Microstructure, growth mechanism and mechanical property of Al2O3-based eutectic ceramic in situ composites

Directionally solidified Al₂O₃-based eutectic ceramic in situ composites with inherently high melting point, low density, excellent microstructure stability, outstanding resistance to creep, corrosion and oxidation at elevated temperature, have attracted significant interest as promising candidate for high-temperature application. This paper reviews the recent research progress on Al₂O₃-based eutectic ceramic in situ composites in State Key Laboratory of Solidification Processing. Al₂O₃/YAG binary eutectic and Al₂O₃/YAG/ZrO₂ ternary eutectic ceramics are prepared by laser zone melting, electron beam floating zone melting and laser direct forming, respectively. The processing control, solidification characteristic, microstructure evolution, eutectic growth mechanism, phase interface structure, mechanical property and toughening mechanism are investigated. The high thermal gradient and cooling rate during solidification lead to the refined microstructure with minimum eutectic spacing of 100 nm. Besides the typical faceted/faceted eutectic growth manner, the faceted to non-faceted growth transition is found. The room-temperature hardness H_V and fracture toughness K_IC are measured with micro-indentation method. For Al₂O₃/YAG/ZrO₂, K_IC = 8.0 ± 2.0 MPa m^1/2 while for Al₂O₃/YAG, K_IC = 3.6 ± 0.4 MPa m^1/2. It is expectable that directionally solidified Al₂O₃-based eutectic ceramics are approaching practical application with the advancement of processing theory, technique and apparatus.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Indirect selective laser sintering of epoxy resin-Al2O3 ceramic powders combined with cold isostatic pressing

To fabricate Al₂O₃ ceramic components with complex shape, selective laser sintering (SLS) combined with cold isostatic pressing (CIP) process was used to consolidate Al₂O₃ powder with additive of epoxy resin E06 (ER06) and polyvinyl alcohol (PVA). The starting material preparation combined spray drying with mechanical mixing to formulate compound powder consisting of PVA (1.5 wt%), ER06 (8 wt%) and Al₂O₃ and provide a good fluidity for SLS. Experimental investigations were carried the shrinkage, relative density, bending strength of Al₂O₃-ER06 SLS specimens in order to optimize the laser sintering parameters. It was found that Al₂O₃-ER06 SLS specimens represented acceptable shrinkage, high density and bending strength when laser power, scanning speed, scanning space and layer thickness were, respectively, 21 W, 1600 mm/s, 100 μm and 150 μm. Following that, the SLS specimens were processed through CIP to eliminate the pores in green ceramics. Finally, the optimized SLS/CIP Al₂O₃ specimens were debinded, sintered to produce crack-free Al₂O₃ bodies. The final Al₂O₃ components achieved a relative high density of more than 92% after furnace sintering. The study shows a novel and promising approach to fabricate complex ceramic matrix and ceramic components via indirect SLS and CIP process.     

Study of the stability of the molten zone and the stresses induced during the growth of Al2O3-Y3Al5O12 eutectic composite by the laser floating zone technique

A series of analytical calculations is used to study both the effect of the thermal gradients and the stability of the molten zone in the laser floating zone growth of Al₂O₃-Y₃Al₅O₁₂ eutectic composite. The thermal gradients in the solidification interface have been calculated and the axial gradient compared with the experimental one of 4.5 × 10⁵ K/m. For these calculations the coefficients of heat transfer from the molten zone to the ambient at the solid-melt interface have been previously obtained. The thermal stresses generated by the high thermal gradients can induce crack formation during the cooling depending on the rod diameter. The theory predicts that it is possible to grow rods free of cracks up to R = 1.7 mm, at low rates (10 mm/h) in close agreement with the experimental critical radius of 1.6 mm.The dependence of the zone length on the input laser power used to carry out the growth is shown. The study of the floating zone profile allows determining the maximum stable zone length, verifying the stability criterion established by some authors.     

