Densification and mechanical properties of fine-grained Al2O3-ZrO2 composites consolidated by spark plasma sintering

Alumina matrix composites containing 5 and 10 wt% of ZrO₂ were sintered under 100 MPa pressure by spark plasma sintering process. Alumina powder with an average particle size of 600 nm and yttria-stabilized zirconia with 16 at% of Y₂O₃ and with a particle size of 40 nm were used as starting materials. The influence of ZrO₂ content and sintering temperature on microstructures and mechanical properties of the composites were investigated. All samples could be fully densified at a temperature lower than 1400 °C. The microstructure analysis indicated that the alumina grains had no significant growth (alumina size controlled in submicron level 0.66-0.79 μm), indicating that the zirconia particles provided a hindering effect on the grain growth of alumina. Vickers hardness and fracture toughness of composites increased with increasing ZrO₂ content, and the samples containing 10 wt% of ZrO₂ had the highest Vickers hardness of 18 GPa (5 kg load) and fracture toughness of 5.1 MPa m^1/2.     

CVD deposition and characterization of coloured Al2O3/ZrO2 multilayers

Coloured Al₂O₃/ZrO₂ multilayers have been deposited onto WC-Co based inserts by a CVD process. Through physical as well as optical analysis of such multilayers, colour is believed to originate from interference. The coatings are obtained with good process reproducibility. It was found that the ZrO₂ process used in the multilayer, with ZrCl₄ as the only metal chloride precursor, results in a mixture of tetragonal and monoclinic ZrO₂ phases. However by adding a relatively small amount of AlCl₃ during such a process results in ZrO₂ layers being composed of predominantly tetragonal ZrO₂ phase. Corresponding multilayers seem to have a more fine grained and smoother morphology whereas multilayers containing monoclinic ZrO₂ phase seem to be less perfect with existence of larger grains of ZrO₂ which are believed to scatter light and alter the reflectance of such a multilayer. In addition to this, such multilayers were found to be free of or with greatly reduced amount of thermal cracks, normally present in pure CVD grown Al₂O₃ layers.It is believed that, in the studied Al₂O₃/ZrO₂ multilayers, the observed tetragonal ZrO₂ phase is the result of a size effect, where small enough ZrO₂ crystallites energetically favor the tetragonal phase. However as the ZrO₂ crystallite size distribution is shifted to larger sizes it is believed that a mixture of crystallites with both stable and metastable tetragonal phases as well as a stable monoclinic phase is obtained. The proposed metastable tetragonal ZrO₂ phase may in fact explain the absence of thermal cracks in such multilayers through a transformation toughening mechanism, well known in ZrO₂ based ceramics.     

Synthesis, vacuum sintering and dielectric characterization of zirconia (t-ZrO2) nanopowder

Phase pure zirconium oxide powders have been synthesized using the single step auto-ignition combustion method, the particles were nanometer sized (20 nm) and the size distribution was very narrow (3.4 nm). Systematic structural characterization revealed the t-ZrO₂ and indexed for its tetragonal structure (a = 3.5975 Å and c = 5.1649 Å). Calculated microstrain in most of the plane indicated the presence of compressive stress (65-288 MPa) along various planes of the particles. Observed space group (P4₂/nmc) revealed the presence of cations in the 8e positions (0.75, 0.25, 0.75) and the anions in the 16 h positions (0.25, 0.25, 0.4534). The metal-oxide (Zr-O) band observed at the low wavenumber region further confirmed the phase purity of the as-prepared ZrO₂ nanopowders. Peaks at the binding energy positions 2.042 and 0.525 keV in the energy dispersive X-ray spectrum revealed oxygen deficient zirconia. The particle size estimated by TEM was in good agreement with the results obtained through X-ray line broadening (20.81 nm) measurements. The nanopowders were sintered to above 98% of the theoretical density by using vacuum sintering technique at a relatively low temperature of 1300 °C. Stable tetragonal ZrO₂ experimentally yield the permittivity value of about 28 at 10 MHz.     

Opportunities for TBCs in the ZrO2-YO1.5-TaO2.5 system

An examination of the ZrO₂-YO_1.5-TaO_2.5 system reveals several promising attributes for use in thermal barrier coating applications. The rather unique presence of a stable, non-transformable tetragonal region in this ternary oxide system allows for phase stability to high temperatures (1500 °C). Selected compositions with high levels of yttria and tantala have also shown superior resistance to vanadate corrosion than the commercially utilized 7YSZ. In addition, Y + Ta stabilized zirconia compositions within the non-transformable tetragonal phase field exhibit toughness values comparable or somewhat higher than those of 7YSZ, which bodes well for their durability as TBCs. These promising attributes are discussed in this paper in the context of recent experimental work.     

