Abstract
Al 2O 3–(m-ZrO 2)/t-ZrO 2 composites with a novel double-network microstructure were fabricated by multi-pass extrusion process using polymer bound ceramic green body. A simultaneous micro- and macro-level microstructure tailoring was made where unidirectionally aligned two-phase Al 2O 3–(m-ZrO 2) fibers were enclosed in a t-ZrO 2 phase connected in a network formation and this network was further enclosed in a thicker t-ZrO 2 phase. Composite green rods were hot extruded and reassembled in parallel for extrusion and after several passes of extrusion very fine microstructure with dimension of a few micrometers was obtained. Material properties such as hardness, bending strength and fracture toughness were measured for the composites. Microstructure characterization was carried out by SEM technique. In the 4th passed Al 2O 3–(m-ZrO 2)/t-ZrO 2 composites, the outer network of t-ZrO 2 was 15 μm, inner network 0.8 μm and the inner Al 2O 3–(m-ZrO 2) core was 2.5 μm. The highest hardness, fracture strength and toughness values were about 1452 Hv, 1006 MPa and 8.6 MPa m 1/2, respectively, in the sample sintered at 1500 °C.
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