was presumably related to more intensive tribo-oxidation at the contact points. At 550°C, the Ti₂SC/Inc718 and Al₂O₃ tribocouples demonstrated comparable μ's of ∼0.35–0.5 and SWRs of ∼7–8 × 10⁻⁵ mm³·(N·m)⁻¹. At 550°C, all tribosurfaces were covered by X-ray amorphous oxide tribofilms. At present, Ti₂SC is the only member of a family of the layered ternary carbides and nitrides (MAX phases) that can be used as a tribo-partner against Al₂O₃ in the wide temperature range from ambient to 550°C.     

Microstructural and Thermoelectric Characteristics of Zinc Oxide-Based Thermoelectric Materials Fabricated Using a Spark Plasma Sintering Process

M-doped zinc oxide (ZnO) (M=Al and/or Ni) thermoelectric materials were fully densified at a temperature lower than 1000°C using a spark plasma sintering technique and their microstructural evolution and thermoelectric characteristics were investigated. The addition of Al₂O₃ reduced the surface evaporation of pure ZnO and suppressed grain growth by the formation of a secondary phase. The addition of NiO promoted the formation of a solid solution with the ZnO crystal structure and caused severe grain growth. The co-addition of Al₂O₃ and NiO produced a homogeneous microstructure with a good grain boundary distribution. The microstructural characteristics induced by the co-addition of Al₂O₃ and NiO have a major role in increasing the electrical conductivity and decreasing the thermal conductivity, resulting from an increase in carrier concentration and the phonon scattering effect, respectively, and therefore improving the thermoelectric properties. The ZnO specimen, which was sintered at 1000°C with the co-addition of Al₂O₃ and NiO, exhibited a ZT value of 0.6 × 10⁻³ K⁻¹, electrical conductivity of 1.7 × 10⁻⁴Ω⁻¹·m⁻¹, the thermal conductivity of 5.16 W·(m·K)⁻¹, and Seebeck coefficient of −425.4 μV/K at 900°C. The ZT value obtained respects the 30% increase compared with the previously reported value, 0.4 × 10⁻³ K⁻¹, in the literature.     

Conduction Mechanism of Single-Crystal Alumina

The electrical conductivity of high-purity single-crystal alumina is determined in a temperature range from 400° to 1300°C. By applying an advanced fully guarded threeterminal measurement technique, reliable conductivity measurements are performed to as low as 10⁻¹⁷Ω⁻¹· cm⁻¹. Gas and surface conduction are measured separately and shown to be negligible. High-purity sapphire exhibits a conductivity of 10⁻¹⁶Ω⁻¹· cm⁻¹ at 400°C, two characteristic activation energies of 0.4 and 4.8 eV with increasing temperature, and a conductivity of 3 × 10⁻⁸Ω⁻¹· cm⁻¹ at 1300°C. The fraction of the current carried by ions is determined by electron probe analysis of the electrodes following a 640-h transference test at 1200°C with 4 kV/cm field applied. Only 0.3% of the current at 1200°C is carried by ions. A mathematical model of electrical conduction in sapphire is developed which describes sapphire as a wide-bandgap semiconductor, doped with one dominant donor and one dominant acceptor. The observed conductivity is well described by the model over the entire temperature range from 400° to 1300°C.     

Correlation Between the Microstructure and the Electrical Properties of ZrTiO4 Ceramics

A series of ZrTiO₄ (ZT) ceramics were prepared by sintering ball-milled precursor powders. Ceramics with homogenously dispersed micropores containing both low-temperature (ordered) and high-temperature (disordered) ZrTiO₄ phases were achieved by sintering at 1400°C. The porosity and the morphology were modified by changing the sintering time. The impedance spectra followed the observed changes in the ceramics' microstructure. The grain boundaries' shape, rather than the grain size, has the major influence on the conductivity. The lowest value for electrical conductivity, 8.1 × 10⁻¹⁰ (Ω·m)⁻¹, was obtained in the ceramics sintered at 1400°C for 4 h. This confirms the blocking effect of the imperfect grain boundaries; i.e., the defects of the grain boundaries, which were formed during the grain growth, were followed by an almost complete loss of pores.     

Oxidation Behavior of SiCN–ZrO2 Fiber Prepared from Alkoxide-Modified Silazane

The oxidation behavior of SiCN–ZrO₂ fibers and SiCN at 1350°C are compared. The as-measured parabolic rate constants for the two materials are nearly the same (15–20 × 10⁻¹⁸ m²/s). However, after implementing a correction for the difference in the compositions, the rate constant is 13.2 × 10⁻¹⁸ m²/s for the fiber, and 29.4 × 10⁻¹⁸ m²/s for SiCN. The lower oxidation rate of the fiber is ascribed to the lower carbon content in the fiber material.     

Microstructure and Mechanical Properties of Hot-Pressed α-Al2O3-Seeded γ-Alumina Ceramics

High-quality alumina ceramics were fabricated by a hot pressing with MgO and SiO₂ as additives using α-Al₂O₃-seeded nanocrystalline γ-Al₂O₃ powders as the raw material. Densification behavior, microstructure evolution, and mechanical properties of alumina were investigated from 1250°C to 1450°C. The seeded γ-Al₂O₃ sintered to 98% relative density at 1300°C. Obvious grain growth was observed at 1400°C and plate-like grains formed at 1450°C. For the 1350°C hot-pressed alumina ceramics, the grain boundary regions were generally clean. Spinel and mullite formed in the triple-grain junction regions. The bending strength and fracture toughness were 565 MPa and 4.5 MPa·m^1/2, respectively. For the 1300°C sintered alumina ceramics, the corresponding values were 492 MPa and 4.9 MPa·m^1/2.     

