Vacuum Vaporization in the System MgO-Cr2O3

The vaporization of the system MgO-Cr₂O₃ was studied in a vacuum of 10⁻⁵ torr (10⁻³N/m²) at 1500° to 1700°C using the Langmuir and Knudsen methods. It was found that the phases in the system vaporize nearly congruently and the logarithm of the vaporization coefficient, α, of MgCr₂O₄ increases linearly with increasing reciprocal temperature. Alpha tends to unity at a temperature near the melting point (2525±23°C). The additivity rule can be applied to the Langmuir vaporization rates on the basis of the surface area ratios of the phases in the 2-phase system MgO-Cr₂O₃. The enthalpies of vaporization of MgCr₂O₄ were 695.0 and 549.2 kcaVmol for activated and equilibrium processes, respectively.     

The Series MgCr2O4-MgFe2O4

The characteristics of spinels in the series MgCr₂O₄-MgFe₂O₄ were determined. The plot of cell size vs. molar composition is unusual in series showing complete solid solution because an unusually large deviation from Vegard's law was observed. This deviation is caused by changes in spinel structure with composition and temperature, and an equation was derived which applies a correction in terms of the degree of inversion. The effects of temperature on compositions high in MgFe₂O₄ include changes in density and refractive index. Solid solution of forsterite in MgCr₂O₄ decreases the cell size to 8.329 A but apparently is less than 1%. Changes in composition caused by vapor loss or by dissociation are small enough that this series is essentially binary below 1400° C.     

Influence of Oxygen Activity on the Sintering of MgCr2O4

The sintering behavior of MgCr₂O₄ powder compacts was investigated as a function of temperature, time, and oxygen activity. The results show that MgCr₂O₄ cannot be densified to >70% of theoretical density at temperatures up to 1700°C if the oxygen activity exceeds 10⁻⁶ atm. The oxygen activity must be decreased to <10⁻¹⁰ atm before densities exceeding 90% of theoretical can be achieved. Weight loss and X-ray data indicated that maximum density occurred at an oxygen activity just above that where MgCr₂O₄ becomes unstable.     

The System MgO-Cr2O3−Fe2O3 at 1300°c in Air

Phase relations in air at 1300°C were determined for the system MgO-Cr₂O₃−Fe₂O₃ by conventional quenching techniques. Details of the phase equilibria were established for: (1) the sesquioxide solid solution between Cr₂O₃ and Fe₂O₃, (2) the spinel solid solution field between MgCr₂O₄ and MgFe₂O₄, and (3) the periclase solid solution field for MgO. Selected tie lines connecting coexisting compositions were established with X-ray diffractometer data. Diffuse reflectance spectra, diffractometer intensity ratios, and lattice parameter measurements were obtained for quenched samples to study the structural inversion in the spinel series MgCr₂O4-MgFe₂O₄.     

Preparation of Porous Cr3C2 Grains with Cr2O3

Porous Cr₃C₂ grains (∼300 to 500 μm) with ∼10 wt% of Cr₂O₃ were prepared by heating a mixture of MgCr₂O₄ grains and graphite powder at 1450° to 1650°C for 2 h in an Al₂O₃ crucible covered by an Al₂O₃ lid with a hole in the center. The porous Cr₃C₂ grains exhibited a three-dimensional network skeleton structure. The mean open pore diameter and the specific surface area of the porous grains formed at 1600°C for 2 h were ∼3.5 (μm and ∼6.7 m²/g, respectively. The present work investigated the morphology and the formation conditions of the porous Cr₃C₂ grains, and this paper will discuss the formation mechanism of those grains in terms of chemical thermodynamics.     

Combustion Synthesis of Metal Chromite Powders

Fine-particle metal chromites (MCr₂O₄, where M = Mg, Ca, Mn, Fe, Co, Ni, Cu, and Zn) have been prepared by the combustion of aqueous solutions containing the respective metal nitrate, chromium(III) nitrate, and urea in stoichiometric amounts. The mixtures, when rapidly heated to 350°C, ignite and yield voluminous chromites with surface areas ranging from 5 to 25 m²/g. MgCr₂O₄, sintered in air at 1500°C for 5 h, has a density of 4.0 g/cm³.     

