Microwave sintering of CeO2 and Y2O3 co-stabilised ZrO2 from stabiliser-coated nanopowders

Tetragonal ZrO₂ polycrystalline (TZP) composites with 2 wt.% Al₂O₃ and co-stabilised with 1 mol% Y₂O₃ and (4, 6 or 8) mol% CeO₂ were sintered at 1450 °C for 20 min in a single mode 2.45 GHz microwave furnace. For comparison, conventional sintering was performed in air at 1450 °C for 20 min. The starting powder mixture was obtained by a suspension coating technique using yttrium nitrate, cerium nitrate and pure m-ZrO₂ nanopowder. Fully dense material grades were obtained by both sintering methods. The influence of the composition and the sintering methods on the final phase composition and microstructure were investigated by X-ray diffraction and scanning electron microscopy. Finer and more uniform microstructures were observed in the microwave sintered ceramics when compared to the conventionally sintered samples. The fracture toughness increases with decreasing stabiliser content, whereas a reverse relation was found for the Vickers hardness. Comparable toughness and hardness values were obtained for the microwave and conventionally sintered samples.     

Effects of ZrO2-La2O3 co-addition on the microstructural and optical properties of transparent Y2O3 ceramics

Commercial Y₂O₃ powder was used to fabricate Y₂O₃ ceramics sintered at 1600 °C and 1800 °C with concurrent addition of ZrO₂ and La₂O₃ as sintering aids. One group with different contents of La₂O₃ (0–10 mol%) with a fixed amount of 1 mol% ZrO₂ and another group with various contents of ZrO₂ (0–7 mol%) with a fixed amount of 10 mol% La₂O₃ were compared to investigate the effects of co-doping on the microstructural and optical properties of Y₂O₃ ceramics. At low sintering temperature of 1600 °C, the sample single doped with 10 mol% La₂O₃ exhibits much denser microstructure with a few small intragranular pores while the samples with ZrO₂ and La₂O₃ co-doping features a lot of large intergranular pores leading to lower density. When the sintering temperature increases to 1800 °C, samples using composite sintering aids exhibit finer microstructures and better optical properties than those of both ZrO₂ and La₂O₃ single-doped samples. It was proved that the grain growth suppression caused by ZrO₂ overwhelms the acceleration by La₂O₃. Meanwhile, 1 mol% ZrO₂ acts as a very important inflection point with regard to the influence of additive concentration on the transmittance, pore structure and grain size. The highest in-line transmittance of Y₂O₃ ceramic (1.2 mm in thickness) with 3 mol% of ZrO₂ and 10 mol% of La₂O₃ sintered at 1800 °C for 16 h is 81.9% at a wavelength of 1100 nm, with an average grain size of 11.2 µm.     

ZrO2-doped Y2O3 transparent ceramics via slip casting and vacuum sintering

Commercial Y₂O₃ powder was used to fabricate highly transparent Y₂O₃ ceramics with the addition of ZrO₂ via slip casting and vacuum sintering. The effects of ZrO₂ addition on the transparency, grain size and lattice parameter of Y₂O₃ ceramics were studied. With addition of ZrO₂ the transparency of Y₂O₃ ceramics increased markedly and the grain size of Y₂O₃ ceramics decreased markedly by cation diffusivity mechanism and the lattice parameter of Y₂O₃ ceramics slightly decreased. The highest transmittance (at wavelength 1100 nm) of the 5.0 mol% ZrO₂–Y₂O₃ ceramic (1.0 mm thick) sintered at 1860 °C for 8 h reached 81.7%, very close to the theoretical value of Y₂O₃.     

Synthesis and microstructure of Gd2O3-doped HfO2 ceramics

The effect of Gd₂O₃-doping on the crystal structure, surface morphology and chemical composition of the Gd₂O₃–HfO₂ system is reported. Gd₂O₃–HfO₂ ceramics with variable composition were prepared by varying the Gd₂O₃ composition in the range of 0–38 mol% balanced HfO₂. X-ray diffraction (XRD) analysis indicates that the Gd₂O₃ concentration influences the crystal structure of the Gd₂O₃–HfO₂ ceramics. Pure HfO₂ and Gd₂O₃ crystallize in monoclinic and body centered cubic structure, respectively. The Gd₂O₃–HfO₂ ceramics exhibit mixed monoclinic and fluorite structure when the Gd₂O₃ concentration is varied from 4 to 12 mol%. At 20 mol% of Gd₂O₃, existence of only the fluorite phase was found. Increasing the Gd₂O₃ concentration to 38 mol% results in the formation of single-phase pyrochlore Gd₂Hf₂O₇ (a = 5.258 Å).     

