Sintering of Nanophase γ-Al2O3 Powder

The sintering of ultrafine γ-Al₂O₃ powder (particle size ∼10–20 nm) prepared by an inert gas condensation technique was investigated in air at a constant heating rate of 10°C/min. Qualitatively, the kinetics followed those of transition aluminas prepared by other methods. Measurable shrinkage commenced at ∼ 1000°C and showed a region of rapid sintering between ∼1125° and 1175°C followed by a transition to a much reduced sintering rate at higher temperatures. Starting from an initial density of ∼0.60 relative to the theoretical value, the powder compact reached a relative density of 0.82 after sintering to 1350°C. Compared to compacts prepared from the as-received powder, dispersion of the powder in water prior to compaction produced a drastic change in the microstructural evolution and a significant reduction in the densification rate during sintering. The incorporation of a step involving the rapid heating of the loose powder to ∼1300°C prior to compaction (which resulted in the transformation to α-Al₂O₃) provided a method for significantly increasing the density during sintering.     

Effect of Calcination on the Sintering of Gel-Derived, Zirconia-Toughened Alumina

The densification behavior of ZrO₂ (+ 3 mol% Y₂O₃)/85 wt% Al₂O₃ powder compacts, prepared by the hydrolysis of metal chlorides, can be characterized by a transition- and an α-alumina densification stage. The sintering behavior is strongly determined by the densification of the transition alumina aggregates. Intra-aggregate porosity, resulting from calcination at 800°C, partly persists during sintering and alumina phase transformation and negatively influences further macroscopic densification. Calcination at 1200°C, however, densifies the transition alumina aggregates prior to sintering and enables densification to almost full density (96%) within 2 h at 1450°C, thus obtaining a microstructure with an alumina and a zirconia grain size of 1 μm and 0.3–0.4 μm, respectively.     

Change of Crystal Phases and Microstructure of Amorphous Si-C-N Powder by Hot Pressing

An amorphous Si-C-N powder with Y₂O₃ and Al₂O₃ powder as sintering additives was hot-pressed at 1900°C for 120 min in a nitrogen atmosphere. Changes in the crystalline phases and microstructure of the amorphous Si-C-N powder during sintering were investigated by X-ray diffractometry (XRD) and transmission electron microscopy (TEM). The defects at the fracture origins of the sintered bodies after bending tests also were investigated by scanning electron microscopy (SEM) and electron probe microanalysis (EPMA). XRD showed that alpha-Si₃N₄ was formed initially from the amorphous Si-C-N by 1530°C, which then transformed to ß-Si₃N₄ at 1600°C. Also, a slight formation of crystalline SiC occurred during the transformation from alpha- to ß-Si₃N₄, and it increased after the transformation was completed at 1900°C. TEM revealed that many SiC nanoparticles were incorporated into ß-Si₃N₄ grains after the transformation from alpha- to ß-Si₃N₄ at 1600°C. They were located at the triple points of the grain boundaries of ß-Si₃N₄ after continued Si₃N₄ grain growth at 1900°C. Besides the SiC nanoparticles, large agglomerations of carbon or SiC particles of 20-60 µm size were observed by SEM and EPMA at the fracture origins of the sintered bodies after the bending tests.     

Densification of Nanocrystalline Yttria by Low Temperature Spark Plasma Sintering

We investigated the densification of undoped, nanocrystalline yttria (Y₂O₃) powder by spark plasma sintering (SPS) at sintering temperatures between 650°C and 1050°C at a heating rate of 10°C/min and an applied stress of 83 MPa. In spite of the low sinterability of the undoped Y₂O₃, a remarkable densification of the powder started at about 600°C, and a theoretical density of more than 97% was achieved at a sintering temperature of 850°C with a grain size of about 500 nm. The low temperature SPS is effective for fabricating dense Y₂O₃ polycrystals.     

