Properties of (Y)ZrO2–Al2O3 and (Y)ZrO2–Al2O3–(Ti or Si)C Composites

The effect of Al₂O₃ and (Ti or Si)C additions on various properties of a (Y)TZP (yttria-stabilized tetragonal zirconia polycrystal)–Al₂O₃–(Ti or Si)C ternary composite ceramic were investigated for developing a zirconia-based ceramic stronger than SiC at high temperatures. Adding Al₂O₃ to (Y)TZP improved transverse rupture strength and hardness but decreased fracture toughness. This binary composite ceramic revealed a rapid loss of strength with increasing temperature. Adding TiC to the binary ceramic suppressed the decrease in strength at temperatures above 1573 K. The residual tensile stress induced by the differential thermal expansion between ZrO₂ and TiC therefore must have inhibited the t - → m -ZrO₂ martensitic transformation. It was concluded that a continuous skeleton of TiC prevented grain-boundary sliding between ZrO₂ and Al₂O₃. In contrast, for the ternary material containing β-SiC in place of TiC, the strength decreased substantially with increasing temperature because of incomplete formation of the SiC skeleton.     

Mechanical Properties of Interpenetrating Microstructures: The Al2O3/c-ZrO2 System

Composites of Al₂O₃ (A) and cubic ZrO₂ (Z) (8 mol% Y₂O₃) (with c -ZrO₂ volume fractions ranging from O to 1) were fabricated by pressureless sintering of mechanically mixed powders. The microstructures of the AZ composites were duplex, with the grains of both phases exhibiting similar size. Room-temperature mechanical properties including Young's modulus (determined from elastic wave velocity measurements), strength and toughness (by indentation-strength-in-bending), and Vickers microhardness were evaluated for the full range of compositions. All properties exhibited a linear decrease with increasing c -ZrO₂ content, and no R -curve behavior was seen in any of the composite compositions. Fracture morphology, observed from cracks emanating from microhardness indentations, changed from essentially intergranular for the tougher Al₂O₃ to transgranular for c -ZrO₂, with AZ composites exhibiting mixed morphology.     

Microstructure and Microwave Dielectric Properties of Ba(Zn1/3Ta2/3)O3 Ceramics with ZrO2 Addition

The effect of ZrO₂ on crystallographic order, microstructure, and microwave dielectric properties of Ba(Zn_1/3Ta_2/3)O₃ (BZT) ceramics was investigated. A small amount of ZrO₂ disturbed the 1:2 cation ordering. The average grain size of the BZT significantly increased with the addition of ZrO₂, which was attributed to liquid-phase formation. The relative density increased with the addition of a small amount of ZrO₂, but it decreased when the ZrO₂ content was increased. Variation of the dielectric constant with ZrO₂ addition ranged between 27 and 30, and the temperature coefficient of resonant frequency increased abruptly as the ZrO₂ amount exceeded 2.0 mol%. The Q value of the BZT significantly improved with the addition of ZrO₂, which could be explained by the increased relative density and grain size. The maximum Q × f value achieved in this investigation was ∼164 000 GHz for the BZT with 2.0 mol% ZrO₂ sintered at 1550°C for 10 h.     

Microstructural Characterization of ZrO2 Particles Prepared by Reaction of Gaseous ZrCl4 with Fe2O3

The microstructure of ZrO₂ fine particles produced by a novel synthesis method at 450° and 950°C has been studied. The fundamentals of the synthesis method, which involves both chemical and diffusion phenomena, are presented. The method is based on mass transport through the gaseous phase between metallic zirconium and Fe₂O₃ powder. The mass-transporting chemical species are zirconium and iron chlorides. This article focuses on the microstructure and structure of ZrO₂ particles formed by the reaction between gaseous ZrCl₄ and solid Fe₂O₃, which is a relevant reaction step that occurs during the synthesis process. The resulting ZrO₂ crystals grown on Fe₂O₃ particles have been analyzed using transmission electron microscopy. Microstructural characterization has been complemented by X-ray diffractometry analysis. Tetragonal-ZrO₂ is produced at 450°C and monoclinic-ZrO₂ single crystals are produced at 950°C.     

Pulse Electric Current Sintering of Al2O3/3 vol% ZrO2 with Constrained Grains and High Strength

The pulse electric current sintering technique (PECS) was demonstrated to be effective in rapid densification of fine-grained Al₂O₃/3Y-ZrO₂ using available commercial powders. The composites attained full densification (>99% of TD) at 1450°C in less than 5 min. The composites sintered at a high heating rate had a fine microstructure. The incorporation of 3 vol% 3Y-ZrO₂ substantially increased the average fracture strength and the toughness of alumina to as high as 827 MPa and 6.1 MPa·m^1/2, respectively. A variation in the heating rate during the PECS process influenced grain size, microstructure, and strength, though there was little or no variation in the fracture toughness.     

