Abstract
Rapidly solidified ZrO2 (Y2O3)–Al2O3 powders were prepared by melting fine‐particle aggregates in a high‐enthalpy plasma flame and then rapidly quenching them in cold water or on a copper chill plate. To ensure complete melting and homogenization of all the particles before quenching, the water‐quenching treatment was often repeated two or even three times. The resulting melt‐quenched powders and splats displayed a variety of metastable structures, depending on composition and cooling rate. ZrO2‐rich material developed an extended solid solution phase, whereas eutectic material formed a nanofibrous or amorphous structure. Under high cooling rate conditions, the ZrO2‐rich material developed a nanocomposite structure (t‐ZrO2+α‐Al2O) directly by melt‐quenching, whereas, more typically, such a structure was developed only after postannealing of the as‐quenched metastable material.
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