Eutectic crystallization in the UO2–Al2O3–HfO2 ceramic phase diagram

In the frame of the Generation IV Sodium Fast Reactor (SFR) safety studies, a core catcher with a sacrificial material could be placed at the bottom of the nuclear reactor. Its role is to dilute the (U, Pu)O₂ molten fuel in case of a hypothetical core meltdown accident. A Al₂O₃–HfO₂ ceramic is a candidate for the sacrificial material. To understand how the molten fuel would mix with this sacrificial material, the UO₂–Al₂O₃–HfO₂ system was investigated at CEA Cadarache PLINIUS corium platform. The eutectic position of the UO₂–Al₂O₃–HfO₂ was determined: the eutectic temperature is 1728±22 °C (2001±22 K) and the eutectic composition is 30 wt% UO₂–35 wt% Al₂O₃–35 wt% HfO₂. Then, the pseudo-binary UO₂–(50 wt% Al₂O₃–50 wt% HfO₂) phase diagram has been proposed.     

Laser machining of Al2O3-ZrO2 (3%Y2O3) eutectic composite

In this work we present the study of the interaction between NIR pulsed laser and Al₂O₃-ZrO₂ (3%Y₂O₃) eutectic composite. The effect produced by modifying the reference position as well as the working conditions and laser beam features has been studied when the samples are processed by means of pulse bursts.The samples were obtained by the laser floating zone technique using a CO₂ laser system. The laser machining was carried out with a Q-switched Nd:YAG laser at its fundamental wavelength of 1064 nm with pulse-widths in the nanosecond range.Geometric dimensions, i.e. ablated depth, machined width and removed volume as well as ablation yield of the resulting holes have been studied. We have described and discussed the morphology, composition and microstructure of the processed samples.     

Development of input output relationships for self-healing Al2O3/SiC ceramic composites with Y2O3 additive using design of experiments

Al₂O₃/SiC ceramic composites with Y₂O₃ as an additive, was synthesized using the Taguchi method of design of experiments, so as to develop statistically sound input output relationships. The proportion of SiC was varied from 12 to 21 vol.% whereas that of Y₂O₃ was varied from 2.5 to 4 vol.%. The composites were sintered at 1500 °C for a soaking time period of 12 h in an air atmosphere. Cracks were induced on the composite surface using a Vickers indenter with a load varying between 20 and 40 kg. Fractographical analyses have been carried out using optical and/or scanning electron microscopy to investigate the surface crack propagation behavior. Thermal aging at 1300 °C in the time range of 0.5-12.5 h was applied to find optimal conditions for healing of the pre-cracked samples. The output parameters such as crack length, healed crack length, hardness and fracture toughness of the samples were correlated with appropriate inputs such as contents of SiC and Y₂O₃, crack-healing temperature, healing time, compaction pressure, indentation load using statistical analysis. Further, the extent of influence, exerted by pertinent input parameters on output parameters, was also identified.     

Fabrication of novel multilayer Al2O3-(m-ZrO2)/t-ZrO2 fibrous ceramics composites

A novel layered microstructure in the Al₂O₃/ZrO₂ composites system was fabricated by the multipass extrusion method. The microstructure consisted with very fine alternate lamina of Al₂O₃-(m-ZrO₂) and t-ZrO₂. The composites were designed in such a way that a small group of 7 cylindrical alternate layers of Al₂O₃-(m-ZrO₂) and t-ZrO₂ made a concentric microgroup around 40 μm in diameter, with a common boundary layer between the adjacent groups. The thickness of both layers was around 2-3 μm. The microstructure was unidirectionally aligned throughout the composites. The composite microstructure was fibrous due to the unidirectional orientation of these microgroups. Detailed microstructure of the fabricated composites was characterized by SEM. The effect of the concentric layered microstructure on mechanical behavior was discussed. Material properties such as density, bending strength, Vickers hardness and fracture toughness were measured and evaluated depending on different sintering temperatures.     

