Al2O3 Phases Research Articles

Overcoming the intrinsic brittleness of high-strength Al2O3–GdAlO3 ceramics through refined eutectic microstructure

High-strength ceramic materials are known for their exceptional mechanical properties; however, they are often plagued by brittleness, limiting their applications. Because of the inherent difficulty of dislocation glide and multiplication in ceramics, efforts to overcome the brittleness of ceramics by activating plastic deformation have faced challenges. This work demonstrates that Al2O3–GdAlO3 (Gadolinium Aluminum Perovskite: GAP) eutectic micropillars with submicron-scale fibrous microstructures exhibit remarkable plastic deformability. They displayed engineering plastic strains of up to 5% even at 25 °C, while the micropillars of Al2O3 or GAP single crystals exhibited brittle fracture similar to conventional high-strength ceramics. The plasticity in Al2O3–GAP eutectic was attributed to the activation of primary prismatic slip and secondary basal slip in the Al2O3 phase, which is typically considered inactive at room temperature. These findings suggest that plastic deformability can be achieved in high-strength ceramic materials by fabricating refined eutectic microstructures.

Microstructure and wear behavior of WC-reinforced AlCoCrFeNiSi high entropy alloy coatings prepared by high-velocity arc spraying

In this study, AlCoCrFeNiSi/WC (WC from 0 to 40 wt%) high entropy alloys (HEAs) coatings were deposited on Q235 steel substrates using high-velocity arc spraying technique. The coatings' phases, microstructure, microhardness, nano-hardness, wear properties, and the mechanisms of wear were examined. The results have shown that the WC reinforced HEA had faced-centered cubic, body-centered cubic solid solution and carbide phases, while faced-centered cubic solution and Cr3Si, Al2O3 phase were observed in AlCoCrFeNiSi coating. The coatings possess a dense, lamellar structure and strong adhesion to the substrates. With the addition of reinforced particles, the porosity of the coatings initially decreases and then increases. The average microhardness of the coatings is significantly improved as WC content increased, reaching a maximum of 530 HV0.1. The ratio of nano-hardness to reduced elastic modulus rises as more WC is introduced. The coatings with the WC particles exhibit good wear resistance with the optimum wear rate at WC content of 40 wt%. Under the same conditions, the coating with 40 wt% of WC displayed the lowest wear rate, which decreased by 60.5 % compared to the AlCoCrFeNiSi coating. The AlCoCrFeNiSi coating experienced a mix of adhesive, abrasive, oxidative, and fatigue wear mechanisms. The wear mechanism changed to more abrasive, adhesive, and oxidative in the reinforced coatings. The load-bearing capacity and secondary phase strengthening effects of WC reduce the wear rate of the coatings.

A new method for direct welding of alumina and zirconia ceramics by ultrashort pulse laser for high temperature application

The direct welding of alumina and zirconia ceramics by ultrashort pulse laser is presented for the first time. Compared to traditional dissimilar ceramic joining techniques such as brazing and diffusion welding, this method shows various advantages, including operation at room-temperature, higher welding efficiency, and negligible impact on base materials. The joint microstructure consists of a combination of Al2O3 and ZrO2 phases, without new phases detected. By adjusting the laser focal point position, the phase content within joint is effectively regulated, successfully preventing crack formation in alumina substrate. The influence of laser power and welding speed on joint morphology and mechanical property is fully investigated. The highest four-point bending strength of 365.5MPa and shear strength of 33.4MPa are achieved. After experiencing thermal cycling test at 1000°C, the joint strength and microstructure does not exhibit significant changes, demonstrating the excellent high-temperature durability of the sample.

