Growth of Single-Crystal and Polycrystalline Thin Films of MgAl2O4 and MgFe2O4

Single-crystal and polycrystalline films of Mg-Al₂O₄ and MgFe₂O₄ were formed by two methods on cleavage surfaces of MgO single crystals. In one procedure, aluminum was deposited on MgO by vacuum evaporation. Subsequent heating in air at about 510°C formed a polycrystalline γ-Al₂O₈ film. Above 540°C, the γ-Al₂O, and MgO reacted to form a single-crystal MgAl₂O₄ film with {001} MgAl₂O₄‖{001} MgO. Above 590°C, an additional layer of MgAl₂O₄, which is polycrystalline, formed between the γ-Al₂O₃ and the single-crystal spinel. Polycrystalline Mg-Al₂O₄ formed only when diffusion of Mg²⁺ ions proceeded into the polycrystalline γ-Al₂O₃ region. Corresponding results were obtained for Mg-Fe₂O₄. MgAl₂O₄ films were also formed on cleaved MgO single-crystal substrates by direct evaporation, using an Al₂O₃ crucible as a source. Very slow deposition rates were used with source temperatures of ∼1350°C and substrate temperatures of ∼800°C. Departures from single-crystal character in the films may arise through temperature gradients in the substrate.     

Reducing the Sintering Temperature for MgO–Al2O3Mixtures by Addition of Cryolite (Na3AlF6)

The preparation of near stoichiometric spinel and alumina-rich spinel composites from Al₂O₃and MgO powders with the addition of Na₃AlF₆up to 4 wt% in the temperature range 700°–1600°C was studied; 98 wt% spinel containing 72 wt% Al₂O₃can be produced from the mixture of 72 wt% (50 at.%) Al₂O₃+ 28 wt% (50 at.%) MgO powders with the addition of 1 wt% Na₃AlF₆fired at 1300°C for 1 h. Spinels containing 81–85 wt% Al₂O₃can be produced from either the mixture of 90 wt% (78 at.%) Al₂O₃+ 10 wt% (22 at.%) MgO or the mixture of 95 wt% (88 at.%) Al₂O₃+ 5 wt% (12 at.%) MgO powders with the addition of 4 wt% Na₃AlF₆in the temperature range 1300°–1600°C by using a torch-flame firing for 3 min, followed by quenching in water, while the same system under slow cooling in a furnace results in spinel containing 74–76 wt% Al₂O₃. Microscopic studies indicate that the alumina-rich spinel composites consist of a continuous majority spinel phase and an isolated minority corundum phase, regardless of slow cooling in a furnace or quenching in water.     

Influence of the Characteristics of Spinels on the Slag Resistance of Al2O3–MgO and Al2O3–Spinel Castables

The XRD patterns at ambient temperature and at 1500°C showed that the spinel in the Al₂O₃–MgO castables fired at 1500°C for 3 h has the higher peak intensity, compared to those in Al₂O₃–spinel castables; the interplanar distance in the set (311) is 2.43 Å for the spinel in Al₂O₃–MgO castables as well as the spinels in Al₂O₃–spinel castables using spinels containing 73, 90, and 94 wt% Al₂O₃, respectively. The corresponding alumina contents of the spinels in these castables were estimated to be around 75 wt%. The smaller grain size of the spinel in Al₂O₃–MgO castables compared to that in Al₂O₃–spinel castables is evidenced by the recrystallization of the in situ spinel only occurring in Al₂O₃–MgO castables as revealed by the XRD patterns at ambient temperature and at 1500°C. The larger amount and smaller grain size of the in situ spinel in the matrix mostly account for the better slag resistance of Al₂O₃–MgO castables, compared to Al₂O₃–spinel castables.     

Solid Solution and Chromium Oxide Loss in Part of the System MgO-Al2O3-Cr2O3-SiO2

Thermal and X-ray studies show that there is complete solid solution between MgO.Cr₂O₃ and MgO.Al₂O₃ and that the spinel solid solutions are stable with no exsolution down to temperatures as low as 510°C. There is no solid solution of excess Cr₂O₃ in MgO.Cr₂O₃ nor of MgO.Cr₂O₃ in Cr₂O₃. The join MgO.Cr₂O₃–Al₂O₃ is found to be nonbinary; compositions along that join yield mixtures of a chromium oxide-alumina solid solution and a spinel solid solution on firing to temperatures high enough to promote solid-state reaction. Chromium oxide loss by volatilization increases at higher temperature. At a given temperature, chromium oxide loss is found to vary directly with the partial pressure of oxygen in the furnace atmosphere and with the ratio of MgO to SiO₂ in the charges heated.     