Improvement on the phase stability,mechanical properties and thermal insulation of Y2O3-stabilized ZrO2 by Gd2O3 and Yb2O3 co-doping

Gd₂O₃ and Yb₂O₃ co-doped 3.5 mol% Y₂O₃–ZrO₂ and conventional 3.5 mol% Y₂O₃–ZrO₂ (YSZ) powders were synthesized by solid state reaction. The objective of this study was to improve the phase stability, mechanical properties and thermal insulation of YSZ. After heat treatment at 1500 °C for 10 h, 1 mol% Gd₂O₃–1 mol% Yb₂O₃ co-doped YSZ (1Gd1Yb-YSZ) had higher resistance to destabilization of metastable tetragonal phase than YSZ. The hardness of 5 mol% Gd₂O₃–1 mol% Yb₂O₃ co-doped YSZ (5Gd1Yb-YSZ) was higher than that of YSZ. Compared with YSZ, 1Gd1Yb-YSZ and 5Gd1Yb-YSZ exhibited lower thermal conductivity and shorter phonon mean free path. At 1300 °C, the thermal conductivity of 5Gd1Yb-YSZ was 1.23 W/m K, nearly 25% lower than that of YSZ (1.62 W/m K). Gd₂O₃ and Yb₂O₃ co-doped YSZ can be explored as a candidate material for thermal barrier coating applications.     

Thermal stability of nanostructured 13 wt% Al2O3–8 wt% Y2O3–ZrO2 thermal barrier coatings

Nanostructured 13 wt% Al₂O₃–8 wt% Y₂O₃–ZrO₂ (13AlYSZ) coatings were developed by atmospheric plasma spraying (APS). The phase structure and the morphology of the 13AlYSZ coatings were characterized using X-ray diffraction (XRD), scanning electron microscope (SEM) and transmission electron microscope (TEM). It was found that the as-sprayed coatings mainly consisted of tetragonal zirconia, with the Al element solid solution in ZrO₂. Heat treatment at 1100 °C increased the average grain size of the ZrO₂ phase from 61 to 120 nm and decreased the porosity from 23.8 to 18%. The addition of the nano-Al₂O₃ can effectively inhibit the grain growth of the zirconia phase. The mechanism on inhibiting the grain growth of nanostructured 8 wt% Y₂O₃–ZrO₂ thermal barrier coatings has been discussed in detail.     

Effects of manganese oxide addition and reductive atmosphere annealing on the phase stability and microstructure of yttria stabilized zirconia

The effects of Mn₃O₄ addition and reductive atmosphere (N₂:H₂ = 97:3) annealing on the microstructure and phase stability of yttria stabilized zirconia (YSZ) ceramics during sintering at 1500 °C for 3 h in air and subsequent annealing in a reductive atmosphere were investigated. Mn₃O₄ added 6 mol% YSZ (6YSZ) and 10 mol% YSZ (10YSZ) ceramics were prepared via the conventional solid-state reaction processes. The X-ray diffraction results showed that a single cubic phase of ZrO₂ was obtained in 1 mol% Mn₃O₄ added 6YSZ ceramic at a sintering temperature of 1500 °C for 3 h. A trace amount of monoclinic ZrO₂ phases were observed for 1 mol% Mn₃O₄ added 6YSZ ceramics after annealing at 1300 °C for 60 cycles in a reductive atmosphere by transmission electron microscopy. Furthermore, a single cubic ZrO₂ phase existed stably as Mn₃O₄ added 10YSZ ceramics was annealed at 1300 °C for 60 cycles in reductive atmosphere.     