Microstructure and Short-Term Oxidation of Hot-Pressed Si3N4/ZrO2(+Y2O3) Ceramics

Composite ceramic materials based on Si₃N₄ and ZrO₂ stabilized by 3 mol% Y₂O₃ have been formed using aluminum isopropoxide as a precursor for the Al₂O₃ sintering aid. Densification was carred out by hot-pressing at temperatures in the range 1650° to 1800°C, and the resulting micro-structures were related to mechanical properties as well as to oxidation behavior at 1200°C. Densification at the higher temperatures resulted in a fibrous morphology of the Si₃N₄ matrix with consequent high room-temperature toughness and strength. Decomposition of the ZrO₂ grains below the oxidized surface during oxidation introduced radial stresses in the subscalar region, and from the oxidation experiments it is suggested that the ZrO₂ incorporated some N during densification.     

Processing and Mechanical Properties of Al2O3/Ni3Al Composites with Interpenetrating Network Microstructure

Composites with microstructures of interpenetrating networks were manufactured by gas pressure infiltration of Ni₃Al into porous preforms of aluminum oxide. Composites with Ni₃Al contents of between 15% and 30% by volume were made and evaluated mechanically at temperatures between room temperature and 1000°C. The fracture strength, the fracture toughness, Young's modulus, and the thermal expansion coefficient were measured for each composite and test condition and were correlated with the microstructures of the composites. Composites with low Ni₃Al contents had strengths below 400 MPa, presumably due to microcracking along the interface between the Ni₃Al and the Al₂O₃. The composite with the highest content of Ni₃Al, 30 vol%, had a mean fracture strength of 675 ± 16 MPa, a Weibull modulus of 23.9, and a room-temperature toughness of 9.2 ± 0.5 MPa·m^1/2.     

Toughening and Strengthening of NiAl with Al2O3 by the Addition of ZrO2(3Y)

NiAl/10-mol%-ZrO₂(3Y) composites of almost full density have been fabricated via spark plasma sintering (SPS) for 10 min at 1300°C and 30 MPa. The former intermetallic compound, which contains a trace amount of Al₂O₃, has been prepared via self-propagating high-temperature synthesis. The composite microstructures are such that tetragonal ZrO₂ (∼0.2 μm) and Al₂O₃ (∼0.5 μm) particles are located at the grain boundaries of the NiAl (∼46 μm) matrix. Improved mechanical properties are obtained: the fracture toughness and bending strength are 8.8 MPa·m^1/2 and 1045 MPa, respectively, and high strength (>800 MPa) can be retained up to 800°C.     

Conversion from β-Ce2O3·11Al2O3 to α-Al2O3 in Tetragonal ZrO2 Matrix

Composites of β-Ce₂O₃·11Al₂O₃ and tetragonal ZrO₂ were fabricated by a reductive atmosphere sintering of mixed powders of CeO₂, ZrO₂ (2 mol% Y₂O₃), and Al₂O₃. The composites had microstructures composed of elongated grains of β-Ce₂O₃·11Al₂O₃ in a Y-TZP matrix. The β-Ce₂O₃·11Al₂O₃ decomposed to α-Al₂O₃ and CeO₂ by annealing at 1500°C for 1 h in oxygen. The elongated single grain of β-Ce₂O₃·11Al₂O₃ divided into several grains of α-Al₂O₃ and ZrO₂ doped with Y₂O₃ and CeO₂. High-temperature bending strength of the oxygen-annealed α-Al₂O₃ composite was comparable to the β-Ce₂O₃·11Al₂O₃ composite before annealing.     

Densification and Mechanical Properties of B4C with Al2O3 as a Sintering Aid

The densification behavior and mechanical properties of B₄C hot-pressed at 2000°C for 1 h with additions of Al₂O₃ up to 10 vol% were investigated. Sinterability was greatly improved by the addition of a small amount of Al₂O₃. The improvement was attributed to the enhanced mobility of elements through the Al₂O₃ near the melting temperature or a reaction product formed at the grain boundaries. As a result of this improvement in the density, mechanical properties, such as hardness, elastic modulus, strength, and fracture toughness, increased remarkably. However, when the amount of Al₂O₃ exceeded 5 vol%, the level of improvement in the mechanical properties, except for fracture toughness, was reduced presumably because of the high thermal mismatch between B₄C and Al₂O₃.     

Phase Stability and Physical Properties of Cubic and Tetragonal ZrO2 in the System ZrO2–Y2O3–Ta2O5

The cubic ( c -ZrO₂) and tetragonal zirconia ( t -ZrO₂) phase stability regions in the system ZrO₂–Y₂O₃–Ta₂O₅ were delineated. The c -ZrO₂ solid solutions are formed with the fluorite structure. The t -ZrO₂ solid solutions having a c/a axial ratio (tetragonality) smaller than 1.0203 display high fracture toughness (5 to 14 MPa · m^1/2), and their instability/transformability to monoclinic zirconia ( m -ZrO₂) increases with increasing tetragonality. On the other hand, the t -ZrO₂ solid solutions stabilized at room temperature with tetragonality greater than 1.0203 have low toughness values (2 to 5 MPa · m^1/2), and their transformability is not related to the tetragonality.     

