Effect of compact structures on the phase transition, subsequent densification and microstructure evolution during sintering of ultrafine gamma alumina powder

Abstract

The effect of compact structures on the phase transition from gamma alumina (γ-Al 2O 3) to alpha alumina (α-Al 2O 3) and densification during sintering of the compacts of ultrafine gamma alumina powder (n-Al 2O 3) has been studied. The onset temperature of gamma→alpha phase transition during the sintering of n-Al 2O 3 compacts is affected significantly by the compact density as well as by the population of α-Al 2O 3 seed particles in the γ-Al 2O 3 matrix. The nucleation and growth of alpha phase is considered to be facilitated by the mass transfer around the particle contacts and by the imbedded α-Al 2O 3 particles. The gamma→alpha phase transition is proved to be detrimental to full densification of the n-Al 2O 3 compacts of gamma phase. The densification of high density compacts seems to be affected detrimentally by the phase transition in the range of 1050°C to 1150°C but finally reaches about 99% of theoretical density (TD) with fine grain structure. The unseeded compacts made by slurry casting are not densified above 73% TD even at 1400°C, whereas the α-Al 2O 3-seeded compacts are densified up to 90% TD at 1400°C and they have very large grain size of about 1 μm in diameter. High density compaction technology is considered a useful method required to achieve fully dense sintered compacts with fine grains below 100nm even in the sintering of ultrafine powder compacts with a metastable phase.