Phase Equilibria in the Systems NiO-Cr2,O3,-O2, MgO-Cr2O3−O2, and CdO-Cr2,O3,-O2, at High Oxygen Pressures

Phase equilibria were determined for the systems NiO-Cr₂O₃−O₂, MgO-Cr₂O₃,-O₂, and CdO-Cr₂O₃−O₂ from 450° to above 850° C and at oxygen pressures of from 2 to 3500 atm. Only two intermediate phases were found in the nickel system: NiCrO., (CrVO₄ structure) and the spinel NiCr₂O₄. The magnesium and cadmium systems are similar in that they have three analogous phases: the low-temperature α-MgCrO₄ and α-CdCrO₄ (both with the CrVO₄ structure), the high-temperature β-MgCrO₄ and β-CdCrO₄ (both with the α-MnMoO₄ structure), and the spinels MgCr₂O₄ and CdCr₂O₄. The cadmium system contains an additional phase, Cd₂CrO₅, which is primitive monoclinic.     

Strength and Phase Stability of Yttria-Ceria-Doped Tetragonal Zirconia/Alumina Composites Sintered and Hot Isostatically Pressed in Argon–Oxygen Gas Atmosphere

Yttria-ceria-doped tetragonal zirconia (Y,Ce)-TZP)/alumina (Al₂O₃) composites were fabricated by hot isostatic pressing at 1400° to 1450°C and 196 MPa in an Ar–O₂ atmosphere using the fine powders prepared by hydrolysis of ZrOCl₂ solution. The composites consisting of 25 wt% Al₂O₃ and tetragonal zirconia with compositions 4 mol% YO_1.5–4 mol% CeO₂–ZrO₂ and 2.5 mol% YO_1.5–5.5 mol% CeO₂–ZrO₂ exhibited mean fracture strength as high as 2000 MPa and were resistant to phase transformation under saturated water vapor pressure at 180°C (1 MPa). Postsintering hot isostatic pressing of (4Y, 4Ce)-TZP/Al₂O₃ and (2.5Y, 5.5Ce)-TZP/Al₂O₃ composites was useful to enhance the phase stability under hydrothermal conditions and strength.     

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.     

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.     

Hot Isostatic Pressing and Characterization of Sol-Gel-Derived Chromium(III) Oxide

Chromium (III) oxide (Cr₂O₃) crystallizes at low temperatures from an amorphous material prepared by adding hydrazine monohydrate to an aqueous solution of Cr(NO₃)₃-9H₂O. Individual particles of Cr₂O₃ tend toward a hexagonal morphology above 800°C. Well-densified Cr₂O₃ pellets (98.8% of theoretical density) have been fabricated by hot isostatic pressing for 2 h at 1100°C and 196 MPa. Their fracture toughness is 4.4 MPa.m^1/2. The sample annealed in air for 12 h at 1300°C exhibits a high electrical conductivity of 3.6 Ω^-1.m^-1at 700°C.     

Properties of Isostatically Hot-Pressed Silicon Nitride

Hot isostatic pressing was studied for densification of reaction-bonded Si₃N₄ containing various levels of Y₂O₃. Near-theoretical density was achieved for com positions containing 3 to 7 wt% Y₂O₃. An Si₃N₄-5 wt% Y₂O₃ composition had a 4-point flexural strength at 1375°C of 628 MPa and survived 117 h of stress rupture testing at 1400°C and 345 MPa .     

Transformation and Densification of Nanocrystalline θ-Alumina during Sinter Forging

The sinter forging behavior of α-Al₂O₃ seeded and unseeded nanocrystalline θ-Al₂O₃ was investigated as a function of temperature, stress, and strain rate. Seeded samples exhibited the highest degree of plastic deformation during the θ- to α-AI₂O₃ phase transformation. As a result, microstructure control, increased densification, and a higher degree of transformation were obtained. A uniform microstructure of 150 nm α-Al₂O₃ grains developed, reaching 57% relative density after sintering 1.5 wt%α-Al₂O₃ seeded samples for 30 min at 1060°C. When sinter forged at 0.25 mm/min to 63 MPa and 1060°C for 30 min large deformations during the phase transformation increased the relative density to 74%. When the stress was increased to 235 MPa (1060°C, 30 min), 99.7% dense α-Al₂O₃ with a grain size of 230 nm was obtained. By increasing the sinter forging temperature to 1150°C, 99.5% relative density was achieved at 190 MPa for 30 min.     

