Directionally solidified eutectic ceramic oxides

Ultra‐High‐Strength Nanofibrillar Al2O3–YAG–YSZ Eutectics

This paper describes a procedure for preparing large surfaces of eutectic composites directionally solidified from the melt, with very fine and uniform microstructures. Large surface plates of the Al 2 O 3 –ZrO 2 eutectic, with thickness up to 250 μm, have been grown by solidification using a modified laser zone melting method suitable for the preparation of large area samples. The surface of a ceramic precursor is scanned with a rectangular CO 2 laser beam of 20×0.5 mm 2 size which induces surface melting. The resulting microstructure is colony free and it consists of fine and alternating interpenetrating Al 2 O 3 and ZrO 2 single crystal lamellae. This microstructure is the basis for improvement of mechanical behaviour in the processed material. The interspacing, crystal structure and orientation relationship between the phases has been determined. Solidification fronts were studied as a function of the processing conditions. A mapping of the residual stresses has also been performed along the transverse plate sections using micro-luminescence techniques.

ZrO2–Al2O3 eutectic plates produced by laser zone melting

During flash sintering, ceramic materials can sinter to high density in a matter of seconds while subjected to electric field and elevated temperature. This process, which occurs at lower furnace temperatures and in shorter times than both conventional ceramic sintering and field-assisted methods such as spark plasma sintering, has the potential to radically reduce the power consumption required for the densification of ceramic materials. This paper reviews the experimental work on flash sintering methods carried out to date, and compares the properties of the materials obtained to those produced by conventional sintering. The flash sintering process is described for oxides of zirconium, yttrium, aluminium, tin, zinc, and titanium; silicon and boron carbide, zirconium diboride, materials for solid oxide fuel applications, ferroelectric materials, and composite materials. While experimental observations have been made on a wide range of materials, understanding of the underlying mechanisms responsible for the onset and latter stages of flash sintering is still elusive. Elements of the proposed theories to explain the observed behaviour include extensive Joule heating throughout the material causing thermal runaway, arrested by the current limitation in the power supply, and the formation of defect avalanches which rapidly and dramatically increase the sample conductivity. Undoubtedly, the flash sintering process is affected by the electric field strength, furnace temperature and current density limit, but also by microstructural features such as the presence of second phase particles or dopants and the particle size in the starting material. While further experimental work and modelling is still required to attain a full understanding capable of predicting the success of the flash sintering process in different materials, the technique non-etheless holds great potential for exceptional control of the ceramic sintering process.

/pdf/flash-sintering-of-ceramic-materials-5o7k19q4ip.pdf

Flash sintering of ceramic materials

The invention relates to uses of glasses and glass-ceramics in dental and orthodontic applications.

Use of ceramics in dental and orthodontic applications

Monolithic ceramics are not widely used as structural materials because of their brittleness. Ceramic matrix composites, in which whiskers 1-3 or fibres 4-7 of strong ceramics such as silicon carbide or silicon nitride are embedded in a ceramic matrix, offer improved toughness and strength because the energy of cracks may be dissipated at the whisker/matrik interface. Here we describe a strong ceramic composite with a different kind of microstructure, made by unidirectional solidification of an Al 2 O 3 / GdAlO 3 eutectic mixture. This composite has a microstructure in which continuous networks of single-crystal Al 2 O 3 and single-crystal GdAlO 3 interpenetrate without grain boundaries. Rather than brittle fracture, the material displays plastic deformation at 1,873K owing to dislocation motion, as in metals. The high strength and resistance to brittle failure of this material at such high temperatures augurs well for applications in mechanical engineering.

A ductile ceramic eutectic composite with high strength at 1,873 K

Unidirectionally solidified Al2O3/Y3Al5O12 (YAG) or Al2O3/Er3Al5O12 (EAG) eutectic composites, which are named as Melt Growth Composites (MGCs) has recently been fabricated by unidirectional solidification. The MGCs have a new microstructure, in which continuous networks of single-crystal Al2O3 phases and single-crystal oxide compounds (YAG or EAG) interpenetrate without grain boundaries. The MGCs fabricated are thermally stable and has the following properties: 1) the flexural strength at room temperature can be maintained up to 2073 K (just below its melting point), 2) a fracture manner from room temperature to 2073 K is an intergranular fracture different from a transgranular fracture of sintered composite with the same composition, 3) the compressive creep strength at 1873 K and a strain rate of 10−4/sec is 7–13 times higher than that of sintered composites, 4) the mechanism of creep deformation is based on the dislocation creep models completely different from the Nabarro-Herring or Coble creep models of the sintered composites, and 5) it shows neither weight gain nor grain growth, even upon heating at 1973 K in an air atmosphere for 1000 hours. The above superior high-temperature characteristics are caused by such factor as the MGCs having a single-crystal Al2O3/single-cryatal oxide compounds without grain boundaries and colonies, and the formation of the thermodynamically stable and compatible interface without amorphous phase.

Fracture and deformation behaviour of melt growth composites at very high temperatures

New Al2O3/Y3Al5O12(YAG)/ZrO2 ternary Melt Growth Composites (MGCs) with a novel microstructure have been fabricated by unidirectional solidification. These MGCs displayed superior high-temperature strength characteristics. The flexural strength increases progressively in the range 650–800 MPa with a rise in temperature from room temperature up to 1873 K. These excellent high-temperature characteristics are closely linked to such factors as: a microstructure consisting of three-dimensionally continuous and complexly entangled single-crystal Al2O3 with a hexagonal structure, single-crystal YAG with a garnet structure and fine ZrO2 with a cubic structure; characteristic dimensions of the microstructure of Al2O3/YAG/ZrO2 ternary eutectic ceramics of around 2–3 μm for YAG, around 2–3 μm for Al2O3 and around 0.4–0.8 μm for ZrO2; and the fact that no amorphous phase is formed at interfaces between any of the phases.

Temperature dependence of flexural strength and microstructure of Al2O3/Y3Al5O12/ZrO2 ternary melt growth composites

Clinical screening using the National Comprehensive Cancer Network (NCCN) testing criteria may fail to identify all patients with hereditary breast and ovarian cancers. Thus, this study aimed to evaluate the strategy of expanding target patients for genetic testing among Japanese patients. We reviewed the medical records of 91 breast cancer patients who underwent genetic testing. Among 91 patients, eight were diagnosed with pathogenic or likely pathogenic variants: BRCA1 (n = 4) and BRCA2 (n = 4). Among 50 patients meeting the testing criteria of the guidelines, 6 (12%) were diagnosed with pathogenic or likely pathogenic variants. The sensitivity and specificity of screening using the testing criteria were 75% and 47%, respectively. Expanding the NCCN criteria to include all women diagnosed with breast cancer aged ≤65 years achieved 88% sensitivity but 8% specificity. The expansion of the NCCN criteria could benefit Japanese patients; however, larger studies are necessary to change clinical practice.

/pdf/efficacy-of-clinical-guidelines-in-identifying-all-japanese-1glgtsz2.pdf

K. Shimizu

Papers

A ductile ceramic eutectic composite with high strength at 1,873 K

Fracture and deformation behaviour of melt growth composites at very high temperatures

Temperature dependence of flexural strength and microstructure of Al2O3/Y3Al5O12/ZrO2 ternary melt growth composites

Efficacy of Clinical Guidelines in Identifying All Japanese Patients with Hereditary Breast and Ovarian Cancer