Formation of NiAl2O4 by Solid State Reaction

The growth of nickel-aluminum spinel, NiAl₂O₄, in diffusion couples of polycrystalline Al₂O₃ and NiO was investigated between 1200° and 1500°C. The growth kinetics for the spinel layer obeyed a parabolic rate law in this temperature range. Marker experiments showed that the spinel layer formed by counterdiffusion of nickel and aluminum ions. Comparison of experimental and theoretical values of the parabolic rate constants suggests that the diffusion of aluminum ions through the spinel layer is rate controlling.     

Conversion of Polycrystalline Al2O3 into Single-Crystal Sapphire by Abnormal Grain Growth

In a given batch more than 30%–40% of polycrystalline, MgO-doped Al₂O₃ tubes were converted into single crystals of sapphire by abnormal grain growth (AGG) in the solid state at 1880°C. Most crystals grew 4–10-cm in length in tubes with wall thicknesses of 1/2 and 3/4 mm and outer diameters of 5 and 7 mm, respectively, and had their c -axes oriented ∼ 90° and 45° to the tube axis. Initiation of AGG was associated with low values of bulk MgO concentration near 50 ppm. The unconverted tubes did not develop centimeter-size crystals but instead exhibited millimeter-size grains. The different grain structures in converted and unconverted tubes may be related to nonuniform concentration of MgO in the extruded tubes. The growth front of the migrating crystal boundary was typically nonuniformly shaped, and the interface between the single crystal and the polycrystalline matrix was composed of many "curved" boundary segments indicative of classical AGG in a single-phase material. The average velocities of many migrating crystal boundaries were quite high and reached ∼1.5 cm/h. The average grain boundary mobility at 1880°C was calculated as 2 × 10⁻¹⁰ m³/(N·s), representing the highest value reported so far in Al₂O₃ and within a factor of 2.5 of the calculated intrinsic mobility. Under similar experimental conditions sapphire crystals did not grow when a codopant of CaO, La₂O₃, or ZrO₂ was added in concentrations of several hundred ppm.     

Indirect Dissolution of (Al, Cr)2O3 in CaO—MgO—Al2O3—SiO2 (CMAS) Melts

The dissolution of (Al, Cr)₂O₃ into CaO—MgO—Al₂O₃—SiO₂ melts, under static and forced-convective conditions was investigated at 1550°C in air. With sufficient MgO in the melt, or sufficient Cr₂O₃ in (Al, Cr)₂O₃, a layer consisting of a spinel solid solution, Mg(Al, Cr)₂O₄, formed at the (Al, Cr)₂O₃/melt interface. The dissolution kinetics of 1.5 and 10 wt% Cr₂O₃ specimens were determined as a function of immersion time, specimen rotation rate, and magnesia content of the melt. Electron microprobe analysis was used to characterize concentration gradients in the (Al, Cr)₂O₃ sample, the Mg(Al, Cr)₂O₄ spinel, or in the melt after immersion of specimens containing 1.5 to 78 mol% Cr₂O₃. The dissolution kinetics and microprobe analyses indicated that a steady-state condition was reached during forced-convective, indirect (Al, Cr)₂O₃ dissolution such that spinel layer formation was rate limited by solid-state diffusion through the spinel layer and/or through the specimen, and spinel layer dissolution was rate limited by liquid-phase diffusion through a boundary layer in the melt. This is consistent with a model previously developed for the indirect dissolution of sapphire in CMAS melts.     

Oxidation Protection of MgO–C Refractories by Means of Al8B4C7

The effect of Al₈B₄C₇ used as an antioxidant in MgO–C refractories and the behavior of Al₈B₄C₇ in CO gas were investigated in the present study. Al₈B₄C₇ was found to react with CO gas, to form Al₂O₃( s ), B₂O₃( l ), and C( s ), at temperatures >1100°C. The Al₂O₃ reacts with MgO to form MgAl₂O₄ near the surface of the material. At the same time, B₂O₃( l ) evaporates and reacts with MgO, to form a liquid phase, at >1333°C, the eutectic point between 3MgO·B₂O₃ and MgO. The coexistence of the liquid and MgAl₂O₄ makes the protective layer more dense, thus inhibiting oxidation of the refractory. At >1333°C, the process apparently is controlled by oxygen diffusion, whereas it is controlled by chemical reaction when the temperature is <1333°C.     

High-Temperature Elastic Properties of Polycrystalline MgO and Al2O3

Adiabatic bulk modulus, B_s , of polycrystalline MgO and Al₂O₃ was measured from 298° to 1473°K using the resonance technique. The Grüneisen constant, calculated from the measured bulk modulus, was constant over the whole temperature range (1.53 for MgO and 1.34 for Al₂O₃). Another important parameter,     , is constant at high temperature and is 3.1 for MgO and 3.6 for Al₂O₃. The Poisson's ratio increases linearly with temperature for MgO and Al₂O₃. To describe the change of bulk modulus with temperature a theoretical equation was verified by using the foregoing constants. A practical form of this theoretical equation is where B_s⁰ is the adiabatic bulk modulus at 0°K, δ is the quantity     , γ is the Grüneisen constant, H is the enthalpy. The experimental data are described very well by this equation, which is equivalent to the empirical equation suggested by Wachtman et al., B_s^T= B_s⁰ - CT exp (-T_c/T) , where C and T_c are empirical constants.     

