Low-temperature densification of ceramics and cermets by the intermediary stage activated sintering method

Abstract

The article explores new concepts in order to promote ceramic and cermet materials sintering at lower temperatures between 1200 and 1300 C. The principle of the new process method called intermediary stage activated sintering (ISAS) involves the preparation of the ceramic powder with dispersed doping agents, such as nanotubes and fibers, which shape the pore structure at pressed pellets with stable interconnected thin cylinders between the grains. This feature resembles and extends the condition found during the intermediary stage sintering, which enhances the ions diffusion rate along tubular pores to increase shrinkage. Carbon nanotubes (CNT) and nanofibers are homogenized into cubic zirconia and alumina in amounts ranging from 1 to 10 vol% at high-energy milling devices and ultrasound disruptor under ethanol media. Ni, Cu and Mo/MoO3 can be also added to provide tubular channel filling. Sintering of uniaxially pressed pellets is carried out in a dilatometer and tubular furnaces at 1200/1300 C under air, argon and controlled oxygen partial pressure atmospheres. TG/DTA/MS analyses of sample pellets reveal the oxidation and gas release temperature and duration. The results demonstrate the ISAS process concept is valid since it further increases the ceramic final density by 8% of the theoretical density at 1200 C, leading to close the porosity at 1300 C, compared to 1500–1600 C temperatures at conventional process. Short CNT and cellulose nanofiber were found to be the best additives in this sense.