Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic

Abstract

Fracture toughness and strength of an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic is increased by incorporating metastable grains of tetragonal ZrO.sub.2 in the structure. During cracking, the metastable tetragonal ZrO.sub.2 transforms to a stable monoclinic structure thus increasing the energy required for the crack to propagate and retarding its growth. The ZrO.sub.2 occupies from 5 to 95% of the volume of the ceramic and has dissolved in it a rare earth oxide such as Y.sub.2 O.sub.3, CeO.sub.2, La.sub.2 O.sub.3 and/or Er.sub.2 O.sub.3 to promote retention of the metastable tetragonal ZrO.sub.2.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of ceramics and particularly to ZrO.sub.2 ceramics.

2. Description of the Prior Art

During cooling, ZrO.sub.2 undergoes a martensitic-type transformation from a tetragonal crystal structure to a monoclinic crystal structure with a concurrent increase in volume and an anisotropic shape change. For pure ZrO.sub.2 the transformation begins at about 1200.degree. C. and proceeds until complete at about 600.degree. C.

Attempts have been made to utilize this transformation in order to improve the fracture toughness of ceramic composites. In one approach, ZrO.sub.2 particles have been added to an Al.sub.2 O.sub.3 matrix to form a second phase dispersion (N. Claussen, J. Am. Ceram. Soc. 59, pg. 49, 1976). Expansion and shape change of the ZrO.sub.2 as it transformed from the high temperature tetragonal structure to the room temperature monoclinic structure created microcracks. The resulting increase in fracture toughness was attributed to energy absorption by these microcracks.

More recently, attempts have been made to increase the toughness of ZrO.sub.2 ceramics by taking advantage of metastable grains of tetragonal ZrO.sub.2 within a surrounding matrix. These are grains of ZrO.sub.2 which are tetragonal rather than monoclinic despite the fact that their temperature is below the unconstrained equilibrium transformation temperature range.

The metastable condition can be obtained by surrounding fine grains of ZrO.sub.2 in a constraining matrix such as Al.sub.2 O.sub.3. The matrix constrains the volume and shape change associated with the transformation of the grains of ZrO.sub.2 and holds the ZrO.sub.2 in its tegragonal state.

The tetragonal grains of ZrO.sub.2 increase the fracture toughness of the ceramic composite by increasing the energy required for a crack to propogate. If a crack starts in the ceramic composite, the metastable grains of tetragonal ZrO.sub.2 in the stress field adjacent the crack transform to the stable monoclinic structure. The work done by the applied stresses to reduce this transformation is loss and thus the stress-induced transformation increases the material's fracture toughness.

Metastable tetragonal grains of ZrO.sub.2 have been observed in an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic composite containing 17 volume % ZrO.sub.2 (N. Claussen, J. Am. Ceram. Soc. 59, pg. 85, 1978). However, to maintain the metastable tetragonal structure, the ZrO.sub.2 grains had to be less than about 0.5 .mu.m in diameter. Larger grains transformed to the stable monoclinic structure. Additional work has shown that the amount of metastable tetragonal ZrO.sub.2 that can be retained in the matrix decreases as the volume % of ZrO.sub.2 in the Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic composite increases. Very little of the ZrO.sub.2 can be retained in the metastable tetragonal structure in Al.sub.2 O.sub.3 /ZrO.sub.2 composites having more than 20 volume % ZrO.sub.2. Such limitations of grain size and volume % of ZrO.sub.2 reduces the practicality and the toughness of prior art Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic composites.

SUMMARY OF THE INVENTION

It is an object of the invention to provide an improved Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic.

It is an object of the invention to provide an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic having increased fracture toughness.

It is an object of the invention to provide an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic having increased strength.

It is an object of the invention to provide an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic having a high volume % of metastable tetragonal ZrO.sub.2.

It is an object of the invention to provide an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic having metastable tetragonal ZrO.sub.2 grains up to about 2 .mu.m in diameter.