Processing and Mechanical Behavior of CrN/ZrO2(2Y) Composites

CrN powder consisting of granular particles of ∼3 μm has been prepared by self-propagating high-temperature synthesis under a nitrogen pressure of 12 MPa using Cr metal. Dense pure CrN ceramics and CrN/ZrO₂(2Y) composites in the CrN-rich region have been fabricated by hot isostatic pressing for 2 h at 1300°C and 196 MPa. The former ceramics have a fracture toughness ( K _IC) of 3.3 MPa ·m^1/2 and a bending strength (σ_b) of 400 MPa. In the latter materials almost all of the ZrO₂(2Y) grains (0.36–0.41 μm) are located in the grain boundaries of CrN (∼4.6 μm). The values of K _IC (6.1 MPa · m^1/2) and σ_b (1070 MPa) are obtained in the composites containing 50 vol% ZrO₂(2Y).     

Crack Resistance and Fatigue of Transforming Ceramics: I, Materials in the ZrO2–Y2O3–Al2O3 System

Crack resistance characteristics and fatigue properties have been studied in four types of Y₂O₃–TZP ceramics including one containing Al₂O₃. The largely linear-elastic behavior connected with the very small transformation zone (<5 μm) explains the absence of any resistance-curve behavior and the flaw-controlled strength. The crack resistance shows high sensitivity to environment-induced subcritical crack growth. This influence is also operative in both types of fatigue experiments, i.e., under static and cyclic stresses, leading to reduced fatigue thresholds compared with K _IC. While for static conditions a benefit is observed from enhanced t-m ZrO₂ transformation, cyclic stresses provoke an additional fatigue effect. However, if the cyclic stresses are restricted to subthreshold values, cyclic stress-induced effects in the process zone provide an improvement of the materials being visible as a strengthening effect.     

Low-Temperature Sintering of Seeded Sol—Gel-Derived, ZrO2-Toughened Al2O3 Composites

Seeding a mixture of boehmite (AIOOH) and colloidal ZrO₂ with α-alumina particles and sintering at 1400°C for 100 min results in 98% density. The low sintering temperature, relative to conventional powder processing, is a result of the small alumina particle size (∼0.3 μm) obtained during the θ-to α-alumina transformation, homogeneous mixing, and the uniform structure of the sol-gel system. Complete retention of pure ZrO₂ in the tetragonal phase was obtained to 14 vol% ZTA because of the low-temperature sintering. The critical grain size for tetragonal ZrO₂ was determined to be ∼0.4 μm for the 14 vol% ZrO₂—Al₂O₃ composite. From these results it is proposed that seeded boehmite gels offer significant advantages for process control and alumina matrix composite fabrication.     

Micromechanical Stresses in SiC-Reinforced Al2O3 Composites

Applying an Eshelby approach, the internal micromechanical stresses within an SiC-inclusion-reinforced (platelet to whisker geometries) polycrystalline alumina matrix composite were calculated. The results are compared to the experimental residual stress measurements of a SiC-whisker-reinforced Al₂O₃ by Predecki, Abuhasan, and Barrett and found to be in excellent agreement. The calculations are then extended to SiC-reinforced composites with polycrystalline mullite, silicon nitride, and cordierite matrices. It is concluded that the internal stresses are significantly influenced by the inclusion geometry as well as the thermoelastic differences between the inclusion and the matrix and also the volume fraction.     

Grain-Size Distribution in Al2O3─ZrO2 Generated by High-Temperature Annealing

Grain-size distribution in various Al₂O₃─ZrO₂ (2.5 mol% Y₂O₃) ceramics during high-temperature annealing was examined. In alumina-rich alloys, the grain size of major and minor phases was very different, while grain size was almost uniform in zirconia-rich alloys. This difference in grainsize distribution was related to the difference in grain growth rate of the major phase and to the effectiveness of grain-boundary pinning by minor-phase grains.     

Dielectric Properties of the Fluorite-like Bi2O3–Nb2O5 Solid Solution and the Tetragonal Bi3NbO7

Our analysis of the microwave dielectric properties of the δ-Bi₂O₃–Nb₂O₅ solid solution (δ-BN_ss) showed a continuous increase in permittivity and dielectric losses with an increasing concentration of Nb₂O₅. The only discontinuity was found for the temperature coefficient of resonant frequency, which is negative throughout the entire homogeneity range but reaches a minimum value for the sample with 20 mol% Nb₂O₅. At the same composition there is a discontinuity in the grain size of the δ-BN_ss ceramics. For the sample containing 25 mol% Nb₂O₅ two structural modifications were observed. A single-phase tetragonal Bi₃NbO₇, in the literature referred to as a Type-III phase, is formed in a very narrow temperature range from 850° to 880°C. A synthesis performed below or above this temperature range resulted in the formation of the end member of the δ-BN_ss homogeneity range. Compared with the δ-BN_ss the Bi₃NbO₇ ceramics exhibit lower microwave dielectric losses, an increased conductivity, and a positive temperature coefficient of resonant frequency.