Phase equilibria and glass formation studies in the (1 − x)TeO2-xCdO (0.05 ≤ x ≤ 0.33 mol) system

Phase equilibria and glass formation studies of the (1 − x)TeO₂-xCdO system (0.05 ≤ x ≤ 0.33 mol) were realized by using differential thermal analysis (DTA), X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques. The samples were prepared by applying a conventional melt-quenching technique at 800 °C. The glass formation range of the system was determined as 0.05 ≤ x < 0.15 and the sample containing 10 mol% CdO showed the highest glass stability. Crystallization behavior of the TeO₂-CdO glasses was investigated and formation and/or transformation of different phases were detected for each crystallization reaction. In order to obtain thermal stability of the system, as-cast samples were heat-treated above all crystallization reaction temperatures at 550 °C for 24 h. A binary eutectic: liquid → TeO₂ + CdTe₂O₅ was detected at 638 ± 4 °C. Crystallization behavior of the TeO₂-CdO glasses and microstructural characterization of the TeO₂-CdTe₂O₅ system was realized.     

Selective oxidation of methanol to dimethoxymethane over acid-modified V2O5/TiO2 catalysts

Selective oxidation of methanol to dimethoxymethane (DMM) was conducted in a fixed-bed reactor over an acid-modified V₂O₅/TiO₂ catalyst. The influence of the acid modification on its structure, redox and acidic properties, and catalytic performance for methanol oxidation were investigated. The results indicated that the content of vanadia in the catalyst exhibits a vital influence on the dispersion of vanadium species, while the acid modification can enhance its surface acidity. Proper amounts of the acid (W() = 15%) and V₂O₅ (W(V₂O₅) = 15%) components loaded in the acid-modified V₂O₅/TiO₂ catalyst are able to build a bi-functional circumstance that is favorable for the formation of DMM with high activity and selectivity. As a result, for the selective oxidation of methanol, the H₂SO₄-modified V₂O₅/TiO₂ catalyst gives a much higher DMM yield at 150 °C than the unmodified one.     

Effects of CaSiO3 addition on sintering behavior and microwave dielectric properties of Al2O3 ceramics

The effects of CaSiO₃ addition on the sintering behavior and microwave dielectric properties of Al₂O₃ ceramics have been investigated. The addition of CaSiO₃ into Al₂O₃ ceramics resulted in the emergence of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈, which acting as liquid sintering aids can effectively lower the sintering temperature of Al₂O₃ ceramic. The Q × f value of Al₂O₃-CaSiO₃ ceramics decreased with the CaSiO₃ addition increasing because of the lower Q × f value of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈. Compared with the pure CaSiO₃ ceramic, the Al₂O₃-CaSiO₃ ceramic with 20 wt% CaSiO₃ addition possessed good dielectric properties of ?_r = 9.36 and Q × f = 13,678 GHz at the similar sintering temperature.     

Effect of Ta2O5 in (Ca,Si, Ta)-doped TiO2 ceramic varistors

TiO₂ varistors doped with 0.2 mol% Ca, 0.4 mol% Si and different concentrations of Ta were obtained by ceramic sintering processing at 1350 °C. The effect of Ta on the microstructures, nonlinear electrical behavior and dielectric properties of the (Ca, Si, Ta)-doped TiO₂ ceramics were investigated. The ceramics have nonlinear coefficients of α = 3.0–5.0 and ultrahigh relative dielectric constants which is up to 10⁴. Experimental evidence shows that small quantities of Ta₂O₅ improve the nonlinear properties of the samples significantly. It was found that an optimal doping composition of 0.8 mol% Ta₂O₅ leads to a low breakdown voltage of 14.7 V/mm, a high nonlinear constant of 4.8 and an ultrahigh electrical permittivity of 5.0 × 10⁴ and tg δ = 0.66 (measured at 1 kHz), which is consistent with the highest and narrowest grain boundary barriers of the ceramics. In view of these electrical characteristics, the TiO₂–0.8 mol% Ta₂O₅ ceramic is a viable candidate for capacitor–varistor functional devices. The characteristics of the ceramics can be explained by the effect and the maximum of the substitution of Ta⁵⁺ for Ti⁴⁺.     