Improvement of Mechanical and Electrical Properties of Scandia-Doped Zirconia Ceramics by Post-Sintering with Hot Isostatic Pressing

Significant improvement in the fracture strength, accompanied by an enhancement in the electrical conductivity, of zirconia polycrystals that were doped with 3–7 mol% Sc₂O₃ was obtained by sintering at 1300°C for 1 h in air, followed by hot isostatic pressing (HIP) at 196 MPa at 1300° and 1450°C for 1.5 h in an argon-gas atmosphere. Dense bodies (with an average grain size of <0.5 μm) that were doped with 3.5 mol% of Sc₂O₃ showed the highest average fracture strength up to 1770 MPa and an electrical conductivity of 0.08 S/cm at 1000°C. The present zirconia ceramics, which consisted of submicrometer-sized grains of tetragonal phases and were stabilized with 5 and 6 mol% of Sc₂O₃, exhibited high strength (1330 and 1140 MPa, respectively) and good conductivity (0.15 and 0.18 S/cm, respectively); values for both properties were greater than those previously reported. The present HIPed zirconia ceramics, which have excellent properties, are candidates for an electrolyte of planar-type solid oxide fuel cells.     

High Electrical Conductivity and High Fracture Strength of Sc2O3-Doped Zirconia Ceramics with Submicrometer Grains

The microstructure, crystal phase, electrical conductivity, and mechanical strength of less than 7-mol%-Sc₂O₃-doped zirconia ceramics fabricated by comparatively low-temperature sintering at 1200–1300°C for 1 h were investigated. Zirconia ceramics having a uniform microstructure (grain size < 0.5 μm) stabilized with 6 mol% Sc₂O₃ showed high electrical conductivity (0.15 S/cm at 1000°C) and high fracture strength (660 MPa). With the increase of Sc₂O₃ content from 3.5 to 7 mol%, the grain size, fracture strength, and electrical conductivity at 1000°C changed from 0.2 to 0.5 μm, 970 to 440 MPa, and 0.07 to >0.2 S/cm, respectively. Sc₂O₃-doped zirconia polycrystals with high fracture strength and high electrical conductivity are promising candidates for the electrolyte material of solid oxide fuel cells.     

High Quality and Yield in Potassium Titanate Whiskers Synthesized by Calcination from Hydrous Titania

Hydrous titanium dioxide (TiO₂· n H₂O) was used to prepare K₂Ti₂O₅ single crystals, K₂Ti₄O₉ whiskers and K₂Ti₆O₁₃ whiskers at 820°, 940°, and 1110°C, respectively, by calcination. At T < 820°C, dehydration of hydrous titania, decomposition of potassium carbonate, and reaction between titanate and potassium oxide occurred simultaneously, ending with a crystallization reaction of K₂Ti₂O₅ single crystals at 820°C. Subsequently, K₂Ti₂O₅ single crystals convert into K₂Ti₄O₉ whiskers at 940°C, and K₂Ti₄O₉ whiskers further convert into K₂Ti₆O₁₃ whiskers at 1110°C. The reaction temperatures for the generations of these types of potassium titanates were all 10°–40°C lower than the corresponding temperatures when anatase was used as the reactant. The whiskers synthesized in the present study exhibited uniform size, good morphology, and a high yield.     

High-Temperature Strength of Liquid-Phase-Sintered SiC with AlN and Re2O3 (RE = Y, Yb)

Using AlN and RE₂O₃ (RE = Y, Yb) as sintering additives, two different SiC ceramics with high strength at 1500°C were fabricated by hot-pressing and subsequent annealing under pressure. The ceramics had a self-reinforced microstructure consisting of elongated α-SiC grains and a grain-boundary glassy phase. High-temperature strength up to 1600°C was measured and compared with that of the SiC ceramics fabricated with AlN and Er₂O₃. SiC ceramics with AlN and Y₂O₃ showed the best strength (∼630 MPa) at 1500°C, while SiC ceramics with AlN and Er₂O₃ the best strength (∼550 MPa) at 1600°C.     