A strategy for single-step elaboration of V2O5-grafted TiO2 nanostructured photocatalysts with evenly distributed pores

V₂O₅-TiO₂ nanostructured porous layers were grown through micro arc oxidation of titanium in vanadate containing electrolytes. This study sheds light on the effect of the electric current type on the photocatalytic performance of the layers. Surface morphology of the layers was investigated by SEM. The results revealed a porous structure with a pores size of 30-180 nm depending on the frequency and the duty cycle. A uniform porous structure was obtained under the pulse-DC regime. Topographical investigations revealed a rough surface which is favorable for catalytic applications. Our XRD and XPS results showed that the layers consisted of anatase, rutile, and vanadium oxide phases whose fraction was observed to change depending on the electric variables. Finally, methylene blue was selected as a model material in order to evaluate the photocatalytic performance of the grown layers. The layers which were fabricated under pulse current, especially those synthesized at the frequency of 500 Hz and duty cycle of 5%, exhibited higher photocatalytic efficiency under ultraviolet and visible illuminations on account of their higher surface area and anatase/rutile fraction.     

An evaluation of Al2O3-ZrO2 composites produced by coprecipitation method

The objective of this work is to produce Al₂O₃-ZrO₂ composite from nano-sized powders processed by coprecipitation method. Al₂O₃ and mixture of Al₂O₃ + 10 wt.% ZrO₂ precipitated successfully by chemical route from aluminum sulfate and zirconium sulfate were pressed under uniaxial compression of 170 MPa and sintered at 1600 °C for 1 h. SEM investigations revealed that, pure alumina sample has a microstructure with coarse grains which anisotropically grown up to 30-40 μm in size. In alumina-zirconia composite, the structure consists of very fine equiaxed grains of typically 2 μm in which zirconia precipitates were uniformly dispersed. By adding zirconia to alumina, hardness and indentation fracture toughness were increased from 11.6 GPa to 16.8 GPa and from 3.2 MPa m^1/2 to 4.9 MPa m^1/2, respectively. Improvement in fracture toughness was attributed to bridging effects of zirconia particles as well as transformation toughening.     

Tetragonal-cubic phase boundary in nanocrystalline ZrO2-Y2O3 solid solutions synthesized by gel-combustion

By means of synchrotron X-ray powder diffraction (SXPD) and Raman spectroscopy, we have detected, in a series of nanocrystalline and compositionally homogeneous ZrO₂-Y₂O₃ solid solutions, the presence at room temperature of three different phases depending on Y₂O₃ content, namely two tetragonal forms and the cubic phase. The studied materials, with average crystallite sizes within the range 7-10 nm, were synthesized by a nitrate-citrate gel-combustion process. The crystal structure of these phases was also investigated by SXPD. The results presented here indicate that the studied nanocrystalline ZrO₂-Y₂O₃ solid solutions exhibit the same phases reported in the literature for compositionally homogeneous materials containing larger (micro)crystals. The compositional boundaries between both tetragonal forms and between tetragonal and cubic phases were also determined.     

Synthesis and crystallization behavior of 3 mol% yttria stabilized tetragonal zirconia polycrystals (3Y-TZP) nanosized powders prepared using a simple co-precipitation process

The synthesis and crystallization behavior of 3 mol% yttria stabilized tetragonal zirconia polycrystals (3Y-TZP) nanopowders prepared using a simple co-precipitation process at 348 K and pH = 7 were investigated using differential scanning calorimetry/thermogravimetry (DSC/TG), an X-ray diffractometer (XRD), the Raman spectra, transmission electron microscopy (TEM), selected area electron diffraction (SAED), and an energy dispersive spectrometer (EDS). The activation energy of tetragonal ZrO₂ crystallization from 3Y-TZP freeze-dried precursor powders using a non-isothermal method, namely, 169.2 ± 21.9 kJ mol⁻¹, was obtained. The growth morphology parameter n was approximated as 2.0, which indicated that it had a plate-like morphology. The XRD, Raman spectra, and SAED patterns showed that the phase of the tetragonal ZrO₂ was maintained at 1273 K. The crystallite size of 3Y-TZP freeze-dried precursor powders calcined at 1273 K for 5 min was 21.3 nm.     