According to the invention, a two phase ceramic composite is provided. One of the phases is ZrO.sub.2 with a rare earth oxide such as Y.sub.2 O.sub.3, CeO.sub.2, La.sub.2 O.sub.3, and/or Er.sub.2 O.sub.3 dissolved therein to maintain at least some of the phase in the tetragonal structure. This phase can occupy from 5 to 95% of the volume of the composite, depending upon the specific properties desired. The other phase is Al.sub.2 O.sub.3 and it occupies essentially the balance of the volume of the composite (95 to 5 volume %).

A sufficient amount of rare earth oxide is included in the composite to increase the amount of ZrO.sub.2 in its metastable tetragonal structure at the expense of the stable monoclinic structure. However, the amount of rare earth oxide must be held below the quantity that produces the cubic structure of ZrO.sub.2.

In a preferred embodiment the rare earth oxide is Y.sub.2 O.sub.3 in the range of 0.5 to 5.5 mole % of ##EQU1##

In a second preferred embodiment the rare earth oxide is CeO.sub.2 in the range of 0.5 to 10 mole % of CeO.sub.2 to CeO.sub.2 plus ZrO.sub.2.

In a third preferred embodiment the rare earth oxide is Er.sub.2 O.sub.3 in the range of 0.5 to 4 mole % of Er.sub.2 O.sub.3 to Er.sub.2 O.sub.3 plus ZrO.sub.2.

In a fourth preferred embodiment the rare earth oxide is La.sub.2 O.sub.3 in the range of 0.5 to 5.0 mole % of La.sub.2 O.sub.3 to La.sub.2 O.sub.3 plus ZrO.sub.2.

The fracture toughness and strength of the Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic is attributed to the metastable grains of tetragonal ZrO.sub.2 in the structure. During cracking, the metastable tetragonal ZrO.sub.2 transforms to a stable monoclinic structure in the vicinity of the crack thus increasing the energy required for the crack to propagate.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Stress-induced, martensitic transformation can be used to increase the fracture toughness of brittle materials containing ZrO.sub.2. Metastable, tetragonal ZrO.sub.2 in the toughening agent. Transformation to its stable, monoclinic structure in the vicinity of the crack front is believed to be responsible for the increased fracture toughness.

To take advantage of this phenomena, it is necessary to fabricate materials containing ZrO.sub.2 in the metastable tetragonal structure rather than in the monoclinic structure normally obtained during cooling after sintering or annealing.

Retention of the metastable tetragonal structure is promoted by the strain energy arising from elastic constraint imposed by the surrounding material on the transformation shape change. This constraint can arise from two sources. First, if the polycrystalline body is single phase, neighboring grains, each with a different crystallographic orientation, will constrain the anisotropic shape change of one another. Second, for two phase materials, any matrix surrounding the particle will constrain the particle's shape change.

To determine the amount of metastable tetragonal ZrO.sub.2 which could be retained in an Al.sub.2 O.sub.3 /ZrO.sub.2 ceramic, samples having different volume % (v/o) of ZrO.sub.2 were prepared. Sub-micron powders were used; the Al.sub.2 O.sub.3 being from Union Carbide Corporation (Linde B powder) and the ZrO.sub.2 being from Zircar Corporation. Composite powders were mixed by ball-milling with methanol and Al.sub.2 O.sub.3 balls in a plastic container, and then dried. Densification was achieved by hot-pressing the powders for 2 hours at a temperature selected to obtain small grain size and therefore favor the retention of tetragonal ZrO.sub.2.

Specimens were cut, ground, and polished prior to phase identification by X-ray diffraction analysis. Polishing was used to reduce surface damage from cutting and grinding which causes the surface to transform. Two-theta scans between 27.degree. to 33.degree. were used to estimate the tetragonal/monoclinic ZrO.sub.2 ratio, and scans between 55.degree. to 62.degree. were used to confirm the tetragonal or the cubic ZrO.sub.2 structure.

Table I shows the amount of tetragonal ZrO.sub.2 which was retained in the structure. High proportions of tetragonal ZrO.sub.2 could be retained only for less than about 10 v/o ZrO.sub.2. The 20 v/o ZrO.sub.2 composition was friable, indicative of its high monoclinic content and suggestive of a highly microcracked material.