Biomorphic Silicon Nitride Ceramics with Fibrous Morphology Prepared by Sol Infiltration and Reduction–Nitridation

Biomorphic silicon nitride (Si₃N₄) ceramics with fibrous morphology were fabricated by combining sol–gel infiltration with carbothermal reduction nitridation from wood precursor. Y₂O₃-incorporated silica sol was used as the infiltrated solution to promote the formation of fibrous Si₃N₄ grain at 1600°C under high nitrogen pressure (0.6 MPa). The influence of sintering conditions (additive and temperature) on the phase composition and microstructure of sintering bodies was analyzed, and the reaction mechanism is discussed.     

Low-Temperature Sintering of La(Ca)CrO3 Powder Prepared through the Combustion Process

Ultrafine La(Ca)CrO₃ (LCC) powder was prepared through the glycine–nitrate gel combustion process. It was shown for the first time that the use of relatively inexpensive CrO₃ as a starting material for chromium has potential for the bulk preparation of sinter-active LCC powder. As-prepared powder, when calcined at 700°C, resulted in LCC along with a small amount of CaCrO₄. The calcined powder was found to be composed of soft agglomerates with a particle size of ≈70–290 nm. The cold pressing and sintering of the calcined powder at 1200°C resulted in the mono-phasic La_0.7Ca_0.3CrO₃ with density ≈98% of its theoretical value. This is the lowest sintering temperature ever reported for La_0.7Ca_0.3CrO₃. The conductivity of the sintered La_0.7Ca_0.3CrO₃ at 1000°C was found to be ≈57 S/cm in air. The sintering and electrical behavior achieved for La_0.7Ca_0.3CrO₃ may find application as an interconnect material for high-temperature solid oxide fuel cells if problems with chemical expansion and poor conductivity in fuel can be overcome.     

Initial Coarsening and Microstructural Evolution of Fast-Fired and MgO-Doped Al2O3

The effect of an initial coarsening step (50-200 h at 800°C) on the subsequent densification and microstructural evolution of high–quality compacts of undoped and MgO–doped Al₂O₃ has been investigated during fast–firing (5 min at 1750°C) and during constant–heating–rate sintering (4°C/min to 1450°C). In constant–heating–rate sintering of both the undoped and MgO–doped Al₂O₃, a refinement of the microstructure has been achieved for the compact subjected to the coarsening step. A combination of the coarsening step and MgO doping produces the most significant refinement of the microstructure. In fast–firing of the MgO–doped Al₂O₃, the coarsening step produces a measurable increase in the density and a small refinement of the grain size, when compared with similar compacts fast–fired conventionally (i.e., without the coarsening step). This result indicates that the accepted view of the deleterious role of coarsening in the sintering of real powder compacts must be reexamined. Although extensive coarsening after the onset of densification must be reduced for the achievement of high density, limited coarsening prior to densification is beneficial for subsequent sintering.     

Soft Ferrite Materials for Multilayer Inductors

Various families of soft ferrites (Ni–Cu–Zn; Mg–Cu–Zn; Co₂–Z; Mn–Zn) with a sintering temperature of T ≤950°C are used for multilayer inductors. It is shown for Ni–Cu–Zn and Mg–Cu–Zn ferrites that composition, powder particle size, and sintering additive concentration strongly affect the shrinkage, sintering behavior, microstructure, and magnetic properties. A maximum permeability of μ _i =700–900 is observed with a Bi₂O₃ addition of about 0.5 wt%. The maximum shrinkage can be shifted down to 700°C using nanosize powders. Z-type hexaferrites with a permeability of 10 are used for high-frequency applications up to 2 GHz.     