Characteristics of BaO-B2O3-SiO2 nano glass powders prepared by flame spray pyrolysis as the sintering agent of BaTiO3 ceramics

Nanosized BaO-B₂O₃-SiO₂ glass powders are directly prepared by flame spray pyrolysis. The mean size of the BaO-B₂O₃-SiO₂ glass powders with amorphous phase and spherical shape is 30 nm. The effects of glass powders on the sintering characteristics of the BaTiO₃ pellet formed from the nanosized BaTiO₃ powders are investigated. The mean size and BET surface area of the BaTiO₃ powders prepared by spray pyrolysis are 110 nm and 9.1 m²/g. The BaTiO₃ pellet with glass additive has large grain size with several microns, dense structure and pure tetragonal crystal structure at a sintering temperature of 1000 °C. The XRD pattern of the pellet has distinct split of (2 0 0) and (0 0 2) peaks at 2θ ≈ 44.95°. The dielectric constant of the pellet without glass additive is 2180. However, the dielectric constants of the pellets with 1, 3, 5 and 7 wt% glass additive with respect to BaTiO₃ are 2496, 2514, 2700 and 2225, respectively.     

Microstructure, kinetic analysis and hardness of Sn-Ag-Cu-1 wt% nano-ZrO2 composite solder on OSP-Cu pads

Nano-sized, nonreacting, noncoarsening ZrO₂ particle-reinforced Sn-Ag-Cu composite solders were prepared by mechanically dispersing ZrO₂ nano-particles into Sn-Ag-Cu solder and the interfacial morphology between the solder and organic solderability preservative (OSP)-Cu pads were characterized metallographically. At their interfaces, island-shaped Cu₆Sn₅ and Cu₃Sn intermetallic compound (IMC) layers were found in solder joints with and without the ZrO₂ particles and the IMC layer thickness was substantially increased with reaction time and temperature. In the solder ball region, needle-shaped Ag₃Sn and spherically-shaped Cu₆Sn₅ IMC particles were found to be uniformly distributed in the β-Sn matrix. However, after the addition of ZrO₂ nano-particles, Ag₃Sn and Cu₆Sn₅ IMC particles appeared with a fine microstructure and retarded the growth rate of the IMC layers at their interfaces. From a kinetic analysis, the calculated activation energies for the total (Cu₆Sn₅ + Cu₃Sn) IMC layers for Sn-Ag-Cu and Sn-Ag-Cu-1 wt% ZrO₂ composite solder joints on OSP-Cu pads were about 53.2 and 59.5 kJ/mol, respectively. In addition, solder joints containing ZrO₂ nano-particles displayed higher hardness due to the uniform distribution of ZrO₂ nano-particles as well as the refined IMC particles. The hardness values of the plain Sn-Ag-Cu solder joint and solder joints containing 1 wt% of ZrO₂ nano-particles after 5 min reaction at 250 °C were about 15.0 Hv and 17.1 Hv, respectively. On the other hand, their hardness values after 30 min reaction were about 13.7 Hv and 15.5 Hv, respectively.     

Effects of oxygen concentration in the Ar/O2 plasma on the bulk structure and surface properties of RF reactively sputtered zirconia thin films

Zirconium oxide is one of the most extensively studied transition-metal oxides for its several attractive properties and the variety of its technological applications. Research was especially stimulated in understanding the factors controlling the structure of ZrO₂ and in identifying the relationship between bulk and surface properties of ZrO₂ thin films. In the present work, ZrO₂ thin films were deposited on Si, without external heating, by RF reactive sputtering from a pure ZrO₂ target in Ar/O₂ plasma with different O₂ concentrations (0 ÷ 20%). Aim of the study was the identification of the effects of the processing parameters - mainly the O₂/Ar ratio in the gas phase - on the film growth and properties. The addition of O₂ was crucial to establish a good stoichiometry, as revealed by Auger depth profiling. The films obtained under O₂-deficient plasma conditions have polycrystalline nanograins whose structure was consistent with either a tetragonal or a cubic phase. Adding O₂ to the gas mixture turns their structure into the stable monoclinic one. Such bulk structural changes were found to affect both their mechanical behaviour and their surface properties: a chemical shift of the Zr3d and O1s core levels to lower binding energies was recorded by XPS analyses, common to all the samples deposited in presence of O₂. This effect was thought to be related to the oxygen induced tetragonal/cubic-to-monoclinic transformation of the oxide structure.     

