Densification of zirconia-based ceramics by non-conventional sintering processes and chemical pathways

Abstract

The present work reports an overview of the main results we have obtained from non-conventional sintering approaches towards the densification of 3mol.% yttria stabilized zirconia (3YSZ), the lessons learned from these results, and open questions that still need to be addressed. A wide range of techniques have been developed in the field of ceramic sintering, both in high temperature regime with extreme heating rates (>10 000 °C/min), as well as in very low temperatures (<400 °C) regime involving chemical reactivity to activate sintering mechanisms. In this context, we have recently explored several of these methods in order to understand and control the different sintering parameters and their impact on microstructure, crystallinity, grain boundaries and defect chemistry. Due to its complex chemistry, 3YSZ is a playground for the exploration of sintering capabilities and their influence on ceramic properties. Our recent studies in this field are presented in the present work, highlighting the effect of high heating rates through Flash Spark Plasma Sintering ( Flash-SPS) and Ultra High temperature Sintering (UHS) on sintering, but also the combination of low temperature Cold Sintering Process (CSP) and the associated precursors chemistry, with Spark Plasma Sintering (SPS). It also shows the possible densification by reactive hydrothermal sintering, using hydroxide precursors, and the effect of High Pressure SPS (HP-SPS) on 3YSZ nanopowders. All of these results touch upon current trends in the field of sintering, and highlight the possibilities in terms of chemical reactivity of precursors and physical parameter control. In particular, they show the importance of defect chemistry, related to the sintering atmospheres and their impact on both microstructures and properties.