The wear resistance of Ni alumina and NiAl2O4 alumina nanocomposites

The influence of metallic Ni or NiAl₂O₄ as a reinforcing particle on grain growth and wear resistance in alumina matrix composites was evaluated. Alumina composites with various Ni or NiAl₂O₄ concentrations were prepared by multiple-infiltrations of Ni-nitrate into bisque-fired (necked) alumina green bodies followed by heat treatment and sintering at 1600 °C for 2 h. Sintering in a reducing environment resulted in composites with metallic Ni nanoparticles, while NiAl₂O₄ alumina composites were formed when sintering in air. The addition of Ni or NiAl₂O₄ resulted in a reduction in alumina grain size after sintering. The material response to abrasive wear was estimated by measuring the time to section samples of a defined area using a diamond wafering saw and was compared to the wear resistance of undoped alumina. In both cases, reinforcing alumina with Ni or NiAl₂O₄ particles resulted in a significant increase in wear resistance, correlated to the reduced grain size.     

Microhardness and wear resistance of Al2O3-TiB2-TiC ceramic coatings on carbon steel fabricated by laser cladding

Al₂O₃-TiB₂-TiC ceramic coatings with high microhardness and wear resistance were fabricated on the surfaces of carbon steel substrates by laser cladding using different coating formulations. The microstructures of these ceramic coatings with the different coating formulations were investigated using X-ray diffraction, scanning electron microscopy, and energy dispersive spectrometer. The wear resistance and wear mechanism were analyzed using Vickers microhardness and sliding wear tests. The results showed that when the amount of independent Al₂O₃ was increased to 30%, the ceramic coatings had a favorable surface formation quality and strong metallurgical bond with the steel matrix. The cladding layer was uniformly and densely organized. The black massive Al₂O₃, white granular TiB₂, and TiC distributed on the Fe substrate significantly increased the microhardness and wear resistance. The laser cladding ceramic coating had many hard strengthening phases, and thus resisted the extrusion of rigid particles in frictional contact parts. Therefore, the wear process ended with a “cutting-off” loss mechanism.     

The controllable microstructure of porous Al2O3 ceramics prepared via a novel freeze casting route

In traditional aqueous slurry freezing casting processing, the growth method of ice crystals is hard to control, resulting in the uncontrollable pore's morphologies of the porous ceramics. In the experimental, the pure Al₂O₃ sol was used to substitute water as a medium for preparing ceramic slurry. With Al₂O₃ sol addition, it becomes easy to control the microstructure and pore's morphologies of the porous Al₂O₃ ceramics via adjusting of the solid loading, composition of the ceramic slurries, as well as the cooling methods. The SEM micrographs showed that the sol-contained ceramic slurry combined with freeze casting processing can easily prepare the porous Al₂O₃ ceramics with different pore sizes and different morphologies. The porous Al₂O₃ ceramics prepared from 70 wt.% to 90 wt.% solid loading sol-contained Al₂O₃ slurries and sintered at 1500 °C for 2 h have open porosities from 81.7% to 64.6%.     

Wear resistance glass-ceramics with a gahnite phase obtained in CaO-MgO-ZnO-Al2O3-B2O3-SiO2 system

The thermal conditions for obtaining the glass-ceramic material of Al_0.107B_0.374Mg_0.043Zn_0.282Ca_0.100Si_0.927O₃ with a crystalline phase in the form of gahnite (ZnAl₂O₄) were specified. The activation energy E_a and the Avrami parameter n for the crystallisation process were determined with the non-isothermal DTA procedure. The maximum temperatures of crystallisation of phases, depending on the rate of heating, ranged between 800-840 °C for willemite and 870-915 °C for gahnite. The homogeneous crystalline spinel phase was obtained by heat treatment above 1000 °C. Precipitation solely of a ghanite phase from glass-ceramic causes a relative increase in its fracture toughness and wear resistance compared to the two-phase materials, i.e., K_IC = 2.12-1.65 MPam^1/2 and w_s = 0.21 × 10⁻⁴ mm³/Nm to w_s = 1.43 × 10⁻⁴ mm³/Nm.     