Microstructural Characterization of Porous Silicon Carbide Membrane Support With and Without Alumina Additive

Porous silicon carbide (SiC) membrane supports sintered at 1500°–1800°C were prepared by cold isostatic pressing (CIP) under different pressures and using different amounts of alumina additive (0%–4%). The relationship between processing factors and pore size and microstructure was examined. Varying the sintering temperature, the CIP pressure and the amount of additive used were found to be effective for controlling pore size and microstructure. The pore size and particle size of the membrane support prepared without alumina were found to increase with increasing sintering temperature. This was attributed to surface diffusion. Densification of the undoped support did not occur, however, because of concurrent pore development. In the SiC membrane support containing 4% alumina, small particles and a pore size of around 100 nm were retained. This was because of the formation of a limited amount of SiO₂–Al₂O₃ liquid phase during sintering.     

Fabrication and Microstructure Characterization of Ti3SiC2 Synthesized from Ti/Si/2TiC Powders Using the Pulse Discharge Sintering (PDS) Technique

Ti/Si/2TiC powders were prepared using a mixture method (M) and a mechanical alloying (MA) method to fabricate Ti₃SiC₂ at 1200°–1400°C using a pulse discharge sintering (PDS) technique. The results showed that the Ti₃SiC₂ samples with <5 wt% TiC could be rapidly synthesized from the M powders; however, the TiC content was always >18 wt% in the MA samples. Further sintering of the M powder showed that the purity of Ti₃SiC₂ could be improved to >97 wt% at 1250°–1300°C, which is ∼200°–300°C lower than that of sintered Ti/Si/C and Ti/SiC/C powders using the hot isostatic pressing (HIPing) technique. The microstructure of Ti₃SiC₂ also could be controlled using three types of powders, i.e., fine, coarse, or duplex-grained, within the sintering temperature range. In comparison with Ti/Si/C and Ti/SiC/C mixture powders, it has been suggested that high-purity Ti₃SiC₂ could be rapidly synthesized by sintering the Ti/Si/TiC powder mixture at relatively lower temperature using the PDS technique.     

Processing and Thermal Conductivity of Sintered Reaction-Bonded Silicon Nitride. I: Effect of Si Powder Characteristics

This paper will present sintered reaction-bonded silicon nitride (SRBSN) material with a high thermal conductivity of 121 W·(m·K)⁻¹, which has been successfully prepared from a coarse Si powder with lower levels of oxygen and aluminum impurities, using a mixture of Y₂O₃ and MgSiN₂ as sintering additives, by nitriding at 1400°C for 8 h and subsequent post-sintering at 1900°C for 12 h at a nitrogen pressure of 1 MPa N₂. This thermal conductivity value is higher than that of the materials prepared from high-purity α-Si₃N₄ powder (UBE SN-E10) with the same additive composition under the same sintering conditions. In order to study the effects of Si powder characteristics on the processing, microstructure, and thermal conductivity of SRBSN, the other type of fine powder with higher native oxygen and metallic impurity (typically Al and Fe) contents was also used. The effects of Si particle size, native oxygen, and metallic impurities on the nitriding process, post-sintering process, and thermal conductivity of the resultant SRBSN materials were discussed in detail. This work demonstrates that the improvement in thermal conductivity of SRBSN could be achieved by using higher purity coarse Si powder with lower levels of oxygen and aluminum impurities. In addition, this work also shows that the nitriding temperature has no significant effect on the microstructure and thermal conductivity of SRBSN during post-sintering, although it does affect the characteristics of RBSN formed during nitridation.     

Microstructure and Humidity-Sensitive Characteristics of α-Fe2O3 Ceramic Sensor

The microstructure and humidity-sensitive characteristics of α -Fe₂O₃ porous ceramic were investigated. Microporous α -Fe₂O₃ powders were obtained by controlling the topotactic decomposition reaction of α -FeOOH. Water vapor adsorption thermogravimetrical experiments were carried out in the relative humidity (rh) range 0% to 95% on the α -Fe₂O₃ powder and the 900°C sintered compact. The microstructure was investigated by SEM, TEM, Hg intrusion, and N₂ adsorption porosimetry techniques. The humidity sensitivity was investigated by the impedance measurements technique in 0% to 95% rh on the compacts sintered at 50°C steps in the 850° to 1100°C range. Humidity response was found to be affected by the microstructure, i.e., the characteristics of the precursor powders and sintering temperatures.     