Oxygen Self-Diffusion in Single-Crystal Mn-Zn Ferrite

Self-diffusion coefficients for the oxygen ion in single-crystal Mn-Zn ferrite were determined by the gas-solid isotope exchange technique. The oxygen volume diffusion coefficients can be expressed as D =6.70 × 10⁻⁴ exp (-330 (kJ /mol) /RT)m₂/s (>1350°C), D=3.94 × 10⁻¹⁰ exp (−137 (kJ/mol)/RT)m²/s (1100° to 1350°C), and D=7.82 × 10⁴ exp (−507 (kJ/mol)/RT)m²/s (<1100°C).     

Synthesis of Nanoparticulate Silica Composite Membranes by the Pressurized Sol–Gel Technique

A crack-free silica composite membrane has been synthesized from a nanoparticulate silica sol (particle diameter <10 nm) by a pressurized sol–gel coating technique developed in this study. The microporous silica layers with an estimated pore radius of 0.78 nm were deposited inside the pores (average pore size of 0.1 μm) of slip cast a-alumina support tubes. The microstructure of the coated layer was controlled by adjusting sol properties and pressurizing conditions. The room-temperature intrinsic permeability of N₂ through the silica membrane layer after heat treatment at 200°C is about 4.9 × 10⁻¹² mol·m/m²·s· Pa, and the mechanism of gas transport is Knudsen flow. The thermal stability of the silica composite membrane is excellent up to 500°C.     

Characterization of Material for Low-Temperature Sintered Multilayer Ceramic Substrates

The sintering temperature of multilayer ceramic substrates must decrease to 1000° or below to avoid melting the conductors (Pd-Ag, Au, or Cu) during sintering. In this study, SiO₂, CaO, B₂O₃, and MgO were used as additives to Al₂O₃ to decrease the firing temperature by liquid-phase sintering. Compositions with 18.0 and 22.5 wt% B₂O₃ were sintered at around 1000° in an air atmosphere to yield dense ceramics with good properties: relative dielectric contant between 6 to 7 (1 MHz), tan δ≤× 3 × 10⁻⁴ (1 MHz), insulating resistivity > 10¹⁴ω cm, coefficient of thermal expansion ∼ 7.0 × 10⁻⁶/°, and thermal conductivity ∼ 4.1 W/(m · K).     

Minimization of Parasitic Currents in High-Temperature Conductivity Measurements on High-Resistivity Insulators

An experimental setup and novel measurement technique are described which allow reliable conductivity measurements to be made at conductivities as low as 10⁻¹⁷Ω⁻¹.cm⁻¹ and temperatures up to at least 1300°C. This capability is of particular interest for conductivity measurements on high-resistivity insulators over a large range of temperatures. This technique has been used to measure the conductivity of single-crystal alumina from 400° to 1300°C in a 10⁻⁷ torr (∼1.3 × 10⁻⁵ Pa) vacuum, equivalent to an oxygen partial pressure of about 10⁻⁸ torr (∼1.3 × 10⁻¹¹ atm or ∼ 1.3 × 10⁻⁶ Pa). Surface and gas-phase conductance are determined as a function of temperature, and the requirements for their minimization are described. A key requirement is a very low voltage between the volume guard and the guarded electrode. The effect of leakage currents due to the sample fixture, electrical feedthroughs, and electronic instrumentation are also evaluated, and proper design features to make these effects negligible are outlined.     

Fabrication of Porous PZT–PZN Piezoelectric Ceramics With High Hydrostatic Figure of Merits Using Camphene-Based Freeze Casting

Porous lead zirconate titanate–lead zinc niobate (PZT–PZN) piezoelectric ceramics with interconnected pore channels were fabricated using the camphene-based freeze-casting method. In this method, warm PZT–PZN/camphene slurries with various solid loadings (10, 15, 20, and 25 vol%) were prepared by ball milling at 60°C and then cast into molds at 20°C, resulting in the formation of solidified green bodies comprised of three-dimensionally interconnected camphene dendrite networks and concentrated ceramic particle walls. After the removal of the frozen camphene via sublimation, the samples were sintered at 1200°C for 2 h. All of the fabricated samples showed highly porous structures, consisting of fully dense PZT–PZN walls without defects, such as cracks or pores. As the initial solid loading was decreased from 25 to 10 vol%, the porosity was linearly increased from 50% to 82%. This increase in the porosity led to a reduction in the permittivity, a moderate decline in the d ₃₃ value, and a rapid decline in the d ₃₁ value, which endowed the porous samples with a high hydrostatic figure of merit (HFOM). The highest HFOM value of 35650 × 10⁻¹⁵ Pa⁻¹ was achieved for the sample with a porosity of 82%, as well as ɛ₃₃=284, d _h =298 pC/N, and g _h =118 × 10⁻³ V·(m·Pa)⁻¹.