Microstructure and microwave dielectric properties of Al2O3 added Li2ZnTi3O8 ceramics

Recently, the rapid development of advanced communication systems increasingly strongly demands high-performance microwave dielectric ceramics in microwave circuits. Among them, Li₂ZnTi₃O₈ ceramics have been one of the most widely investigated species, due to its high quality factor, moderate firing conditions and low cost. However, the dielectric constants of the already reported Li₂ZnTi₃O₈ ceramics are fixed in a narrow range, limiting their wider applications. To adjust the dielectric constant of the Li₂ZnTi₃O₈ based ceramics, in this work Li₂ZnTi₃O₈ ceramics added with different amounts of Al₂O₃ (0–8?wt%) were prepared by conventional solid-state reaction. The microstructure and microwave dielectric properties of the samples were investigated. Due to the addition of Al₂O₃, the sintering temperature of the ceramics would be increased somewhat. Some Al³⁺ ions could substitute for Ti⁴⁺ ions in Li₂ZnTi₃O₈, and the added Al₂O₃ would react with ZnO to produce a ZnAl₂O₄ phase accompanying with the formation of TiO₂ phase, which would inhibit the growth of Li₂ZnTi₃O₈ grains. The dielectric constant of the finally obtained ceramics would be reduced from 26.2 to 17.9, although the quality factors of the obtained ceramics would decrease somewhat and the temperature coefficient of resonant frequency would deviate further from zero.     

Al2O3/Cu-O composites fabricated by pressureless infiltration of paper-derived Al2O3 porous preforms

Al₂O₃/Cu-O composites were fabricated from the paper-derived alumina matrix infiltrated with a Cu-3.2?wt% O alloy. Paper-derived alumina preforms with an open porosity ranging from ～ 14 to ～ 25?vol% were prepared by sintering of alumina-loaded preceramic papers at 1600?°C for 4?h. Pressureless infiltration at 1320?°C for 4?h of the preforms with Cu–O alloy resulted in the nearly dense materials with good mechanical and electrical properties, e.g. fracture toughness up to 6?MPa?m^0.5, four-point-bending strength up to 342?MPa, Young's modulus up to 281?GPa and electrical conductivity up to 2?MS/m depending on the volume fraction of copper alloy in the composites. The technological capability of this approach was demonstrated using prototypes in various engineering fields fabricated by lamination, corrugating and Laminated Object Manufacturing (LOM) methods.     

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.     

Effects of Al2O3 addition on the microstructure and microwave dielectric properties of Ba4Nd9.33Ti18O54 ceramics

Ba₄Nd_9.33Ti₁₈O₅₄·x wt%Al₂O₃ (BNT-A) ceramics (x=0, 0.5, 1.0, 1.5, 2.0, 2.5) were prepared by the conventional solid state reaction. The effects of Al₂O₃ on the microstructure and microwave dielectric properties of Ba₄Nd_9.33Ti₁₈O₅₄ (BNT) ceramics were investigated. X-ray diffraction and backscatter electronic images showed that the Al₂O₃ additive gave rise to a second phase BaAl₂Ti₅O₁₄ (BAT). The formation mechanism and grain growth of the BAT phase were first discussed. Dielectric property test revealed that the Al₂O₃ additive had improved the dielectric properties of the BNT ceramics: increased the Q×f value from 8270 to 12,180 GHz and decreased the τ_f value from 53.4 to 11.2 ppm/°C. A BNT-A ceramic with excellent dielectric properties: ε_r=70.2, Q×f=12,180 GHz, τ_f=20 ppm/°C was obtained with 2.0 wt% Al₂O₃ added after sintering at 1320 °C for 4 h.     