TABLE I______________________________________Phase Content and Properties of Al.sub.2 O.sub.3 /ZrO.sub.2 Composites Tetra- Stress gonal Vickers IntensityZrO.sub.2 Pressing ZrO.sub.2 Density Hardness Factor, K.sub.c.sup.v /o Temp, .degree.C. Phase % gm/cm.sup.3 G Pa MPam.sup.1/2______________________________________0 1400 3.98 17.6 4.897.5 1500 .about.90 4.12 17.2 5.8810.0 1500 .about.80 4.15 15.8 6.7312.5 1500 .about.70 4.22 16.9 6.2115.0 1500 .about.50 4.25 17.3 5.7120.0 1600 <20 (friable) 10.1 (friable)______________________________________

It has been discovered that the tetragonal ZrO.sub.2 phase can be retained at much higher ZrO.sub.2 contents by adding a controlled amount of Y.sub.2 O.sub.3 to the composite. Samples were prepared and evaluated as previously described for Al.sub.2 O.sub.3 /ZrO.sub.2 composites (Table I) except that ##EQU2## was added to the powders. The Y.sub.2 O.sub.3 was introduced as yttrium nitrate (from Research Chemicals Inc.) and the mixture of dried powders was calcined at 400.degree. C. for 4 hours prior to hot pressing.

Examples according to the invention are shown in Table II. When 2 m/o Y.sub.2 O.sub.3 was included in the Al.sub.2 O.sub.3 /ZrO.sub.2 composite, the ZrO.sub.2 was 100% tetragonal for compositions up to about 45 v/o ZrO.sub.2. Approximately 80% of the ZrO.sub.2 was tetragonal even at 100 v/o ZrO.sub.2. Thus, the Y.sub.2 O.sub.3 addition greatly increased the amount of tetragonal ZrO.sub.2 which could be retained in the Al.sub.2 O.sub.3 /ZrO.sub.2 composite as can be seen by comparing samples made under similar conditions with and without the Y.sub.2 O.sub.3 (Tables II and I). With 2 m/o Y.sub.2 O.sub.3, up to 80 v/o of the entire sample could be tetragonal ZrO.sub.2 (for the 100 v/o ZrO.sub.2 sample); without the Y.sub.2 O.sub.3 the maximum amount of tetragonal ZrO.sub.2 which could be retained in the sample was only about 9% (for the 12.5 v/o ZrO.sub.2 sample).

TABLE II__________________________________________________________________________Phase Content and Properties ofAl.sub.2 O.sub.3 /ZrO.sub.2 Composites Containing 2 .sup.m /.sub.oY.sub.2 O.sub.3 Stress Tetragonal Vickers Intensity Modulus FlexureZrO.sub.2 Pressing ZrO.sub.2 Phase Density Hardness Factor,K E Strength.sup.v /.sub.o Temp, .degree.C. % gm/cm.sup.3 GPa MPam.sup.1/2 GPa MPa__________________________________________________________________________6.0 1600 100 4.12 16.8 5.97 -- 76012.3 1600 100 4.26 15.9 6.22 -- 75018.2 1600 100 4.38 16.1 6.58 356 109023.9 1600 100 4.50 16.4 6.38 -- 86029.5 1600 100 4.62 15.7 7.43 -- 115045.0 1600 trace 4.89 15.1 8.12 291 -- monoclinic60.0 1600 .about.95 5.24 13.7 7.45 -- --80.0 1400 .about.85 5.57 12.6 6.79 237 --100.0 1400 .about.80 6.01 11.6 6.62 210 --__________________________________________________________________________