Self-propagating high-temperature synthesis of AlN–TiC powder composition using sodium azide and C2F4 fluoroplastic

Producing powder compositions using conventional processing technology can lead to the formation of large agglomerates and, therefore, makes it difficult to obtain a uniform microstructure. The production of composites by self-propagating high-temperature synthesis can reduce costs and the number of technological stages, as well as lead to obtaining composites that are more homogeneous. Synthesis by the combustion of mixtures of powder reagents of sodium azide (NaN3), fluoroplastic (C2F4), aluminum and titanium with different ratios of reagents in a nitrogen gas atmosphere at a pressure of 4MPa was used for the production of a highly dispersed powder ceramic AlN–TiC composition. Thermodynamic calculations have confirmed the possibility of synthesis of AlN–TiC compositions of different formulations in combustion mode. The dependences of temperature and combustion rate on the composition of the initial mixtures of reagents were experimentally determined for all stoichiometric reaction equations. The study have shown that the experimentally found dependences of combustion parameters on the ratio of the initial components correspond to the theoretical results of thermodynamic calculations. The formulation of the synthesized composition differs from the theoretical composition by a lower content of target phases and the formation of Al2O3, Na3AlF6 and TiO2 side phases. The powder composition consists of aluminum nitride fibers with a diameter of 100–250nm and ultradisperse particles of predominantly equiaxed and lamellar shapes with a particle size of 200–600nm. As the combustion temperature increases to produce the largest amount of titanium carbide phase, the particle size increases to the micron level.

Synthesis, Structure and Luminescence Properties of Mn-doped MgAl2O4 Red-Emitting Phosphors with Varying Sintering Temperature.

Oxide matrix red-emitting phosphors are deemed as excellent color converters for white light emitting diodes (WLEDs) and laser diodes (LDs). Manganese-doped MgAl2O4 powder was synthesized by a solid-state reaction method at different sintering temperatures. Microstructure shows that grain size is mainly in the range of 0.2-5μm, and grain agglomeration occurs with increased sintering temperature. XPS analysis indicates that the doped Mn ion exhibits a valence state of + 4 within the MgAl2O4 matrix. The diffraction peak of the phosphors is shifted by the sintering temperature, which affects lattice constant. Upon excitation by 300nm ultraviolet light, the samples emit asymmetric broadband red light within the range of 620-720nm, attributed to Mn4+ ion's transition from 2Eg to 4A2g states. With the increasing temperature, the main emission peak shifts from 677nm to 650nm, ascribed to the change in energy level (2Eg) resulting from the reduction of Al2O3 phase. Crystal field theory confirmed that Mn4+ ions are within a strong crystal field environment created by MgAl2O4 matrix. By affecting particle size and crystallinity, the sintering temperature influences the fluorescence lifetime of the Mn4+ ion. Notably, these red-emitting phosphors exhibits remarkable thermal stability as their emission intensity remains approximately at 58% of initial intensity even at elevated temperature (435K). Consequently, Mn4+: MgAl2O4 red-emitting phosphors with high thermal stability render them promising candidates for WLED applications.

The effect of oxygen vacancies on the optical and thermophysical properties of (1-x)Si3N4 – xAl2O3 ceramics

Interest in composite ceramics based on silicon nitride (Si3N4) and aluminum oxide (Al2O3) is due to the possibility of using them as semiconductor applications associated with their operation under conditions of external influences, including heating. The paper presents the results of assessing the influence of variations in the phase composition of (1-x)Si3N4 – xAl2O3 ceramics on alterations in optical and thermophysical parameters, as well as their relationships. Analysis of the optical characteristics of the ceramics under study showed that changes in the phase composition associated with the dominance of the Al2O3 phase in the composition of the ceramics lead to a change in covalent bonds and an increase in the number of ionic bonds, which also affects the change in the semiconductor nature of the ceramics, and therefore, a change in the thermophysical properties. According to the assessment of changes in the thermal conductivity coefficient of the studied ceramics, with the dominance of the Al2O3 phase in the composition, the observed growth in the concentration of structural defects, as well as oxygen vacancies, results in the thermal conductivity coefficient decrease, as well as an elevation in the thermal expansion of ceramics during thermal heating. It has been determined that the presence of a combination of Al2(SiO4)O and Si3N4 phases in the ceramic composition leads to an increase in the thermal conductivity coefficient, as well as maintaining its stability over a wide temperature range.