Kinetics of geopolymerization: Role of Al2O3 and SiO2

The early-stage reaction kinetics of metakaolin/sodium silicate/sodium hydroxide geopolymer system have been investigated. The setting and early strength development characteristics, and associated mineral and microstructural phase development of mixtures containing varying SiO₂/Al₂O₃ ratios, cured at 40 °C for up to 72 h, were carefully studied. It was observed that setting time of the geopolymer systems was mainly controlled by the alumina content. Essentially, the setting time increased with increasing SiO₂/Al₂O₃ ratio of the initial mixture. Up to a certain limit, the SiO₂/Al₂O₃ ratio was also found to be responsible for observed high-strength gains at later stages. An increase in the Al₂O₃ content, i.e. for low SiO₂/Al₂O₃ ratio, led to products of low strength, accompanied by microstructures with increased amounts of Na-Al-Si-containing “massive” phases (grains). EDAX analyses showed that the SiO₂/Al₂O₃ ratios of geopolymer gel phases were quite similar to those of the starting mixtures, but with an overall lower Na content. Most importantly, this study clearly demonstrates that the properties of resulting geopolymer systems can be drastically affected by minor changes in the available Si and Al concentrations during synthesis.     

Effect of Nb2O5 and MgO/Nb2O5 doping on densification,microstructure and wear resistance of alumina

In this paper, the influence of Nb₂O₅ single-doping and MgO/Nb₂O₅ co-doping on the densification, microstructure and wear resistance of Al₂O₃ has been investigated. The results show that Nb₂O₅ single-doping can increase the density of alumina effectively, but excessive Nb₂O₅ will lead to abnormal grain growth. Comparing with Nb₂O₅ single-doping, MgO/Nb₂O₅ co-doping can further increase the density and suppress the abnormal grain growth of the alumina. Meanwhile, the co-doped samples also show much lower wear rates. Typically, when 500 ppm MgO/1000 ppm Nb₂O₅ co-doped, the alumina ceramics has a minimum wear rate of 0.01‰, which is about 1/5 of the alumina ceramics with 1000 ppm Nb₂O₅ single-doped. The inhibiting effect of co-doping on abnormal grain growth and the reasons for the decrease of wear rate are also discussed.     

Fabrication and microstructure evolution of Al2O3/ZrBN-SiCN/Al2O3 high-temperature oxidation-resistant composite coating

The oxidation-resistance of thin film sensors, particularly at high temperatures, is critical for the lifetime and performance of the sensor. The preparation and oxidation-resistance of an Al₂O₃/ZrBN-SiCN/Al₂O₃ composite film with a sandwich-structure was performed using reactive magnetron sputtering. The microstructure evolution of the composite film is examined herein using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) analysis. Oxygen diffusion was significantly inhibited by the formation of crystalline Al₂SiO₅ and Zr-B-C amorphous phase inside the composite film. The Pt-13%Rh/Pt thin film thermocouple (TFTC) with the Al₂O₃/ZrBN-SiCN/Al₂O₃ composite film as a protective layer was fabricated and calibrated. Both the stability and lifetime of the TFTC was significantly enhanced for temperatures up to 1000?℃. The test error of the TFTC was reduced by half, compared with that of the TFTC with the Al₂O₃ protective layer, indicating an excellent oxidation-resistant performance of the composite film.     

Microstructure refinement approaches of melt-grown Al2O3/YAG/ZrO2 eutectic bulk

Microstructure developments of melt-grown Al₂O₃/YAG/ZrO₂ ceramic bulks were investigated by controlling composition, cooling rate, heterogeneous nucleation sites and melt superheating treatment. The solidification microstructure of sample with hypereutectic composition (ZrO₂ 20 mol%) is finer than that with hypoeutectic or eutectic ones. With increasing the cooling rate, microstructure of melt-grown samples develops from colony to dendrite and finally to cell. The microscopy and the components of samples vary with the melt superheating temperature and the type of heterogeneous nucleation sites. The microstructure evolutions of melt-grown Al₂O₃/YAG/ZrO₂ eutectic relate to the melt undercooling level and the solid–liquid interfaces stability.     

Thermal shock of ground and polished alumina and Al2O3/SiC nanocomposites

The thermal shock behaviour of sintered alumina and alumina/SiC nanocomposites with 1, 2.5 and 5 vol.% SiC was studied. The thermal shock testing was carried out by means of quenching into water from high temperatures (ΔT in the range 0–750 °C). Both single shocks and repeated shocks were used. The damage introduced by thermal shock was characterised by degradation of strength in four-point bending and by changes in Young's modulus. The effects of the surface finish of the test specimens (either ground or highly polished surfaces) on the thermal shock resistance were also studied. In both alumina and nanocomposite materials, specimens with ground surfaces showed a better resistance to thermal shocks than specimens with polished surfaces. However, the resistance of the nanocomposite material to single and repeated thermal shocks was no better than that of the pure alumina.     