ZrO.sub.2 can also exist in a cubic structure. The ZrO.sub.2 -Y.sub.2 O.sub.3 phase diagram (K. K. Srivastaba, et al, Trans. Brit. Ceram. Soc. 73, 85, 1974) shows that cubic ZrO.sub.2 is stable when the m/o of Y.sub.2 O.sub.3 is over about 7 m/o Y.sub.2 O.sub.3. Samples were fabricated as described above except 7.5 m/o Y.sub.2 O.sub.3 was included in the composite. The results obtained from these samples is shown in Table III. In all the samples ZrO.sub.2 existed in the cubic structure rather than the desired tetragonal structure or the monoclinic structure obtained in the samples shown in Tables I and II. These results, and conclusions drawn from studying the ZrO.sub.2 -Y.sub.2 O.sub.3 phase diagram indicate that the maximum amount of Y.sub.2 O.sub.3 which can be used to retain the desired tetragonal structure is about 5.5 m/o. The optimum amount of Y.sub.2 O.sub.3 for strengthening the composite is approximately 2 m/o.

TABLE III______________________________________Phase Content and Properties ofAl.sub.2 O.sub.3 /ZrO.sub.2 Composites Containing 7.5.sup.m /.sub.oY.sub.2 O.sub.3 Pressing Cubic Den- Vickers Stress IntensityZrO.sub.2 Temp, ZrO.sub.2 sity Hardness Factor, K.sub.c.sup.v /.sub.o .degree.C. Phase % g/cm.sup.3 GPa MPam.sup.1/2______________________________________20.0 1600 100 4.46 15.8 4.5440.0 1600 100 4.89 15.9 3.7560.0 1600 100 5.28 15.0 3.5080.0 1600 100 5.63 14.3 3.14100.0 1600 100 5.95 11.4 3.90______________________________________

All the samples (except the end members of pure Al.sub.2 O.sub.3 and ZrO.sub.2) had a microstructure consisting of two phases, the Al.sub.2 O.sub.3 phase and the ZrO.sub.2 phase. In general, the minor phase was uniformly dispersed, although there was some agglomeration of the minor phase in occasional groups of 2 to 5 grains. The average grain size for the composite materials was dependent on the fabrication temperature; namely about 0.2 .mu.m at 1400.degree. C., 0.5 .mu.m at 1500.degree. C., and 1 .mu.m at 1600.degree. C. The average grain size of the end member compositions which were hot-pressed at 1400.degree. C. was about 2 .mu.m for the Al.sub.2 O.sub.3 and about 0.5 .mu.m for the ZrO.sub.2.

Theoretical calculations by the present inventor (F. F. Lange, "Stress-Induced Phase Transformation: Theory of Phase Retention and Fracture Toughness", Office of Naval Research Report #6, Contract N00014-77-C-0441, October, 1979) indicate that a critical size exists, below which a particle of tetragonal ZrO.sub.2 can be constrained from transforming by an elastic matrix. The critical particle (or grain) size can be increased by increasing the elastic properties of the constraining matrix. It has been estimated that a particle size less than about 0.2 .mu.m would be required to retain pure, tetragonal ZrO.sub.2 in a ZrO.sub.2 constraining matrix (E=about 210 GPa). However, pure, tetragonal ZrO.sub.2 can be retained for an average particle size of 0.5 .mu.m when the elastic modulus of the constraining material is increased to that of Al.sub.2 O.sub.3 (E=about 390 GPa) by incorporating a large volume % of Al.sub.2 O.sub.3 in an Al.sub.2 O.sub.3 /ZrO.sub.2 matrix. Less tetragonal ZrO.sub.2 is retained in the Al.sub. 2 O.sub.3 /ZrO.sub.2 composite as the volume % of Al.sub.2 O.sub.3 is decreased because the elastic modulus of the composite decreases and shifts the critical particle size to smaller values than those achieved during fabrication.

According to this invention, Y.sub.2 O.sub.3 is included in an Al.sub.2 O.sub.3 /ZrO.sub.2 composite. The Y.sub.2 O.sub.3 is held in solid solution in the ZrO.sub.2 and it increases the critical grain size below which tetragonal ZrO.sub.2 can be retained in an Al.sub.2 O.sub.3 /ZrO.sub.2 matrix. Consequently, tetragonal ZrO.sub.2 can be obtained in Al.sub.2 O.sub.3 /ZrO.sub.2 composites with grain sizes up to about 2 .mu.m. The actual amount of ZrO.sub.2 retained in the composite depends on the size of the grains in the composite and on the amount of Al.sub.2 O.sub.3 ; small grain size and large v/o of Al.sub.2 O.sub.3 favoring increased retention of tetragonal ZrO.sub.2.

