Influence of Atmosphere on the Final‐Stage Sintering Kinetics of Ultra‐High‐Purity Alumina

Abstract

The influence of sintering atmosphere on the final‐stage sintering of ultra‐high‐purity alumina has been investigated. Model final‐stage microstructures were tailored via a latex sphere impregnation and burnout technique. Critical experiments have been conducted to quantitatively examine the influence of the oxygen partial pressure on the final‐stage sintering kinetics. Samples were sintered at 1850°C in either dry hydrogen (Po2∼ 3 × 10−17 atm) or wet hydrogen Po2∼ 5 × 10−10 to 2 × 10−11 atm), and their microstructures were characterized as a function of sintering time, Sintering in dry hydrogen decreased the susceptibility of the final‐stage microstructure to pore/boundary breakaway. In the kinetic analysis, the variation in the number of pores per grain, Ng, was taken into account. It was found that in both atmospheres, the densification rate was controlled by grain boundary diffusion, and that sintering in dry hydrogen increased the densification rate by a factor of 2.25. In addition, it was determined that the grain growth rate in both atmospheres was controlled by the rate of surface diffusion of matter around the pores and that sintering in dry hydrogen enhanced the grain growth rate by a factor of 5.6. The overall effect of the dry hydrogen atmosphere was that it enhanced the coarsening rate relative to the densification rate by a factor of 2.5, and consequently shifted the grain size‐density trajectory to much lower densities for a given grain size.