Low temperature sintering and microwave dielectric properties of Li2ZnTi3O8 ceramics doped with ZnO–La2O3–B2O3 glass

Li₂ZnTi₃O₈ ceramics doped with ZnO–La₂O₃–B₂O₃ glass were prepared by the conventional solid-state ceramic route. The effects of the ZnO–La₂O₃–B₂O₃ glass on the sintering temperature, phase composition, microstructure and microwave dielectric properties of Li₂ZnTi₃O₈ ceramics were investigated. The addition of ZLB glass can reduce the sintering temperature of Li₂ZnTi₃O₈ ceramic from 1075 °C to 925 °C without obvious degradation of the microwave dielectric properties. Only a single phase Li₂ZnTi₃O₈ with cubic spinel structure is formed in Li₂ZnTi₃O₈ ceramic with ZLB addition sintered at 925 °C. Typically, 1.0 wt% ZLB-doped Li₂ZnTi₃O₈ ceramic sintered at 925 °C can reach a maximum relative density of 95.8% and exhibits good microwave dielectric properties of ε_r=24.34, Q×f=41,360 GHz and τ_f=−13.4 ppm/°C. Moreover, this material is compatible with Ag electrode, which makes it a promising candidate for LTCC application.     

Mixed oxides Ca2Fe2O5 and Ca2Co2O5 as anode materials for Li-ion batteries

The electrochemical performance of mixed oxides, Ca₂Fe₂O₅ and Ca₂Co₂O₅ for use in Li-ion batteries was studied with Li as the counter electrode. The compounds were prepared and characterized by X-ray diffraction and SEM. Ca₂Fe₂O₅ showed a reversible capacity of 226 mAh/g at the 14th cycle and retained 183 mAh/g at the end of 50 cycles at 60 mA/g in the voltage window 0.005-2.5 V. A reversible capacity in the range, 365-380 mAh/g, which is stable up to 50 charge-discharge cycles is exhibited by Ca₂Co₂O₅ in the voltage window, 0.005-3.0 V and at 60 mA/g. This corresponds to recycleable moles of Li of 3.9±0.1 (theoretical: 4.0). Significant improvement in the cycling performance and attainable reversible capacity were noted for Ca₂Co₂O₅ on cycling to an upper cut-off voltage of 3.0 V as compared to 2.5 V. Coulombic efficiency for both compounds is >98%. Electrochemical impedance spectroscopy (EIS) data clearly indicate the reversible formation/decomposition of polymeric surface film on the electrode surface of Ca₂Co₂O₅ in the voltage window, 0.005-3.0 V. Cyclic voltammetry results compliment the galvanostatic cycling data.     

Microwave dielectric properties and structure of ZnO-Nb2O5-TiO2 ceramics

Ceramic samples based on ZnO-Nb₂O₅-TiO₂ compositions have been prepared using solid state ceramic route. The work was carried out over a wide range of initial ZnNb₂O₆ and Zn_0.17Nb_0.33Ti_0.5O₂ compounds concentration. The crystal structure and microstructure developments were studied using X-ray diffraction (XRD) and scanning electron microscopy (SEM). It was shown that the phase compositions of the samples present itself a columbite type and mixture of two phases—solid solutions of columbite and rutile types.The sintering behavior, permittivity, its temperature coefficients and quality factor had been characterized for ceramic samples in depending on compositions. The permittivity of the samples in this system is within the limits from 24 to 80, τ_? from 150 to −560 ppm/°C. For the samples with τ_? ∼ 0, ?_r ∼ 43.8 and Q·f = 35000 GHz at f = 9 GHz. The comparatively low sintering temperature (≤1080 °C) and high dielectric properties in microwave range make these ceramics promising for application in electronics.     

