Co-Axially Laminated Continuously Porous Composites in Al2O3-(m-ZrO2)/t-ZrO2 System for High Mechanical Strength

A micro-channeled composite with a laminated microstructure was fabricated in Al2O3-ZrO2 composite system through a multipass extrusion process. Using this approach, Al2O3-(monoclinic-ZrO2)/tetragonal-ZrO2 continuously porous composites with concentric laminates were fabricated. The entire matrix phase had a laminated microstructure of alternate lamina of Al2O3-(m-ZrO2) and t-ZrO2 with a homogeneous thickness and central channel. Each of the continuous channels was coaxially encircled by a group of 5 alternate laminates. The laminate plane was oriented along the axis of the continuous channels. The design strategy was to incorporate concentric lamellar microstructural units in a macro scaled ceramic body comprising a central channel for each. The frame modification was intended to improve the material properties of the channeled body which in turn could act as a porous space for the inclusion of additional functional attributes. Filaments of polymer mixed ceramic powders and pore forming agent carbon were stacked in a pre-designed arrangement to obtain the desired microstructure and then extruded to obtain green composites. The channel diameter and channel frame thickness were approximately 198 +/- 10 mu m and 158 +/- 10 mu m, respectively. The channel frame region was furnished with 9 alternating shells of Al2O3-(m-ZrO2) and t-ZrO2 with a thickness of around 10 similar to 20 mu m. The material properties including the relative density and bending strength, which depend on temperature, were evaluated. The detailed microstructure of the channeled bodies was also characterized by Scanning Electron Microscope (SEM). [doi:10.2320/matertrans.M2010193]