Porous 2H-Silicon Carbide Ceramics Fabricated by Carbothermal Reaction between Silicon Nitride and Carbon

Porous SiC ceramics were synthesized by sintering pressed and pressed/CIPed powder compacts of α-Si₃N₄, carbon (Si₃N₄:C = 1:3 mol as ratio), and sintering aids, at 1600°C for few hours to achieve a reaction, and subsequently sintering at a temperature range of 1750°–1900°C, in an argon atmosphere. High porosities from 45%–65% were achieved by low shrinkage with large weight loss. Formation of pure 2H-SiC phase via a reaction between Si₃N₄ and carbon can be demonstrated by X-ray diffractometry. The resultant porous SiC samples were characterized by SiC grain microstructures, pore-size distribution, and flexural strength. This method has the advantage of fabricating high-porous SiC ceramics with fine microstructure and good properties at a relatively low temperature.     

Sintering Behavior of Fine Aluminum Nitride Powder Synthesized from Aluminum Polynuclear Complexes

The sintering behavior of fine AIN powder synthesized from an aluminum polynuclear complex was investigated. The focus of this work was to investigate the densification behavior of the AIN powder with different particle sizes (specific surface area: 3.2–22.8 m²/g). The AIN powder was synthesized from basic aluminum chloride and glucose mixed in a water solution. This powder was divided into two groups: one with 2 wt% Y₂O₃ added as the sintering aid and the other without such an additive. The AIN powder investigated possessed favorable densification potential. The density of the AIN powder with a surface area of 16.6 m²/g and without additives attained theoretical density at 1700°C. Adding Y₂O₃ further decreased the sintering temperature required for full densification to 1600°C. It is speculated that low-temperature sintering of our fine AIN powder with Y₂O₃ proceeds in two steps: in the initial stage, sintering proceeds predominantly through interdiffusion between yttrium aluminates formed on the AIN powder surface; in the second stage, the densification may occur by the interdiffusion between solid phases formed by a reaction between the yttrium aluminates and AIN. To investigate the effect of oxygen on sintering, the content of oxygen in AIN powder was varied while the particle size was kept constant. In this study, the difference in surface oxygen content scarcely affected the sintering behavior of fine AIN powder.     

Sinterability of Agglomerated Powders

A concept is presented which relates the sinterability of a powder compact to its particle arrangement as defined by the distribution of pore coordination numbers, i.e., the number of touching particles surrounding and defining each void space. Previous thermodynamic arguments suggest that pores will disappear only when their coordination numbers are less than a critical value. The coordination-number distribution of an agglomerated powder is discussed with respect to the size of the multiple-particle packing unit, consolidation forces, and phenomena occurring during sintering. One pertinent conclusion is that the multiple-particle packing units densify and support grain growth as sintering initiates. Grain growth and rearrangement processes decrease the coordination number of remaining pores to allow them to disappear during latter states of sintering. Porosimetry and direct observations of powder compacts of <1 μm Al₂O₃ heat-treated between 600° and 1600°C support this concept.     

A Simple Way to Synthesize Yttrium Aluminum Garnet by Dissolving Yttria Powder in Alumina Sol

A precursor for Y₃Al₅O₁₂ was synthesized as a YAG sol by simply dissolving Y₂O₃ powder in an alumina sol. Phase-pure Y₃Al₅O₁₂ powder was obtained by precipitating the YAG sol with an aqueous dilute ammonia solution followed by calcination at 1100°C. TG/DTA analysis showed an exotherm at 938°C attributed to formation of YAG phase and weight loss of 44% at 1000°C. XRD and FT-IR analysis showed that phase-pure YAG can be formed through noncrystalline and metastable hexagonal YAlO₃ without forming either yttrium or aluminum formate intermediate.     