Synthesis, mechanical characterization, and biocompatibility evaluation of Graphene-TiO2 reinforced alumina for biomedical applications

The study addresses the limited fracture toughness of Al2O3 ceramics by developing graphene-TiO2 reinforced alumina nanocomposites through pressing. Mechanical properties, including hardness, fracture toughness, and elasticity, were examined, alongside the structural characterization via XRD analysis and microstructure evaluation using SEM. Cytotoxicity and cell adhesion tests were conducted for in vitro biological evaluation. The inclusion of a graphene additive led to a nearly threefold increase in fracture toughness, reaching up to 8.161 MPa m1/2. Graphene doping induced a discernible shift to lower angles in the XRD pattern, revealing the presence of Al2O3, Al2TiO5, and TiO2 phases. Samples immersed in artificial body fluid for 14 days exhibited minimal ion release, with Titanium ion below 0.001 mg/L and aluminum ion below 0.05 mg/L, indicating a lack of significant ion release. The cytotoxic activity of the samples against NIH/3T3 cells was assessed through Alamar Blue analysis, revealing no significant change in cell viability after 48 h of exposure.

Fabrication of Co-Based Cladding Layer by Microbeam Plasma and Its Corrosion Mechanism to Molten Salt.

Corrosion of the molten salts Na2SO4 and NaCl has become one of the major factors in the failure of steel components in boilers and engines. In this study, CoNiCrAlY cobalt-based cladding layers with different NiCr-Cr3C2 ratios were prepared by microbeam plasma cladding technology. The influence of the NiCr-Cr3C2 content on the microstructure, mechanical properties, and molten salt corrosion resistance of CoNiCrAlY was investigated. The CoNiCrAlY with a 25 wt.% NiCr-Cr3C2 (NC25) cladding layer possessed the highest microhardness (348.2 HV0.3) and the smallest coefficient of friction (0.4751), exhibiting great overall mechanical properties. The generation of protective oxides Cr2O3, Al2O3, and spinel phase (Ni,Co)Cr2O4 is promoted by the addition of 25 wt.% NiCr-Cr3C2, which significantly reduces the corrosion of the cladding layer, and this effect is much more obvious at 950 °C than that at 750 °C. Furthermore, its corrosion mechanism was clarified. From the findings emerge a viable solution for the design and development of new high-temperature corrosion-resistant coatings.

Improving single-slope passive solar still efficiency through integration of phase change materials and Al2O3 nanoparticles

Improving single-slope passive solar still efficiency through integration of phase change materials and Al2O3 nanoparticles

Fe2O3/γ-Al2O3 and NiO/γ-Al2O3 catalysts for the selective catalytic oxidation of ammonia

Ammonia, a significant atmospheric pollutant, requires effective emission control due to its inherent toxicity and the generation of secondary pollutants like particulate matter. This control can be achieved through various methods, including catalytic processes. Therefore, our study focuses on evaluating the potential of catalysts based on iron oxide and nickel oxide supported on γ–Al2O3 for the selective catalytic oxidation of NH3 to N2 (NH3-SCO). The γ–Al2O3 was obtained by thermal decomposition of aluminum hydroxide, and 5 or 10 wt% of Fe or Ni was added through wetness incipient impregnation. XRD diffractograms confirmed the formation of the γ–Al2O3 phase. XRD, H2-TPR, and UV–vis DRS data showed the presence of Fe2O3, NiO, and NiAl2O4 in the catalysts. Introducing metal oxides onto the support led to a drop in the specific area, pore size, pore volume, and NH3 desorption, which was higher for the catalysts containing Fe. The catalysts were active in NH3-SCO, and the insertion of Fe or Ni was essential because it promoted a significant increase in the NH3 conversion (∼75 % Fe and ∼55 % Ni), compared to pure support (∼8 %), mainly from 400 °C. However, doubling the metal content has not resulted in a considerable increase in NH3 conversion. The N2 selectivity was higher for the catalysts containing Ni (∼85 %) from 400 °C compared to catalysts containing Fe (∼76 %). Such behavior was due to the larger surface area of the Ni-containing catalysts. Despite that, the 5Fe/γ–Al2O3 catalyst emerged as the most effective option for NH3-SCO applications, combining higher NH3 conversion and good N2 selectivity.