Al.sub.2 O.sub.3 /ZrO.sub.2 ceramics produced according to this invention have improved fracture toughness as measured by the stress intensity factor (K.sub.c). K.sub.c was measured on polished specimens by using the indentation technique and the function ##EQU3## developed by Evans and Charles (J. Am. Ceram. Soc. vol. 59, pp. 371-372, 1976). The hardness (H) was measured at a load of 20 Kgm. The half-diagonal (d) of the pyramidal indent and half-crack length (c) were used with Young's modulus and the experimentally obtained function (f(c/d)) to compute K.sub.c. As shown in Tables I and II, K.sub.c is substantially higher in the 2 m/o Y.sub.2 O.sub.3 containing Al.sub.2 O.sub.3 /ZrO.sub.2 ceramics (Table II) than in pure Al.sub.2 O.sub.3 or the non-yttrium containing Al.sub.2 O.sub.3 /ZrO.sub.2 ceramics (Table I).

The flexure strength of the 2 m/o composites was measured using four-point bending tests (inner span of 1.22 cm, outer span of 2.54 cm) on diamond cut specimens (0.32.times.0.32 cm cross section) finished with a 220 grit diamond grinding wheel. The high values shown for samples containing 18.2 and 29.5 v/o are attributed to compressive stresses caused by surface grinding which induces transformation of the tetragonal ZrO.sub.2 to the monoclinic ZrO.sub.2. When the 29.5 v/o sample was annealed at 1300.degree. C. to eliminate the transformed surface layer, its strength was reduced to 920 MPa. Even for the annealed samples, the flexure strength of the Al.sub.2 O.sub.3 /ZrO.sub.2 +2 m/o Y.sub.2 O.sub.3 composites was higher than for pure Al.sub.2 O.sub.3 (580 MPa).

Young's modulus was measured at room temperature by the resonance technique in two modes of vibration: flexural at 9 kHz and extensional at 60 kHz.

Density was measured on 5 cm diameter hot-pressed billets using Archimede's technique. Vickers hardness was measured using a 20 kgm load. Both these properties appeared to follow the linear rule of mixtures for the end members (Al.sub.2 O.sub.3 and ZrO.sub.2).

Yttrium (Y) belongs to a family of 16 rare earth metals. A comparison of the phase diagrams ("Phase Diagrams for Ceramists" compiled by the National Bureau of Standards and published by The American Ceramic Society) of ZrO.sub.2 -Y.sub.2 O.sub.3 with ZrO.sub.2 -CeO.sub.2, with ZrO.sub.2 -Er.sub.2 O.sub.3, and with ZrO.sub.2 -La.sub.2 O.sub.3 shows similar behavior in that these four metal oxides each tend to lower the temperature of the transformation of ZrO.sub.2 from the tetragonal to the monoclinic structure. It is therefore concluded that the addition of CeO.sub.2, Er.sub.2 O.sub.3, or La.sub.2 O.sub.3 to an Al.sub.2 O.sub.3 /ZrO.sub.2 composite would also favor the retention of tetragonal ZrO.sub.2 in a manner analogous to the Y.sub.2 O.sub.3 addition. As in the case of Y.sub.2 O.sub.3, the amount added must be sufficient to cause the retention of tetragonal ZrO.sub.2 but not so much as to cause the formation of substantial amounts of cubic ZrO.sub.2. According to the phase diagrams, CeO.sub.2 is beneficial in the range of about 0.5 to 10 m/o, Er.sub.2 O.sub.3 is beneficial in the range of 0.4 to 4 m/o, and La.sub.2 O.sub.3 is beneficial in the range of about 0.5 to 5 m/o, ##EQU4##

Mixtures of Y.sub.2 O.sub.3, CeO.sub.2, Er.sub.2 O.sub.3, and La.sub.2 O.sub.3 could be added in various portions within the above ranges to promote the tetragonal ZrO.sub.2.