Characterization of Heterogeneous Microstructure Evolution in ZrO2–3 mol%Y2O3 during Isothermal Sintering

Pore boundary tessellation and quantitative stereology were used to characterize microstructure evolution in ZrO₂–3 mol%Y₂O₃ (3YSZ) that had been pressed to a green density of 46% and isothermally sintered at 1275°C for 0.1–10 h. Scanning electron micrographs showed that, relative to classical sintering models, the sintered 3YSZ microstructure was spatially heterogeneous, and that this heterogeneity affected the way in which the microstructure evolved during sintering. Pore boundary tessellation cell maps revealed the presence of dense regions within the microstructure that grew by the preferential elimination of smaller pores and resulted in larger more widely spaced porosity at longer sintering times. In consequence, the average pore separation distance increased much faster than the average grain size. This would call into question the use of the grain size as a measure of microstructural scale for the prediction of densification kinetics for this material.     

Double Precursor Solution Coating Approach for Low-Temperature Sintering of [Pb(Mg1/3Nb2/3)O3]0.63[PbTiO3]0.37 Solids

Lead-based piezoelectric ceramics typically require sintering temperatures higher than 1000°C at which significant lead loss can occur. Here, we report a double precursor solution coating (PSC) method for fabricating low-temperature sinterable polycrystalline [Pb(Mg_1/3Nb_2/3)O₃]_0.63-[PbTiO₃]_0.37 (PMN–PT) ceramics. In this method, submicrometer crystalline PMN powder was first obtained by dispersing Mg(OH)₂-coated Nb₂O₅ particles in a lead acetate/ethylene glycol solution (first PSC), followed by calcination at 800°C. The crystalline PMN powder was subsequently suspended in a PT precursor solution containing lead acetate and titanium isopropoxide in ethylene glycol to form the PMN–PT precursor powder (second PSC) that could be sintered at a temperature as low as 900°C. The resultant d ₃₃ for samples sintered at 900°, 1000°, and 1100°C for 2 h were 600, 620, and 700 pm/V, respectively, comparable with the known value. We attributed the low sintering temperature to the reactive sintering nature of the present PMN–PT precursor powder. The reaction between the nanosize PT and the submicrometer-size PMN occurred roughly in the same temperature range as the densification, 850°–900°C, thereby significantly accelerating the sintering process. The present PSC technique is very general and should be readily applicable to other multicomponent systems.     

Kinetics and Products of Molybdenum Disilicide Powder Oxidation

In this study, we investigated the kinetics and products of the oxidation of MoSi₂ powder with an average particle size of 1.6 μm at 900°, 1000°, and 1100°C, using a small sample size of 0.5 g. Such a small sample size allowed us to minimize the effect of oxygen transportation through the powder volume, while maintaining a good relative weighing accuracy. X-ray diffraction of oxidized samples indicated the formation of Mo₅Si₃ and Mo metal. Analysis of the oxidation kinetics suggested that gaseous MoO₃ formed initially and amorphous SiO₂ film later. The oxidation kinetics and products observed in this study differ from those reported in an early study, in which a larger sample size was used.     

Influence of Pyridine–Borane on the Sintering Behavior and Properties of α-Silicon Carbide

In the present study, α-SiC powder is coated with pyridineborane (BH₃·C₅H₅N), a liquid molecular compound, which forms a boron carbonitride (BC_3.5N) layer by heat treatment at 1000°C under argon. The precipitation method leads to an improved chemical homogeneity in the compacted powder resulting in enhanced densification and significant reduction in grain growth during subsequent sintering at temperatures exceeding 2070°C. Thus, small average grain sizes of d ₅₀= 1.3 μm and a narrow grain size distribution ( d ₁₀= 0.6 μm, d ₉₀= 2.2 μm) are detected in the liquid-phase-processed sample sintered at 2200°C for 0.5 h in argon. Final densities of at least 98% of theoretical could be obtained by pressureless sintering at 2100°C. These results as well as the microstructural distribution of the sintering aids in the densified samples are discussed.