Composite Ni/Al2O3 coatings and their corrosion resistance

Composite coatings Ni/Al₂O₃ were electrochemically deposited from a Watts bath. Al₂O₃ powder with particle diameter below 1 μm was codeposited with the metal. The obtained Ni/Al₂O₃ coatings contained 5-6% by weight of corundum. The structure of the coatings was examined by scanning electron microscopy (SEM). It has been found that the codeposition of Al₂O₃ particles with nickel disturbs the nickel coating's regular surface structure, increasing its microcrystallinity and surface roughness. DC and AC electrochemical tests were carried out on such coatings in a 0.5 M solution of Na₂SO₄ in order to evaluate their corrosion resistance. The potentiodynamic tests showed that the corrosion resistance of composite coating Ni/Al₂O₃ is better than that of the standard nickel coating. After 14 days of exposure the nickel coating corrodes three times faster than the Ni/Al₂O₃ coating. The electrochemical behaviour of the coatings in the corrosive solution was investigated by electrochemical impedance spectroscopy (EIS). An equivalent circuit diagram consisting of two RC electric circuits: one for electrode, nickel corrosion processes and the other for processes causing coating surface blockage, were adopted for the analysis of the impedance spectra. The changes in the charge transfer resistance determined from the impedance measurements are comparable with the changes in corrosion resistance determined from potentiodynamic measurements.     

Corrosion mechanisms of Al2O3/MgAl2O4 by V2O5, NiO, Fe2O3 and vanadium slag

The effects of V₂O₅, NiO, Fe₂O₃ and vanadium slag on the corrosion of Al₂O₃ and MgAl₂O₄ have been investigated. The specimens of Al₂O₃ and MgAl₂O₄ with the respective oxides above mentioned were heated at 10 °C/min from room temperature up to three different temperatures: 1400, 1450 and 1500 °C. The corrosion mechanisms of each system were followed by XRD and SEM analyses. The results obtained showed that Al₂O₃ was less affected by the studied oxides than MgAl₂O₄. Alumina was only attacked by NiO forming NiAl₂O₄ spinel, while the MgAl₂O₄ spinel was attacked by V₂O₅ forming MgV₂O₆. It was also observed that Fe₂O₃ and Mg, Ni, V and Fe present in the vanadium slag diffused into Al₂O₃. On the other hand, the Fe₂O₃ and Ca, S, Si, Na, Mg, V and Fe diffused into the MgAl₂O₄ structure. Finally, the results obtained were compared with those predicted by the FactSage software.     

Influence of rare earth Tb4O7 addition on the densification,abrasion resistance and microstructure of alumina ceramics

This study aimed to improve the purity and performance of alumina ceramics used as ball milling media. High-alumina ceramics (>?96?wt% Al₂O₃), with high densification and excellent abrasion resistance, were fabricated by the cold isostatic pressing method. The effects of adding the rare earth Tb₄O₇ on the densification, abrasion resistance, crystalline phase, micro-morphology and grain size of the ceramics were studied. The experiment results showed that the densification and abrasion resistance of the samples increased with Tb₄O₇ addition. The sample with 0.8?wt% Tb₄O₇ sintered at 1625?°C exhibited the best performance, with a linear shrinkage, relative density and abrasion rate of 22.28%, 95.70% and 0.103‰^, respectively. The abrasion resistance improved by 27.5% compared with the sample without Tb₄O₇. X-ray diffraction analysis indicated that the primary phases of the samples were corundum, spinel, CaAl₁₂O₁₉ and α-quartz, and a small quantity of Tb₃Al₅O₁₂ was generated when more than 0.4?wt% Tb₄O₇ was added. Furthermore, some Mg²⁺ and Ca²⁺ ions in the liquid phases dissolved into Tb₃Al₅O₁₂ crystalline grains during the sintering process, which enhanced the grain boundary cohesion of the materials. Scanning electron microscopy indicated that the existence of Tb₃Al₅O₁₂ at grain boundaries reduced the average size of the corundum grains. This helped transform inter-granular fractures into trans-granular fractures, thereby improving the abrasion resistance of the ceramic materials.     

