The paper studies the structural features, phase composition and complex mechanical properties of two-layer composite ceramics based on alumina-toughened zirconia with silica added (Ca-ATZ/Ca-ATZ+SiO2). The ceramics under study were manufactured using a cost-effective technology involving grinding and mixing powders, layering of powder mixtures (different compositions), uniaxial pressing and two-stage sintering. It was found that at the interface of the compositions, there is an abrupt increase in fracture toughness (by 33%) and a decrease in hardness and Young's modulus (by 8% and 7%, respectively). The possibility of manufacturing composite ceramics Ca-ATZ+SiO2 (with a thin surface layer, not containing SiO2) with a high ratio of hardness (not lower than 14 GPa) and fracture toughness (not lower than 12 MPa m1/2) was shown. Given the increased resistance to low-temperature degradation of the developed ceramics, this will increase the service life of products operated under high mechanical loads in a humid atmosphere.
DuhJG, WanJU.Developments in highly toughened CeO2–Y2O3–ZrO2 ceramic system. J Mater Sci1992;27:6197–6203. DOI:10.1007/BF01133771.
4.
ZhangF, LinLF, WangEZ.Effect of micro-alumina content on mechanical properties of Al2O3/3Y-TZP composites. Ceram Int2015;41:2417–12425. DOI:10.1016/j.ceramint.2015.06.081.
5.
LeeJ-K, KimMJ, LeeEG.Influence of dispersed-alumina particle size on the fracture toughness of 3 mol-% yttria-stabilized zirconia polycrystals (3Y-TZP). J Mater Sci Lett2002;21:259–261. DOI:10.1023/A:1014737614591.
6.
SequeiraS, FernandesMH, NevesN, Development and characterization of zirconia–alumina composites for orthopedic implants. Ceram Int2017;43:693–703. DOI:10.1016/j.ceramint.2016.09.216.
7.
PorozovaSE, KulmetyevaVB.Influence of matrix replacement on consolidation processes of composite ceramic materials of ZrO2–Al2O3 system. Inorg Mater: Appl Res.2014;5(4):420–426. DOI:10.1134/S2075113314040406.
8.
KobayashiK, KuwajimaH, MasakiT.Phase change and mechanical properties of ZrO2-Y2O3 solid electrolyte after aging. Solid State Ionics. 1981;3-4:489–493. DOI:10.1016/0167-2738(81)90138-7.
9.
GaillardY, Jimenez-PiqueE, SolderaF, Quantification of hydrothermal degradation in zirconia by nanoindentation. Acta Mater. 2008;56(16):4206–4216. DOI:10.1016/j.actamat.2008.04.050.
10.
LinJ-D, DuhJ-G, LoC-L.Mechanical properties and resistance to hydrothermal aging of ceria- and yttria-doped tetragonal zirconia ceramics. Mater Chem Phys. 2002;77:808–818. DOI:10.1016/S0254-0584(02)00161-X.
11.
DmitrievskiiAA, ZhigachevaDG, EfremovaNY, Phase composition stability of nanostructured composite ceramics based on CaO-ZrO2 under hydrothermal impact. Nanotechnol Russ. 2019;14(3–4):125–131. DOI:10.1134/S1995078019020058.
12.
DmitrievskiiAA, ZhigachevAO, ZhigachevaDG, Effect of silica on phase composition stability and mechanical properties of alumina-reinforced zirconia-based ceramics. Tech Phys. 2020;65(12):2016–2025. DOI:10.1134/S1063784220120075.
13.
KoizumiM.Recent progress of functionally gradient materials in Japan ceram. Eng Sci Proc. 1992;13:333–346.
14.
MiyamotoY, KaisserW, RabinBH, Functionally graded materials: design, processing, and applications. New York: Springer Science & Business Media; 1999.
15.
SamM, JojithR, RadhikaN.Progression in manufacturing of functionally graded materials and impact of thermal treatment – a critical review. J Manuf Process. 2021;68:1339–1377. DOI:10.1016/j.jmapro.2021.06.062.
16.
WatanabeY, InagumaY, SatoH, A novel fabrication method for functionally graded materials under centrifugal force: the centrifugal mixed-powder method. Materials. 2009;2:2510–2525. DOI:10.3390/ma2042510.
17.
EbhotaWS, KarunAS, InambaoFL.Centrifugal casting technique baseline knowledge, applications, and processing parameters: overview. Int. J. Mater. Res. 2016;107(10):960–969. DOI:10.3139/146.111423.
18.
AliE, WoldeyesK, UrgessaG.Fire performance of functionally-graded-material sheathed load bearing thin-walled structural framing. Fire Saf J. 2021;125:103425, DOI:10.1016/j.firesaf.2021.103425.
19.
ZhangC, ChenF, HuangZ, Additive manufacturing of functionally graded materials: a review. Mater Sci Eng A. 2019;764:138209, DOI:10.1016/j.msea.2019.138209.
20.
UdupaG, RaoSS, GangadharanKV.Functionally graded composite materials: an overview. Proc Mater Sci.2014;5:1291–1299. DOI:10.1016/J.MSPRO.2014.07.442.
21.
MaJ, TanGE.Processing and characterization of metal–ceramics functionally gradient materials. J Mater Process Technol.2001;113:446–449. DOI:10.1016/S0924-0136(01)00613-6.
22.
BertoleteM, BarbosaPA, de RossiW, Mechanical characterisation and machining evaluation of ceramic cutting tools functionally graded with six layers. Ceram Int.2020;46:15137–15145. DOI:10.1016/j.ceramint.2020.03.048.
23.
BinnerJ, AnnapooraniK, PaulA, Dense nanostructured zirconia by two stage conventional/hybrid microwave sintering. J Eur Ceram Soc.2008;28:973–977. DOI: 10.1016/j.jeurceramsoc.2007.09.002.
24.
GalusekD, GhillányováK, SedláčekJ, The influence of additives on microstructure of sub-micrometre alumina ceramics prepared by two-stage sintering. J Eur Ceram Soc.2012;32:1965–1970. DOI: 10.1016/j.jeurceramsoc.2011.11.038.
25.
MoradkhaniA, BaharvandiH.Effects of additive amount,: testing method, fabrication process and sintering temperature on the mechanical properties of Al2O3/3Y-TZP composites. Eng Fract Mech.2018;191:446–460. DOI:10.1016/j.engfracmech.2017.12.033.
26.
MecartneyML.Influence of an amorphous second phase on the properties of yttria-stabilized tetragonal zirconia polycrystals (Y-TZP). J Am Ceram Soc. 1987;70:54–58. DOI:10.1111/j.1151-2916.1987.tb04853.x.
27.
DanilenkoI, KonstantinovaT, VolkovaG, The role of powder preparation method in enhancing fracture toughness of zirconia ceramics with Low alumina amount. J Ceram Sci Tech.2015;6(3):191–200. DOI:10.4416/JCST2015-00020.