Phase stability and thermal conductivity of RE2O3 (RE=La,Nd, Gd,Yb) and Yb2O3 co-doped Y2O3 stabilized ZrO2 ceramics

Y₂O₃ stabilized ZrO₂ (YSZ) has been considered as the material of choice for thermal barrier coatings (TBCs), but it becomes unstable at high temperatures and its thermal conductivity needs to be further reduced. In this study, 1 mol% RE₂O₃ (RE=La, Nd, Gd, Yb) and 1 mol% Yb₂O₃ co-doped YSZ (1RE1Yb–YSZ) were fabricated to obtain improved phase stability and reduced thermal conductivity. For 1RE1Yb–YSZ ceramics, the phase stability of metastable tetragonal (t′) phase increased with decreasing RE³⁺ size, mainly attributable to the reduced driving force for t′ phase partitioning. The thermal conductivity of 1RE1Yb–YSZ was lower than that of YSZ, with the value decreasing with the increase of the RE³⁺ size mainly due to the increased elastic field in the lattice, but 1La1Yb–YSZ exhibited undesirably high thermal conductivity. By considering the comprehensive properties, 1Gd1Yb–YSZ ceramic could be a good potential material for TBC applications.     

Phase diagram of the Al2O3–ZrO2–La2O3 system

The phase diagram of the Al₂O₃–ZrO₂–La₂O₃ system was constructed in the temperature range 1250–2800 °C. The liquidus surface of the phase diagram reflects the preferentially eutectic interaction in the system. Three new ternary and two new binary eutectics were found. The minimum melting temperature is 1665 °C and it corresponds to the ternary eutectic LaAlO₃ + T-ZrO₂ +  La₂O₃·11Al₂O₃. The solidus surface projection and the schematic of the alloy crystallization path confirm the preferentially congruent character of phase interaction in the ternary system. The polythermal sections present the complete phase diagram of the Al₂O₃–ZrO₂–La₂O₃ system. No ternary compounds or regions of remarkable solid solution were found in the components or binaries in this ternary system. The latter fact is the theoretical basis for creating new composite ceramics with favorable properties in the Al₂O₃–ZrO₂–La₂O₃ system.     

Thermodynamic calculations of t to m martenstic transformation of ZrO2–CaO binary system

The phase transformation of different polymorphs in zirconia is very important for the processing and mechanical properties of zirconia ceramics. This paper adopts thermodynamic model which is suitable for ceramic system to calculate the Gibbs free energy change of tetragonal and monoclinic phases in ZrO₂–CaO binary system. The difference of the Gibbs free energy between tetragonal and monoclinic phases in ZrO₂–CaO as a function of composition and temperature, namely t → m phase transformation driving force, is thermodynamically calculated from the binary systems. Furthermore, in 8.0 mol% CaO–ZrO₂, the equilibrium temperature between tetragonal and monoclinic phases, T₀, was obtained as 1270.3 K, and martensitic transformation starting temperature (M_s) for t → m transformation of this ceramic with a mean grain size of 2.0 mm was calculated as 805.9 K, which is good agreement with experiment one of 793 K with 12.9 K residual.     

Fabrication of transparent ceramics through melt solidification of near eutectic compositions in HfO2–Al2O3–GdAlO3 system

Solidification of eutectic melts in multiple oxide systems can produce directionally solidified eutectic composites by slow cooling, while rapid cooling would give the formation of amorphous phases as super cooled liquids. We have successfully fabricated an amorphous bulk ceramics in the ternary system HfO₂–Al₂O₃–GdAlO₃ for the first time. It has the near eutectic composition of HfO₂ (14 mol%), Al₂O₃ (63 mol%) and Gd₂O₃ (23 mol%) and highly transparent, >85%, in the visible region after the cooling of around 200–500 K/s for 2–5 mm Ø globules. The sample had kept amorphous up to 1073 K but crystallized above 1273 K then lost the transparency. The formation of an amorphous phase could be discussed by the equilibrated temperature (T₀) lines in meta-stable phase diagram. The present study suggests possible formation of transparent bulk ceramics by the melt-solidification of eutectic melts in various ternary or multiple phase systems.     