Structural, thermal and mechanical properties of transparent Yb:(Y0.97Zr0.03)2O3 ceramic

Yb doped (Y_0.97Zr_0.03)₂O₃ transparent ceramics were fabricated by solid state reaction and vacuum sintering. The microstructure, thermal and mechanical properties of Y₂O₃ ceramic, as well as the effect of Yb doping concentration on these properties were investigated in detail. The lattice parameter and unit cell volume decrease with the increasing of Yb content, whereas thermal expansive coefficient increases. With Yb content increasing from 0 to 8 at.%, the mean grain size increases from 15.82 μm to 26.54 μm, and the thermal conductivity at room temperature (RT) decreases from 11.97 to 6.39 W/m/K. The microhardness decreases with Yb content, and the microhardness and fracture toughness of (Y_0.97Zr_0.03)₂O₃ transparent ceramic is 11.11 GPa and 1.29 MPa m^1/2, respectively.     

Synthesis and transport properties in La2−xAxMo2O9−δ (A = Ca, Sr, Ba, K) series

The La_2−xA_xMo₂O_9−δ (A = Ca²⁺, Sr²⁺, Ba²⁺ and K⁺) series has been synthesised as nanocrystalline materials via a modification of the freeze-drying method. The resulting materials have been characterised by X-ray diffraction (XRD), thermal analysis (TG/DTA, DSC), scanning electron microscopy (SEM) and high-resolution transmission electron microscopy (HRTEM). The high-temperature β-polymorph is stabilised for dopant content x > 0.01. The nanocrystalline powders were used to obtain dense ceramic materials with optimised microstructure and relative density >95%. The overall conductivity determined by impedance spectroscopy depends on both the ionic radius and dopant content. The conductivity decreases slightly as the dopant content increases in addition a maximum conductivity value was found for Sr²⁺ substitution, which show an ionic radii slightly higher than La³⁺ (e.g. 0.08 S cm⁻¹ for La₂Mo₂O₉ and 0.06 S cm⁻¹ for La_1.9Sr_0.1Mo₂O_9−δ at 973 K). The creation of extrinsic vacancies upon substitution results in a wider stability range under reducing conditions and prevents amorphisation, although the stability is not enhanced significantly when compared to samples with higher tungsten content. These materials present high thermal expansion coefficients in the range of (13-16) × 10⁻⁶ K⁻¹ between room temperature and 753 K and (18-20) × 10⁻⁶ K⁻¹ above 823 K. The ionic transport numbers determined by a modified emf method remain above 0.98 under an oxygen partial pressure gradient of O₂/air and decreases substantially under wet 5% H₂-Ar/air when approaching to the degradation temperature above 973 K due to an increase of the electronic contribution to the overall conductivity.     

Injection molding of surface modified powders with high solid loadings: A case for fabrication of translucent alumina ceramics

Solid loading is a critical key to the fabrication of ceramic compacts with high densities via ceramic injection molding. As reported in most previous work, solid loading of ultra-fine alumina feedstock system could be achieved only up to ∼58 vol% with stearic acid (SA) as the surface modification agent. In present work, different from the traditional work in which SA has been introduced just in the powder blending process, we have successfully prepared the feedstock with a much higher solid loading up to ∼64 vol% by a prior ball milling treatment of ceramic powders with a small amount of SA before the traditional blending process. It can be attributed to that SA can be coated homogeneously around the powder surfaces by a chemical reaction induced by ball milling treatment. Highly translucent Al₂O₃ ceramics have been fabricated, which suggests an alternative route for fabrication of translucent ceramics with high quality.     

Electrical properties of Pr6O11-doped WO3 capacitor–varistor ceramics

The microstructure and electrical properties of Pr₆O₁₁-doped WO₃ ceramics were investigated. Results showed that the breakdown voltage of doped samples was lower than that of the undoped. The dielectric constant of doped samples was higher than that of the undoped, and the high dielectric constant made Pr₆O₁₁-doped WO₃ ceramics to be applicable as a kind of capacitor–varistor materials. A small content of Pr₆O₁₁ could significantly improve nonlinear properties of the samples. The WO₃–0.03 mol% Pr₆O₁₁ obtained a large nonlinear coefficient of 3.8, a low breakdown voltage of 8.8 V/mm, and a high dielectric constant of 7.69 × 10⁴ at 1 kHz. The defects theory was introduced to explain the nonlinear electrical behavior of Pr₆O₁₁-doped WO₃ ceramics.