Thermal, Mechanical, and Chemical Properties of Sintered Xenotime-Type RPO4 (R = Y, Er, Yb, or Lu)

Xenotime-type RPO₄ (R = Y, Er, Yb, or Lu) powder was dry-pressed into disks and bars. The disks and bars could be sintered to a relative density of greaterthan equal to98% in air without cracking at 1300° (R = Yb or Lu) or 1500°C (R = Y or Er), depending on the grain size. The linear thermal expansion coefficient (at 1000°C), thermal conductivity (at 20°C), and bending strength (at 20°C) of the xenotime-type RPO₄ ceramics were 6.2 10^-6/°C, 12.02 W(mK)^-1, and 95 ± 29 MPa for R = Y; 6.0 10^-6/°C, 12.01 W(mK)^-1, and 100 ± 21 MPa for R = Er; 6.0 10^-6/°C, 11.71 W(mK)^-1, and 135 ± 34 MPa for R = Yb; and 6.2 10^-6/°C, 11.97 W(mK)^-1, and 155 ± 25 MPa for R = Lu. The xenotime-type RPO₄ ceramics did not react with SiO₂, TiO₂, Al₂O₃, ZrO₂, or ZrSiO₄, even at 1600°C for 3 h in air, and were stable in aqueous solutions of HCl, H₂SO₄, HNO₃, NaOH, and NH₄OH at 20°C.     

Transformation Plasticity and Toughening in CeO2-Partially-Stabilized Zirconia–Alumina (Ce-TZP/Al2O3) Composites Doped with MnO

Microstructure, phase stability, and mechanical properties of CeO₂-partially-stabilized zirconia (12 mol% Ce-TZP) containing 10 wt% Al₂O₃ and 1.5 wt% MnO were studied in relation to the base Ce-TZP and the Ce-TZP/Al₂O₃ composite without MnO. The MnO reacted with both CeO₂ and Al₂O₃ to form a new phase of approximate composition CeMnAl₁₁O₁₉. The reacted phase had a magnetoplumbite structure and formed elongated, needlelike crystals. The MnO-doped Ce-TZP/Al₂O₃ composites sintered at an optimum temperature of 1550°C exhibited high strength (650 MPa in four-point bending) and rising crack-growth-resistance behavior, with fracture toughness increasing from 7.6 to 10.3 MPa.In¹² in compact tension tests. These improved mechanical properties were associated with relatively high tetragonal-to-monoclinic transformation temperature ( M _s=−42°C) at small grain size (2.5 μm), significant transformation plasticity in mechanical tests (bending, uniaxial tension, and uniaxial compression) and transformation zones at crack tips in compact tension specimens. The transformation yield stress, zone size, and fracture toughness were sensitive to the sintering temperature varied in the range 1500° to 1600°C. Analysis of the transformation zones using Raman microprobe spectroscopy and calculation of zone shielding for the observed zones indicated that a large fraction of the fracture toughness (∼70%) was derived from transformation toughening.     

Microstructure-Mechanical Property Relationships in Hot Isostatically Pressed Alumina and Zirconia-Toughened Alumina

The rates of densification and the mechanical properties of pure Al₂O₃ and ZrO₂-toughened Al₂O₃ (ZTA) have been investigated as a function of the temperatures and time schedules used for hot isostatic pressing (HIP) as a postsintering heat treatment for samples which had already been pressureless sintered in air at 1460°C for 45 min. ZTA hot isostatically presed at 1400°C had a finer grain size and a narrower grain size distribution than ZTA hot isostatically pressed at 1600°C. At both HIP conditions, the density which could be obtained was almost the maximum theoretical density. The amount of grinding-induced and fracture-induced monoclinic ZrO₂ formed as a result of the tetragonal → monoclinic martensitic transformation in ZTA was higher in the samples hot isostatically pressed at 1400°C. ZTA hot isostatically pressed at 1600°C and 100 MPa had fewer flaws and higher strengths than ZTA hot isostatically pressed at 1400°C for the same time, with a gradual improvement in mechanical properties with increasing HIP time at each of these two temperatures. The best mechanical properties were obtained from ZTA hot isostatically pressed at 100 MPa and 1600°C for 1 h: these specimens had a four-point bend strength of 940 ± 15 MPa at room temperature and 540 ± 15 MPa at 1000°C and an indentation fracture toughness at room temperature of 9.4 ± 0.2 MPa·m^1/2.