Dielectric and microwave properties of ZrO2 doped CaO-SiO2-B2O3 ceramic matrix composites

The behavior of dielectric and microwave properties against sintering temperature has been carried out on CaO-SiO₂-B₂O₃ ceramic matrix composites with ZrO₂ addition. The results indicated that ZrO₂ addition was advantageous to improve the dielectric and microwave properties. X-ray diffraction (XRD) patterns show that the major crystalline β-CaSiO₃ and a little SiO₂ phase existed at the temperature ranging from 950 °C to 1050 °C. At 0.5 wt% ZrO₂, CaO-SiO₂-B₂O₃ ceramic matrix composites sintered at 1000 °C possess good dielectric properties: ?_r = 5.85, tan δ = 1.59 × 10⁻⁴ (1 MHz) and excellent microwave properties: ?_r = 5.52, Q · f = 28,487 GHz (11.11 GHz). The permittivity of Zr-doped CaO-SiO₂-B₂O₃ ceramic matrix composites exhibited very little temperature dependence, which was less than ±2% over the temperature range of −50 to 150 °C. Moreover, the ZrO₂-doped CaO-SiO₂-B₂O₃ ceramic matrix composites have low permittivity below 5.5 over a wide frequency range from 20 Hz to 1 MHz.     

Self-organized porous TiO2 and ZrO2 produced by anodization

The present work investigates the electrochemical formation of self-organized high aspect ratio TiO₂ and ZrO₂ nanotube layers. The formation and growth of a self-organized porous layer can be achieved directly by anodization without any templates in fluoride containing electrolytes. The morphology of the porous layers is affected by the electrochemical conditions such as the electrolyte composition, the pH and the exact polarization treatment (such as the potential sweep rate from the open-circuit potential to the anodizing potential). For Ti, nanotube layers are formed with diameters varying from approx. 20 nm to 100 nm and lengths from approx. 0.25 μm to 2.5 μm depending on the electrolytes and pH. On the other hand, for Zr, tubes of 50 nm in diameter and up to approx. 17 μm in length can be grown—a key parameter in this case is the potential sweep rate. The large difference between Ti and Zr in the achievable thickness of nanotube layers indicates a difference in the growth mechanism which may be based on the different chemical dissolution rates of electrochemically formed oxides.     

On the thermodynamics and microstructure of variably cooled and co-doped Y2O3-ZrO2 for application to thermal barrier coatings

For application to thermal barrier coatings (TBCs), ytterbia (Yb₂O₃), ceria (CeO₂) and niobia (Nb₂O₅) are investigated for their effect as co-dopants on the stability of 7 wt% yttria (Y₂O₃)-stabilized zirconia (ZrO₂), known as 7YSZ. Zirconia TBCs must be stabilized to prevent transformations between cubic (c), tetragonal (t) and monoclinic (m) phases during operation, since the latter causes cracking and failure. However, with an increasing use of co-dopants in industry, very little data exist on the cooling rate sensitivities of the stabilizing mechanisms involved. Thus, that is the focus of the current study, together with microstructural and mechanical effects. Co-dopants are added to separate samples of 7YSZ and three cooling schemes are applied. It is found that the stabilizing mechanism of lattice distortions is the most sensitive to cooling rate, and that of oxygen vacancies is relatively insensitive while providing roughly four times more stability against m phase. Additionally, it is shown that m, t and c phases can be identified on fracture surfaces by intergranular, textured transgranular, or smooth transgranular crack propagation, respectively. Furthermore, co-dopants are found to influence Young's modulus according to their cationic properties, their effect on oxygen vacancies and their effect on the amounts of phases retained: Young's modulus is decreased by cationic radii larger than that of Zr⁴⁺, increased with raised concentrations of oxygen vacancies, and decreased with an increased presence of m phase.     

Effect of ZrO2 on corrosion behaviour of chromium coatings

To study the effect of ZrO₂ particles on corrosion behaviour of Cr coating, steel samples were plated in Cr(VI) baths without and with ZrO₂. The corrosion behaviour of plated samples was studied at different exposure times in a solution containing 0.01 mol l⁻¹ H₂SO₄ + 0.5 mol l⁻¹ Na₂SO₄ using cyclic voltammetry and impedance spectroscopy. The equivalent circuit model R_e(Q_cR_pore)(Q_s[OR_s]) was proposed to fit the corrosion process and the parameters Y₀(Q_c),Y₀(Q_s) and R_pore reflecting corrosion behaviour of samples were evaluated. From the results, it was found that samples plated in bath containing ZrO₂ exhibited improved protective properties as a result of the structural characteristics of the coatings obtained; namely, the size and shape of pores.     