Phase evolution and chemical durability of Zr1-xNd xO2-x/2 (0 ≤ x ≤ 1) ceramics

A series of Zr_1-xNd _xO_2-x/2 (0 ≤ x ≤ 1) ceramics was prepared by solid-state reaction method. The effects of Nd content on the phase evolution were investigated. The chemical durability of resulting waste forms was also examined. The results show that the ceramics with x < 0.1 show monoclinic and cubic zirconia phase, with 0.2 ≤ x < 0.4 exhibit a single cubic phase, with 0.4 ≤ x ≤ 0.6 exhibit a single pyrochlore phase, with 0.6 < x < 0.8 exhibit a single cubic phase and remain cubic phases and hexagonal Nd₂O₃ when 0.8 ≤ x ≤ 1. The unit cell parameters of the Nd-doped zirconia samples increase as the Nd content increases. Moreover, the normalized element release rates of Nd element in Nd-doped zirconia ceramics firstly decrease with leaching time and almost no change after 21 days (∼0⁻⁶ g m⁻² d⁻¹), demonstrating its good chemical durability.     

Densification and biocompatibility of sintering 3.0 mol% yttria-tetragonal ZrO2 polycrystal ceramics with x wt% Fe2O3 and 5.0 wt% mica powders additive

The densification and biocompatibility of sintered 3.0 mol% yttria-tetragonal zirconia polycrystal (3Y-TZP) ceramics, with X wt% Fe₂O₃ and 5.0 wt% mica powders (denoted by 3Y-TZP: X-5.0 wt% mica) have been studied. When the pellets of 3Y-TZP: X-5.0 wt% mica were sintered at 1300 °C for 1 h, the relative shrinkage increases from 19.20–19.43% with the X increased from 0.3 to 1.0. The relative shrinkage of pellets containing 1.0 wt% Fe₂O₃ (X=1.0) increased from 19.43–19.59% when sintering temperatures were raised from 1300 °C to 1450 °C. X-ray diffraction results show that the pellets of 3Y-TZP: X-5.0 wt% mica sintered at 1400 °C for 1 h only contained single phase of tetragonal ZrO₂ (t-ZrO₂). When the sintering temperature was higher than 1400 °C, the Vickers microhardness was greatest in the pellets with X=0.5. Within pellets with the same Fe₂O₃ content, the dominant wavelength (λ_d) was only slightly different for pellets sintered at 1300 °C and those sintered at 1450 °C. The results of the materials were evaluated in vitro cytotoxicity tests reveals that the powders and sintered pellets are safe materials. The oral mucosa irritation tests did not find erythema or histopathological change including normal epithelium, and was free from leucocyte infiltration, vascular congestion and oedema.     

Effect of the Y2O3–ZrO2 support composition on nickel catalyst evaluated in dry reforming of methane

Nickel catalysts with a load of 5 wt.% Ni, supported on pure ZrO₂ and ZrO₂ stabilized with 4 mol%, 8 mol% and 12 mol% of Y₂O₃, were prepared by the polymerization method. The samples were characterized by X-ray diffraction (XRD), temperature-programmed reduction with hydrogen (TPR-H₂), specific surface area (BET) and electronic paramagnetic resonance (EPR) and tested as catalysts for carbon dioxide reforming of methane. The XRD patterns showed the presence of the oxide precursor (NiO) and the tetragonal phase of a Y₂O₃–ZrO₂ solid solution. According to the TPR-H₂ analysis, the reduction of various NiO species was influenced by the composition of the support. Catalytic tests were conducted at 800 °C for 6 h, and the composition of the gaseous products and the catalytic conversion rate depended on the composition of the Y₂O₃–ZrO₂ solid solution and its influence on the supported NiO species. A direct relation was observed between the variation in the support, the nickel species supported on it and the performance in the catalytic tests.     

Sintering,microstructure and mechanical properties of Al2O3–Y2O3–ZrO2 (AYZ) eutectic composition ceramic microcomposites

We report on how the mechanical properties of sintered ceramics (i.e., a random mixture of equiaxed grains) with the Al₂O₃–Y₂O₃–ZrO₂ eutectic composition compare with those of rapidly or directionally solidified Al₂O₃–Y₂O₃–ZrO₂ eutectic melts. Ceramic microcomposites with the Al₂O₃–Y₂O₃–ZrO₂ eutectic composition were fabricated by sintering in air at 1400–1500 °C, or hot pressing at 1300–1400 °C. Fully dense, three phase composites of Al₂O₃, Y₂O₃-stabilized ZrO₂ and YAG with grain sizes ranging from 0.4 to 0.8 μm were obtained. The grain size of the three phases was controlled by the size of the initial powders. Annealing at 1500 °C for 96 h resulted in grain sizes of 0.5–1.8 μm. The finest scale microcomposite had a maximum hardness of 19 GPa and a four-point bend strength of 282 MPa. The fracture toughness, as determined by Vickers indentation and indented four-point bending methods, ranged from 2.3 to 4.7 MPa m^1/2. Although strengths and fracture toughnesses are lower than some directionally or rapidly solidified eutectic composites, the intergranular fracture patterns in the sintered ceramic suggest that ceramic microcomposites have the potential to be tailored to yield stronger, tougher composites that may be comparable with melt solidified eutectic composites.     