Study of optical characteristics of microdischarges in the micro-arc oxidation process

Micro-arc oxide coatings of aluminum alloy AD31 samples were formed in an electrolyte containing 2 g/l NaOH and 9 g/l Na2SiO3 for 2, 4, 8, 16 min in the anode and anode-cathode modes. During the processing, the forming curve, the time dependences of the charge passed through the galvanic cell, and the optical parameters of the microdischarges were measured using the optical synchronization method developed by the authors with subsequent image recognition. The thickness of the coatings was measured using a point autofocus probe surface texture measuring instrument Mitaka PF-60, the surface morphology was studied using a VEGA3 scanning electron microscope using SBH surface topography. The elemental composition of the coatings was determined using a scanning electron microscope JSM-6610LV. The analysis of the elemental composition and morphology of the surface revealed that the inner layer of synthesized coatings consists of Al2O3, the outer layer consists of Al2O3·SiO2 mullite, and the ratio of phases Al2O3 and mullite changes with changes in current density and oxidation mode. The formation of mullite is due to the presence of Na2SiO3 in the electrolyte. It is shown that with increasing processing time and current density, the thickness, roughness and porosity of coatings increase. The interrelation of the optical parameters of microdischarges with the morphology of the surface and the elemental composition of the formed coatings is substantiated; it is shown that the ratio of illuminated and non-illuminated sections of the sample surface by microdischarges can be used as a rough estimate of the ratio of electron and ion currents corresponding to microplasma and electrochemical processes. A mathematical model describing the dependence of the coating thickness on the oxidation time based on Faraday's laws for electrolysis and the results of measuring the optical parameters of microdischarges and the electrical parameters of the MAO process without taking into account microplasma processes that do not lead to an increase in the thickness of coatings is proposed. The error of adequacy of the proposed model does not exceed ±10 %. The results of the study can be used in the development of a digital twin of the micro-arc oxidation process.

Influence of (Co+Al) co−doping on structural, micro-structural, optical and electrical properties of nanostructured zinc oxide

This study investigates the effect of (Co + Al) co−doping on the physical properties of the ZnO nanoparticles, synthesized via the simple co−precipitation method. X−ray diffraction (XRD) analysis revealed a hexagonal structure for all samples, with a formation of Al2O3 phase in both Zn0.98Co0.01Al0.01O and Zn0.94Co0.01Al0.05O nanoparticles. The crystallite size increased from 26.5 nm for ZnO to 16.6 nm for Zn0.94Co0.01Al0.05O nanoparticles. Scanning electron microscopy (SEM) technique showed a notable alteration in the morphology of ZnO upon the incorporation of Al. A transition from spherical nanoparticles in ZnO and Co doped ZnO to irregular, dendritic-like structures in (Co + Al) co−doped nanoparticles is observed. Transmission electron microscopy (TEM) substantiated the presence of the Al2O3 phase in the co−doped samples. Raman and FTIR spectroscopy confirmed the incorporation of Co and Al into the ZnO lattice through the presence of Co–O–Co and Al–O bonds. Optical characterization indicated a decrease in the band gap energy from 3.18 eV in ZnO to 2.84 eV in Zn0.94Co0.01Al0.05O nanoparticles. Electrical conductivity measurements revealed an increase from 1.2 × 10−4 Ω−1 cm−1 to 1.8 × 10−3 Ω−1 cm−1 as the Al content increased from 0 % to 5 % at the frequency of 103 Hz and the temperature of 423K. Likewise, dielectric constant raised from 775 in ZnO to 5455 in Zn0.94Co0.01Al0.05O nanoparticles at the temperature 423K. These results highlight the potential of (Co + Al) co−doped ZnO nanoparticles for advanced optoelectronic applications.