The composition of the matrix can range from 5 to 95 v/o ZrO.sub.2 (including the rare earth oxide dissolved therein) with the balance being essentially Al.sub.2 O.sub.3. While the available test data shown the highest toughness and strength for compositions in the 30 to 45 v/o ZrO.sub.2 range, there are other factors which may dictate a different composition. For example, ZrO.sub.2 is a better insulator than Al.sub.2 O.sub.3 and higher ZrO.sub.2 compositions may be preferred for applications requiring high insulation. Al.sub.2 O.sub.3 is lighter and harder than ZrO.sub.2 and higher Al.sub.2 O.sub.3 compositions may be preferred for applications requiring these properties.

The compositions according to the invention are useful in many applications, for example forming dies and tools, cutting tools, structural parts requiring electrical insulation, and many other applications in which a tough ceramic may be advantageous.

Numerous variations and modifications can be made without departing from the invention. For example, additives can be included in the composition to improve the fabricability or properties of the ceramic in accordance with recognized principles. Accordingly, it should be clearly understood that the form of the invention described above is illustrative only and is not intended to limit its scope.

Claims

1. A ceramic comprising:

5 to 95 v/o ZrO.sub.2 in the form of crystalline grains having a diameter less than about 2 .mu.m and a substantially tetragonal structure;

a rare earth oxide selected from the group consisting of Y.sub.2 O.sub.3, CeO.sub.2, Er.sub.2 O.sub.3, and La.sub.2 O.sub.3, there being at least enough of said rare earth oxide to increase the amount of ZrO.sub.2 having a tetragonal crystal structure, but not enough of said rare earth oxide to form substantial amounts of said ZrO.sub.2 having a cubic crystal structure; and

the remainder of said ceramic being substantially Al.sub.2 O.sub.3.

2. A ceramic comprising:

5-95 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m;

about 2 m/o Y.sub.2 O.sub.3 ; and

95 to 5 v/o Al.sub.2 O.sub.3, whereby said ZrO.sub.2 grains are substantially tetragonal in structure and said ceramic is free of ZrO.sub.2 grains having a cubic structure.

3. A ceramic comprising:

5 to 95 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m and a sbstantially tetragonal structure;

0.5 to 5.5 m/o Y.sub.2 O.sub.3 ; and

95 to 5 v/o Al.sub.2 O.sub.3.

4. A ceramic comprising:

5 to 95 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m and a substantially tetragonal structure;

0.5 to 10 m/o CeO.sub.2 ; and

95 to 5 v/o Al.sub.2 O.sub.3.

5. A ceramic comprising:

5 to 95 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m and a substantially tetragonal structure;

0.4 to 4 m/o Er.sub.2 O.sub.3 ; and

95 to 5 v/o Al.sub.2 O.sub.3.

6. A ceramic comprising:

30 to 60 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m and a substantially tetrogonal structure;

about 2 m/o Y.sub.2 O.sub.3 ; and

the remainder of said ceramic being substantially Al.sub.2 O.sub.3.

7. A two phase ceramic composite comprising:

a first phase occupying 5 to 95% of the volume of said ceramic composite, said first phase comprising ZrO.sub.2 grains having a diameter less than about 2 .mu.m with a rare earth oxide dissolved therein, at least 80% of said ZrO.sub.2 having a tetragonal structure, said rare earth oxide being selected from the group consisting of Y.sub.2 O.sub.2, CeO.sub.2, and Er.sub.2 O.sub.3 ; and

a second phase comprising Al.sub.2 O.sub.3 and occupying substantially all remaining volume of said ceramic composite.

8. The ceramic composite as claimed in claim 7 wherein said rare earth oxide comprises Y.sub.2 O.sub.3.

9. A ceramic comprising:

5 to 95 v/o ZrO.sub.2 in the form of grains having a diameter less than about 2 .mu.m and a substantially tetragonal structure;

0.5 to 5 m/o La.sub.2 O.sub.3 ; and

95 to 5 v/o Al.sub.2 O.sub.3.