Fabrication and characterization of highly transparent Er:Y2O3 ceramics with ZrO2 and La2O3 additives

In this study, we report highly transparent Er:Y₂O₃ ceramics (0–10 at% Er) fabricated by a vacuum sintering method using compound sintering additives of ZrO₂ and La₂O₃. The transmittance, microstructure, thermal conductivity and mechanical properties of the Er:Y₂O₃ ceramics were evaluated. The in-line transmittance of all of the Er:Y₂O₃ ceramics (1.2 mm thick) exceeds 83% at 1100 nm and 81% at 600 nm. With an increase in the Er doping concentration from 0 to 10 at%, the average grain size, microhardness and fracture toughness remain nearly unchanged, while the thermal conductivity decreases slightly from 5.55 to 4.89 W/m K. A nearly homogeneous doping level of the laser activator Er up to 10 at% in macro-and nanoscale was measured along the radial direction from the center to the edge of a disk specimen, which is the prominent advantage of polycrystalline over single-crystal materials. Based on the finding of excellent optical and mechanical properties, the compound sintering additives of ZrO₂ and La₂O₃ are demonstrated to be effective for the fabrication of transparent Y₂O₃ ceramics. These results may provide a guideline for the application of transparent Er:Y₂O₃ laser ceramics.     

Microstructure and electrical properties of Mn/Y codoped Ba0.67Sr0.33TiO3 ceramics

Pure and Mn/Y codoped Ba_0.67Sr_0.33TiO₃ (BST) ceramics were fabricated via the citrate–nitrate combustion technique, and the microstructure and electrical properties of BST ceramics were mainly investigated. The Mn/Y codoping concentration has a strong influence on the microstructure and electrical properties of BST ceramics. All BST ceramics possess a pure polycrystalline structure. The density, dielectric loss, leakage current, and ferroelectric properties are improved by codoping 0.5 mol% Mn and 1.0 mol% Y to BST. The relative density of 0.5 mol% Mn/1.0 mol% Y-codoped BST (BST0510) ceramics reaches 97.5% of the theoretical value. BST0510 ceramics have the lowest dielectric loss (tanδ < 0.0073 at 1 kHz) among all BST ceramics. BST0510 ceramics also demonstrate a low leakage current density (1.23 × 10^?7 A/cm²) at an applied field of 10 kV/cm, and excellent ferroelectric properties with a remanent polarization of 2P_r = 15.327 μC/cm² and a coercive field of 2E_c = 3.456 kV/cm. Therefore, the Mn and Y with optimum content help improve the electrical properties of BST materials.     

Phase structure and thermal conductivities of Er2O3 stabilized ZrO2 toughened Gd2Zr2O7 ceramics for thermal barrier coatings

3.5 mol% Er₂O₃ stabilized ZrO₂ (ErSZ) and Gd₂Zr₂O₇ powders were produced by a chemical co-precipitation and calcination method, and ErSZ was used to toughen Gd₂Zr₂O₇. The phase structure, toughness and thermal conductivities of ErSZ toughened Gd₂Zr₂O₇ ceramics were investigated. When the ErSZ content was below 15 mol%, the compound consisted of pyrochlore phase, the ordering degree of which decreased with the increase of the ErSZ content. High ErSZ doping led to the formation of metastable tetragonal (t′) phase in the compound. The addition of ErSZ in Gd₂Zr₂O₇ benefited its toughness, mainly attributable to the presence of t′ phase in the compound. With the increase of the ErSZ content in the compound, the thermal conductivity first decreased and then showed an upward tendency, and 10 mol% ErSZ toughened Gd₂Zr₂O₇ exhibited the lowest thermal conductivity.