Elimination mechanism of voids caused by density differences in high crystallinity alumina/alumina joints bonded with dysprosium aluminum silicate glass ceramic filler

In this work, the Dy2O3-Al2O3-SiO2 (DASN) and Dy2O3-Al2O3-SiO2-TiO2 (DAST) glass fillers were used for joining alumina ceramic. During the cooling process of the alumina/DASN/alumina joints, Dy2Si2O7 and Al2O3 were precipitated simultaneously and gradually grown. As a result, voids were formed due to the poor flowability of the glass ceramic filler and the large density difference between the glass filler and Dy2Si2O7 crystals. On the contrary, the addition of TiO2 altered the sequence of the crystalline phase precipitation during the cooling process. During cooling from the joining temperature (1450 °C) to 1100 °C, only Dy2Si2O7 was formed in the brazing seam. Simultaneously, the flowing glass phase was able to fill the spaces caused by the density differences. When the growth of Dy2Si2O7 phase ceased, the Al2O3 phase began to precipitate. Therefore, the voids caused by density differences can be eliminated in the alumina/DAST/alumina joints with high crystallinity. The optimal flexural strength of alumina/DAST/alumina joints tested at room temperature and 1000 °C reached 350 MPa and 158 MPa, respectively.

Effect of the alloying element Sc and Zr in 5B70 Al alloy on the microstructure, toughness and tribological properties of MAO ceramic film

The existence form of alloying element Sc and Zr in the micro arc oxidation (MAO) ceramic film on 5B70 Al alloy and their effects on the microstructure, fracture toughness, and tribological properties of the MAO ceramic film was investigated. The findings suggested that the Zr element primarily existed in the form of ZrO2, distributed around the Al2O3 phase. The Sc element remained spherical and dispersed in the form of Al3Sc in the ceramic film. The synergistic effect of ZrO2 and Al3Sc significantly improved the hardness, fracture toughness, and wear resistance of the dense layer in MAO ceramic film on 5B70 Al alloy. This provided theoretical basis and technical support for the development of high-performance MAO composite films on Al alloy surfaces.

Sliding interface characteristics and self-lubrication mechanism of B4C-Al2O3 composite ceramics

B4C ceramics are an important structural material in the field of engineering. However, B4C ceramics have two fatal drawbacks: low fracture toughness and high friction coefficient. The design strategy and tribological mechanism of B4C ceramics with low friction are studied in this paper. The results show that the incorporation of Al2O3 as a second phase can not only increase the fracture toughness but also reduce the friction coefficient of B4C ceramics, achieving the self-lubrication of B4C ceramics. The low friction design strategy of B4C ceramics is realized by incorporating a second phase of Al2O3 to change the physical characteristic of the sliding surface. The sliding interface characteristic of in situ formed surface texture with an appropriate proportion of valleys in the sliding process is the most important factor for the improved tribological properties of B4C-Al2O3 composite ceramics. As the amount of Al2O3 incorporated is 30 wt%, B4C-Al2O3 composite ceramics have the most appropriate proportion of valleys in the surface texture, thus exhibiting the lowest friction coefficient. The clean phase boundary makes the bonding between B4C and Al2O3 grains firm, which is the key to achieving the function of the surface texture formed in situ. B4C-Al2O3 composite ceramics with both high fracture toughness and low friction coefficient will open a wider range of applications.

Effect of B on hot corrosion behavior of silicide coatings under different corrosive environments at 900 °C

Silicide coatings and B-modified silicide coatings were prepared on Nb-Si based alloys using halide activated pack cementation. The hot corrosion behavior of the coatings exposed to Na2SO4 and Na2SO4 + NaCl mixture salts at 900 °C was investigated. The results show that B-modified silicide coatings possess better hot corrosion resistance than the silicide coatings. The hot corrosion products of silicide coatings show a regional microstructure, including uplift regions of AlNaSiO4 imbedded with Al2O3 phases, and depressed silica regions with NaNbO3 and TiO2 particles. The addition of B to the silicide coatings promotes the formation of the uniform and dense boroaluminosilicate scale with better fluidity during hot corrosion, which impedes the self-sustaining cyclic chlorination/sulfidation reactions, and thus, improves the hot corrosion resistance of the silicide coatings.