Effect of Ti amount on wear and corrosion properties of Ti-doped Al2O3 nanocomposite ceramic coated CP titanium implant material

Al₂O₃ and Ti-doped Al₂O₃ nanocomposite ceramic coatings were prepared by using a sol-gel dip-coating process. Corrosion and wear resistance of Al₂O₃ ceramic coatings in relation to Ti amount were carried out using pin-on-disk tribotester, potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). Surface characterizations before and after the corrosion and wear tests were investigated by the scanning electron microscope (SEM) and X-ray diffraction (XRD) and hardness analysis. The results of corrosion and wear tests exhibited that the corrosion and wear resistance of nanocomposite ceramic coatings became better than uncoated samples. Also, corrosion and wear resistance of nanocomposite ceramic coatings improved with Ti doping content increased.     

Phase analysis and wear behavior of in-situ spark plasma sintered Ti3SiC2

In-situ synthesis of dense near-single phase Ti₃SiC₂ ceramics from 3Ti/SiC/C/0.15Al starting powder using spark plasma sintering (SPS) at 1250 °C is reported. Systematic analysis of the phase development over a range of sintering temperatures (1050–1450 °C) suggested that solid state reactions between intermediate TiC and Ti₅Si₃ phases lead to the formations of Ti₃SiC₂. The effect of starting powder composition on phase development after SPS at 1150 °C was also investigated using three distinct compositions (3Ti/SiC/C, 2Ti/SiC/TiC, and Ti/Si/2TiC). The results indicate that the starting powder compositions, with higher amounts of intermediate phase such as TiC, favor the formation of Ti₃SiC₂ at relatively lower sintering temperature. Detailed analysis of wear behavior indicated that samples with higher percentage of TiC, present either as an intermediate phase or a product of Ti₃SiC₂ decomposition, exhibited higher microhardness and better wear resistance compared to near single phase Ti₃SiC₂.     

Formation of GdAlO3–Al2O3 composite having fine pseudo-eutectic microstructure

GdAlO₃ and Al₂O₃ powders were mixed and pulverized using ball mills. The prepared powder was sintered by SPS at 1450 °C without holding time. SEM observation of the sintered specimen showed a eutectic-like microstructure. This is called ‘pseudo-eutectic’ in this research. The microstructure formed from a powder pulverized by a tumbling ball mill for one week was much finer than that by a planetary ball mill for 5 and 10 h. The fine homogeneous eutectic-like (pseudo-eutectic) microstructures could be formed at both eutectic and off-eutectic compositions. In case of crystallization from a melt of eutectic components, homogeneous eutectic microstructures can be formed only at restricted compositions very close to the eutectic one. Coarse primary crystals generally exist in the eutectic microstructure at off-eutectic compositions. The pseudo-eutectic microstructures can be formed at any compositions because a mixing ratio of the starting powders can be varied.     

Microstructure, electrical properties, and aging behavior of ZnO-Pr6O11-CoO-Cr2O3-Y2O3-Er2O3 varistor ceramics

The microstructure, electrical properties, and aging behavior of the ZnO-Pr₆O₁₁-CoO-Cr₂O₃-Y₂O₃-Er₂O₃ varistor ceramics were investigated for different contents of Er₂O₃. The microstructure consisted of ZnO grain and an intergranular layer (Pr, Y, and Er-rich phases) as a secondary phase. The increase of Er₂O₃ content decreased the average grain size and increased the sintered density. As the Er₂O₃ content increased, the breakdown field increased from 4206 V/cm to 5857 V/cm and the nonlinear coefficient increased from 32.6 to 48.6. The varistor ceramics added with 1.0 mol% Er₂O₃ exhibited excellent stability by exhibiting −0.2% in the variation rate of the breakdown field and −2.7% in the variation rate of the nonlinear coefficient for aging stress of 0.95 E_1 mA/150 °C/24 h.