In situ developed laminates with large microstructural differences between layers of similar composition

Fabrication of alumina-aluminium titanate laminates that combine high strength external layers with flaw tolerant internal layers is limited by the difficulty of the co-sintering of layers with large differences in the green state. This work describes a new method to obtain alumina-aluminium titanate layered materials constituted by layers with large differences in terms of grain size starting from green bodies with similar microstructures. The approach is based on the effect of small amounts of titania (TiO₂) as agents for alumina grain growth enhancement. Starting from a fine grained green body that combined alumina layers with composite layers made of mixtures of alumina and titania, a two step sintering schedule led to a layered structure with external layers of small grain sized alumina combined with internal alumina layers with large grain size due to the diffusion of titanium. The large grain sized alumina layers conferred flaw tolerant behaviour to the laminate due to crack branching and bridging.