Effect of Rapid Solidification on Microstructural Evolution in MgO–MgAl2O4

The response of the MgO–20 and 30 mol% Al₂O₃ compositions to rapid solidification has been studied. The oxides were twin-roller quenched and the resulting flakes were characterized by X-ray diffraction and transmission electron microscopy. The results indicate that metastable extensions of spinel and periclase occurred and the microstructural pathway was determined from the final microstructure. The flakes having MgO–20 mol% Al₂O₃ show a dendritic structure consisting of periclase and spinel. In the MgO–30 mol% Al₂O₃ composition, the liquid transforms to spinel partitionlessly. The spinel is believed to undergo decomposition by a modulation in composition, and the resulting microstructure consists of spinel and periclase. Kinetic and thermodynamic aspects of phase selection have been rationalized based on the metastable extensions of the different phase fields in the phase diagram. It has been proposed that composition fluctuations in spinel are stabilized because of the formation of disordered phases with a continuous range of order parameter on the tetrahedral sublattice.     

Mineralizing Effect of Li2B4O7 and Na2B4O7 on Magnesium Aluminate Spinel Formation

Lithium borate (Li₂B₄O₇) and sodium borate (Na₂B₄O₇) mineralize spinel formation from stoichiometric MgO and Al₂O₃ between 1000° and 1100°C. Mineralization with both compounds is shown to be mediated by B-containing liquids which form glass on cooling. However, the liquid compositions depend on the type of mineralizer and temperature, suggesting that templated grain growth or dissolution–precipitation mechanisms are operating, one dominating over the other under certain conditions. Na₂B₄O₇-mineralized compositions show predominantly templated grain growth at 1000°C, which changes to dissolution–precipitation at 1100°C, whereas Li₂B₄O₇-mineralized compositions show dissolution–precipitation from 1000°C. Li₂B₄O₇ is a stronger mineralizer as spinel formation is complete with 3 wt% Li₂B₄O₇ at 1000°C and with ≥1.5 wt% addition at 1100°C, whereas Na₂B₄O₇-mineralized compositions are found to retain some unreacted corundum even at 1100°C.     

Phase Relations and Lattice Constants in the MgO-Al2O3-Ga2O3 System at 1550°C

Phase relations and lattice constants in the MgO–Al₂O₃–Ga₂O₃ system at 1550°C have been determined experimentally. In a large part of this system, only a nonstoichiometric spinel is stable. Compositions as extreme as 12.5 mol% MgO–20.5 mol% Ga₂O₃–67 mol% Al₂O₃ for a homogeneous spinel are possible. In the bordering phase diagrams of MgO–Al₂O₃ and MgO–Ga₂O₃, the composition of the spinel is as high as 63 mol% Al₂O₃ or Ga₂O₃, respectively. The contributions of all simple ionic exchange reactions on the lattice constant of the spinel have been deduced from X-ray diffractometry data.     

Thermal Grooving of MgO and Al2O3

High-purity polycrystalline MgO and Al₂O₃ were thermally grooved at 1500° and 1600°C. Accurate techniques were developed for following the growth of a single groove. For high-purity samples growth kinetics were essentially similar to those reported in the literature but were determined to be controlled by volume diffusion. Specimens for thermal grooving were prepared from Al₂O₃ to which transition metal oxides (Fe₂O₃₉, MnO, and TiO₂), which are known to accelerate shrinkage and sintering of Al₂O₃ powder compacts, had been added; the rate of groove growth was increased remarkably by minor amounts of these additives. Control of partial pressure indicated that Fe²⁺ and Ti⁴⁺ are the species active in promoting groove growth. Substantial evidence was found for volume diffusion as the mechanism controlling groove formation.     

The Al2O3-Nd2O3 Phase Diagram

A tentative phase diagram for the system Al₂0₃-Nd₂O₃ is presented. Three compounds were obtained: a β -A1₂O₃-type compound, the perovskite NdAlO₃, and Nd₄Al₂O₉. The perovskite melts congruently (mp 2090°C), and the two other compounds exhibit incongruent melting behavior: β -Nd/Al₂O₃, mp 1900°C; Nd₄Al₂O₉, mp 1905°C. Two eutectics exist with the following compositions and melting points: 80 mol% Al₂O₃, 1750°C; 23 mol% Al₂O₃,1800°C. Nd₄Al₂O9 decomposes in the solid state at 1780°C.     