Properties and fast low-temperature consolidation of nanocrystalline Ni-ZrO2 composites by high-frequency induction heated sintering

Nanopowders of Ni and ZrO₂ (11 nm and 90 nm, respectively) were synthesized from NiO and Zr by high energy ball milling. A highly dense nanostructured 2Ni-ZrO₂ composite was consolidated at low temperature by high-frequency induction heat sintering within 2 min of the mechanical synthesis of the powders (Ni-ZrO₂) with horizontal milled NiO + Zr powders under 500 MPa pressure. This process allows very quick densification to near theoretical density and prohibits grain growth in nano-structured materials. The grain sizes of Ni and ZrO₂ in the composite were calculated. Finally, the average hardness and fracture toughness values of nanostructured 2Ni-ZrO₂ composites were investigated.     

Nanostructured MgFe2O4 as anode materials for lithium-ion batteries

Transition metal oxides in the nano size region are enormous attention as a new generation of anode materials for high energy density Li-ion batteries. MgFe₂O₄ is used for the first time as active electrode vs. lithium metal in test cells. The research has been focused on the effect of grain size of MgFe₂O₄ and their electrochemical performance studied. In this studies, nanostructured milled MgFe₂O₄ (grain size 19 nm) sample have been compared with relatively large-sized as-prepared sample (grain size 72 nm). From the result, the 19 nm grain size sample delivered an improved discharge capacity of around 850 mAh/g, whereas it is only 630 mAh/g for as-prepared sample (72 nm). These values are two times higher than that of a carbon anode (372 mAh/g). The anomalous capacity may be associated with the formation of oxygen rich MgFe₂O₄ samples.     

Improving the piezoelectric thermal stability by tailoring phase transition behavior in the new (1 − x)[0.65PbMg1/3Nb2/3O3-0.35PbTiO3]-xBiZn1/2Ti1/2O3 perovskite solid solutions

The phase transition behavior and its effect on thermal stability of the piezoelectric properties of the (1 − x)[0.65PbMg_1/3Nb_2/3O₃-0.35PbTiO₃]-xBiZn_1/2Ti_1/2O₃ ceramics with 0 ≤ x ≤ 0.06 were investigated. The phase transition from the monoclinic to tetragonal phase was determined by the dielectric constant and elastic constant measurements. The temperature independent piezoelectric response with −d₃₁ = 188 pC/N was obtained from 175 to 337 K for the composition with x = 0.02. The enhanced thermal stability of piezoelectric response was achieved by shifting the monoclinic-tetragonal phase transition to the lower temperature.     

Microstructure and mechanical properties of laminated ZrB2-SiC ceramics with ZrO2 interface layers

Laminated ZrB₂-SiC ceramics with ZrO₂ interface layers were successfully prepared by tape casting, laminating and hot pressing. The flexural strength and fracture toughness are 561 ± 20 MPa and 14.4 ± 0.3 MPa m^1/2 for parallel direction, and 432 ± 18 MPa and 5.8 ± 0.3 MPa m^1/2 for perpendicular direction. The fracture toughness for parallel direction is improved significantly compared to monolithic ZrB₂-SiC ceramics. The toughening mechanism was attributed to the deflection and branch of the crack and the new microcracks, which would increase the propagation path and fracture work.     

Growth, crystal structure and optical properties of layered dibarium cadmium diborate, Ba2Cd(BO3)2

A novel dibarium cadmium diborate, Ba₂Cd(BO₃)₂, has been successfully synthesized by standard solid-state reaction. Large sheet-like crystal with size up to 20 mm × 15 mm × 0.7 mm has been obtained using top-seed solution growth method. Ba₂Cd(BO₃)₂ crystallizes in the monoclinic space group C2/m with a = 9.6305(4) Å, b = 5.3626(3) Å, c = 6.5236(2) Å, β = 118.079(3)°, Z = 2. The crystal structure is composed of isolated [BO₃] triangles, [CdO₆] octahedra and [BaO₉] polyhedra. CdO₆ are vertex-connected with six BO₃ to form infinite _∞[Cd(BO₃)₂] layers extending in (0 0 1) plane, and two rows of Ba atoms closely occupy two side of _∞[Cd(BO₃)₂] layers to forming stoichiometric sheets. IR and transmittance spectrum of Ba₂Cd(BO₃)₂ were reported.