A novel process for the preparation of high-performance heat-resistant Al-Si-Fe alloy by powder metallurgy method

A novel method combining rotational extrusion with rapid solidification/powder metallurgy was developed to enhance the microstructure and properties of Al-Si-Fe alloys. This study conducted a comprehensive investigation into the phase composition, microstructure, and mechanical properties of the rotationally extruded Al-Si-Fe alloy. Experimental results confirmed the presence of α-Al, β-Si, α-Al8Fe2Si, Al2FeSi, and Al2O3 phases within the alloy. The rotary extrusion technique significantly increased the density and reduced the porosity of the Al-Si-Fe alloy. The rotationally extruded alloy demonstrated considerably higher maximum microhardness and tensile strength (170 HV and 487 MPa, respectively) compared to the alloy produced by single forward extrusion. This study highlights how the superposition of deformation not only modifies the structure but also breaks the initial boundaries of the alloy powder particles, enhancing metallurgical bonding during subsequent sintering.

Effects of magnetic fields on the formation of passive films on the surface of 5083 aluminum alloy

This research explores the effect of the magnetic fields on the passive film of 5083 aluminum alloy. After the application of a 0.3 T magnetic field, 5083 aluminum alloy exhibits an improvement in passivation performance. These improvements manifest as a reduction in passivation current density and an increase in impedance, passive film thickness, and carrier concentration. Additionally, there is an augmentation in the content of the Al2O3 phase within the passive film. The magnetic field facilitates the movement of metal ions during the corrosion process of 5083 aluminum alloy through microscale magnetohydrodynamics, facilitating passive film growth and improving corrosion resistance.

Microstructure and mechanical properties of high-entropy diboride-based ceramic assisted by Ti3AlC2 additive

Ti3AlC2 was used as the additive to fabricate a novel (Zr0·2Ta0·2Nb0.2Hf0.2Mo0.2)B2-based (HEBTAC) ceramic using spark plasma sintering at 1900 °C. The as-prepared HEBTAC ceramic sample consists of (Ti, Zr, Hf, Ta, Nb, Mo)B2, multiscale (Zr, Hf, Ta, Nb, Mo)C, and Al2O3 phases, which are produced by the decomposition of Ti3AlC2 and subsequent exchange reaction & solid solution reactions during the sintering process. The relative density, hardness, fracture toughness, and flexural strength of the HEBTAC ceramic sample are 99.43 %, 27.92 ± 1.87 GPa, 5.84 ± 0.14 MPa m1/2, and 629 ± 8.7 MPa, respectively, which are even better than the same class of high-entropy diboride ceramics previously published. Solid-solution strengthening, dislocation strengthening and nano-HEC strengthening existed in the ceramic sample contribute to its excellent mechanical properties. The in situ formed Al2O3 and (Zr, Hf, Ta, Nb, Mo)C effectively enhances the toughness of the HEBTAC ceramic sample through the synergistic effect of intrinsic and extrinsic toughening. This study presents a new approach for reactive sintering densification of high-entropy diborides with both high strength and high toughness.

Effects of Al2O3 content on the microstructure and performance of Inconel 625-xAl2O3 composite non-skid coatings by plasma enhanced high-velocity arc spraying

The efficient preparation of metal/ceramic composite coatings with excellent performance has been a hot research topic in the field of thermal spraying. In this study, a novel plasma enhanced high-velocity arc spraying (PE-HAS) technique is developed. A series of Inconel 625-xAl2O3 composite non-skid coatings are deposited by PE-HAS with different feeding ratio of alloy wire (1.6 mm in diameter) and ceramic powder (13.5 μm in average particle size). Specifically, the microstructure, mechanical properties, corrosion resistance and tribological performances of the coatings have been comprehensively investigated. Results indicate that all of the composite coatings with different Al2O3 contents are characterized by high densities, low defects (porosity≤3.52 %), strong bonding (≥50 MPa) and high friction coefficient (≤ 1.034). The coatings with low Al2O3 content feature a more homogeneous structure and superior bonding strength. The microhardness and wear resistance of the coatings increases significantly with increasing Al2O3 content, which should be attributed to the formation of many localised enhancement areas composed of different forms of Al2O3 phases. It is worth noting that the unique feedstock feeding method promotes the formation of the in-situ double-layer structure of coatings with high Al2O3 content, which further improves the wear and corrosion resistance. However, the friction coefficient gradually decreases when the Al2O3 content is too high, thus affecting the anti-slip performance of the coating.