The System MgO–MgAl2O4

In the determination of the liquidus, solidus, and subsolidus of the system MgO-MgAl₂O₄ the limits of the solid solution of A1 ions in periclase and Mg ions in spinel were measured. By using both X-ray diffraction and optical techniques, the maximum periclase solid solution was found at 82 wt% MgO, 18 wt% A12O3 (9.5% A1³⁺) and maximum spinel solid solution at 39% MgO, 61 % A1203 (6% Mg⁺⁺). Periclase and spinel solid solutions existed stably in easily detectable amounts at temperatures above approximately 1500°C.     

Activity–Composition Relations in NiAl2O4─MnAl2O4 Solid Solutions and Stabilities of NiAl2O4 and MnAl2O4 at 1300° and 1400°C

Activities of NiO were measured in the oxide and spinel solutions of the system MnO–NiO–Al₂O₃ at 1300° and 1400° C with the aim of deriving information on the thermodynamic properties of the spinel phases. Synthetic samples in selected phase assemblages of the system were equilibrated with metallic nickel and a gas phase of known oxygen partial pressures at a total pressure of 1 atm. The data on NiO activities and directions of conjugation lines between coexisting oxide and spinel phases were used to establish the activity–composition relations in spinel solid solutions at 1300° and 1400°C. The MnAl₂O₄–NiAl₂O₄ solid solutions exhibit considerable negative deviations from ideality at these temperatures. The free energy of formation of MnAl₂O₄ from its oxide components (MnO + Al₂O₃) at 1300° and 1400°C is calculated to be −24.97 and −26.56 kJ. mol⁻¹, respectively. The activities determined in the stoichiometric spinel solid solutions are more negative as compared with those predicted from cation distribution models.     

Molten Salt Synthesis of Magnesium Aluminate (MgAl2O4) Spinel Powder

MgAl₂O₄ (MA) spinel powder was synthesized by heating an equimolar composition of MgO and Al₂O₃ in LiCl, KCl, or NaCl. The synthesis temperature can be decreased from >1300°C (required by the conventional solid–solid reaction process) to ∼1100°C in LiCl, or to ∼1150°C in KCl or NaCl. The molten salt synthesized MA powder was pseudomorphic and retained, to a large extent, the size and morphology of the original Al₂O₃ raw material, indicating that a "template formation mechanism" plays an important role in the synthesis process.     

Coherent Precipitation in the System MgO-Al2O3-Cr2O3

An isothermal section of the ternary system MgO–Al₂O₃-Cr₂O₃ was determined at 1700°± 15°C to delineate the stability field for spinel crystalline solutions (cs). Crystalline solutions were found between the pseudobinary joins MgAl₂O₄–Cr₂O₃ and MgCr₂O₄-Al₂O₃, and the binary join MgAl₂O₄-MgO. The first two crystalline solutions exhibit cation vacancy models while the latter can probably be designated as a cation interstitial model. Precipitation from spinel cs may proceed directly to an equilibrium phase, (Al_1-xCr_x)₂O₃, with the corundum structure or through a metastable phase of the probable composition Mg(Al_1-xC_r)₂₆O₄₀. The composition and temperature limits were defined where the precipitation occurs via metastable monoclinic phases. The coherency of the metastable monoclinic phase with the spinel cs matrix can be understood by considering volume changes with equivalent numbers of oxygens and known crystallographic orientation relations. Electron probe and metallographic microscope investigations showed no preferential grain boundary precipitation.     

Strength Degradation and Crack Propagation in Thermally Shocked Al2O3

Strength degradation and crack propagation in Al₂O₃ are shown to depend on the initial strength and grain size of the material. The strengths of single-crystal sapphire and polycrystalline Al₂O₃ specimens with grain sizes of 10, 34, and 40 μ m decreased discontinuously at the critical quenching temperature. In contrast, the strength of polycrystalline Al₂O₃ with a grain size of 85 μm decreased gradually as the quenching temperature increased. The strength retained after thermal shock and the extent of crack propagation decrease with increasing initial strength and grain size, respectively, in Al₂O₃.     

Crystalline Solution in the System MgO-Mg,SiO4,-MgAl2,O4,

Crystalline solubility relations in the system MgO-Mg₂SiO₄MgAl₂O₄ (periclase-forsterite-spinel) were studied using coprecipitated gels as starting materials. The substitution 2Al = Mg + Si was investigated along the join Mg₂SiO₄-Mg-Al₂O₄,. At 1720°C the maximum crystalline solution in forsterite is about 0.5 mole % MgAI₂O₄, and in spinel it is slightly more than 5.0 mole % Mg₂SiO₄. The solubility of MgO in forsterite was 0.5 mole % at 1860°C, whereas more than 11 mole % Mg₂SiO₄ can be dissolved in the periclase structure at this temperature. Ternary crystalline solution exists in the periclase structure to a composition of Mg_0.853Al_0.063Si_0.026O at 1710°C.