A ceramic material, reinforced by the incorporation of alumina fibers and process for production thereof

Abstract: The whiskers-reinforced ceramic is prepared from alumina powder activated by dry milling, with which Ti-based whiskers are mixed, by molding and sintering said mixture. By the present invention the bending strength of the sintered body can be increased without impairing the effect of improving the fracture toughness which is imparted by the incorporation of Ti-based whiskers, since the particle size of alumina crystal in the sintered body can be controlled to 3 microns or less.

Description: The present invention relates to whiskers-containing fibers-reinforced ceramics and, more particularly, relates to such ceramics with high fracture toughness that is particularly suitable for uses as cutting tools and other abrasion resistant parts, and the process production thereof. While sintered bodies produced from alumina (Al₂O₃) are utilized as materials excelling in abrasion resistance for various industrial machine parts, its applicable field has been kept from expanding because of its shortcomings: inferior fracture toughness. In view of the aforementioned circumstance, there have been proposed various improvements aimed at its improved fracture toughness. As one example of the aforementioned proposals, there has been proposed in Japanese Laid-Open Application Sho 61-286271 and Japanese Laid-Open Application Sho 62-41776 certain means of improving fracture toughness by blending a fibrous material represented by silicon carbide whiskers. Such a ceramic material reinforced by the incorporation of fibers containing SiC whiskers exhibits excellent performance properties in cutting certain ultra-heat resistant alloys (e.g. roughing cut on Inconel 718) when it is used as a cutting tool, since SiC by itself has high hardness and good heat conductivity. Nevertheless, since SiC tends to readily react with iron, particularly iron oxides, Al₂O₃-SiC whiskers-based tools in many cases tend to wear off at a higher rate than tools consisting principally of Al₂O₃. For example, when a material constructed of SUS 304 is worked on for cutting, the tool containing SiC whiskers gives rise to such problem that cutting is practically impossible to perform due to rapid progress of wear even under comparable conditions which sufficiently enable the conventional Al₂O₃ tool to accomplish cutting. Besides, it has been verified that the wear rate of Al₂O₃-SiC whiskers-containing tool is higher than that of Al₂O₃ tool in cutting cast iron-made stock material. As stated above, the Al₂O₃-Sic whiskers-containing tool poses a problem that cutting properties notably vary with the material to work on. Meanwhile, there has been recently proposed the incorporation of titanium carbide (TiC) whiskers, which have a lower reactivity with iron than SiC, instead of SiC whiskers, for the purpose of eliminating such reactivity with the ferrous material to work on. Nevertheless, in the case of Al₂O₃-TiC material, its strength tends to decrease, since the particle size of alumina increases due to the grain growth of alumina in the sintering step is excessively high. As for the cause of excessively high grain growth of Al₂O₃ in the sintering step, it is inferred firstly that the difficulty with the preparation of fine, uniform TiC whiskers restrains the effect inferent in the whiskers to inhibit the grain growth of alumina only to a low level, and secondly that TiO₂ produced by oxidation of TiC whiskers on their surfaces accelerates the grain growth of Al₂O₃. Ordinarily, mechanical properties of the alumina-based sintered body to a large extent depend upon the particle size of alumina crystal in the sintered body, and it is said that the smaller the particle size, the higher becomes its strength. Hence, under the present circumstance, the conventional Al₂O₃-Tic whiskers-containing material has not its properties upgraded to an extent that such materials is rendered practically useful. From WO-A-88/09243 a sintered ceramic composition comprising 40 to 90 volume percent high purity alumina, 10 to 50 volume percent single crystal titanium carbide whiskers and up to 3 volume percent sintering aids is known wherein the average grain size of the alumina matrix is of 0.5 to 3 micrometers. No boron-containing metal compound, silicon carbide or carbon as a third component can be derived from said document. From EP-A-02 84 584 a sintered ceraminc body obained by compounding a specific ratio of a Cr-compound such as Cr₂O₃ with base components such as alumina, refractory hard phases and ZrO₂, HfO₂ and/or partially stabilized ZrO₂ is known. The specific features of the present application can not be derived from said document. EP-A-02 83 454 discloses an oxide-based ceramic cutting insert for chip forming machining of steel wherein the inserts comprise 5 to 50 percent by volume homogeneously dispersed whiskers of carbides, nitrides and/or borides of titanium and/or zirconium besides the oxide-based matrix. Summary of the Invention The inventors of the present invention have found, through intensive studies on the aforementioned problems liable to occur with TiC whiskers-reinforced ceramics containing fibrous substances like TiC whisker, that a sintered body can be obtained such that the grain growth of alumina is inhibited and properties such as strength are notably improved by means of incorporating whiskers in Al₂O₃ powder which has been activated by dry pulverization or the addition of carbon powder, silicon carbide, or a boron-containing compound or limitation of the oxygen content of whiskers and then sintering the mixture. Namely, the object of the present invention is to provide ceramic materials reinforced by the incorporation of alumina containing whiskers wherein the grain growth of alumina is inhibited and properties such as strength are improved, and a process for production thereof. Said object is solved by the features of claims 1 and 6. Preferred embodiments can be derived from the dependent claims. According to the present invention an alumina ceramic material reinforced by the incorporation of whiskers is provided which comprises a matrix consisting principally of alumina having 3 micrometer or less of average particle size, whiskers at a ratio of 5 to 70 percent by volume, said whiskers being selected from at least one kind from titanium carbide whiskers, titanium nitride whiskers and titanium carbo-nitride whiskers, and one component selected from the group consisting of (a) a boron-containing metal compound at a ratio of 0.02 to 40 percent by weight, (b) silicon carbide particles at a ratio of 3 to 30 percent by volume, and (c) carbon at a ratio of 0.05 to 2 percent by weight with the proviso that where (b) or (c) is selected as the component, the whiskers incorporated in the ceramic material are titanium carbide. The present invention further provides a process for producing a ceramic material reinforced by the incorporation of alumina fibers which is characterized by the steps of activating alumina with an average particle size of 3 micrometers or less, mixing the alumina with 5 to 70 percent by volume of whiskers selected from the group consisting of titanium carbide, titanium nitride and titanium carbo-nitride, mixing the alumina with a boron-containing metal compound which is 0.02 to 40 percent by weight and molding and sintering the mixture. According to the present invention, activation of alumina power is achieved by dry pulverization as energy is accumulated in the power owing to particle-to-particle contact and impingement. If the sintered body is produce from such powder, the particle size of Al₂O₃ crystal in the finally obtained sintered body is small even in cases where there can not be recognized any effect of inhibiting the grain growth alumina which could be expected from whiskers, since the sintering temperature can be set at a relatively low level, thus allowing the process of sintering Al₂O₃ to proceed with the side effect of inhibiting the grain growth of alumina. As has been discussed above, since the particle size of Al₂O₃ crystal in the sintered body can be controlled to a very fine level by the present invention, the bending strength and fracture toughness of the sintered body can be increased without impairing the effect of improving fracture toughness which is achieved by the incorporation of whiskers. Detailed Description of the Invention The TiC whiskers-reinforced ceramics of the present invention is basically composed of the matrix principally consisting of alumina (Al₂O₃) in which is dispersed titanium-based whiskers. One of the essential characteristics of the present invention derives from the average particle size of alumina constituting the matrix which is controlled to less than 3 µm (microns) in the fibers-reinforced ceramics. In conjunction with such inhibition of the grain growth of alumina as described above, the whiskers-ceramics of the present invention notably excels in mechanical properties. As titanium-based whiskers dispersed in the aforementioned matrix consisting principally of alumina, TiC whiskers, TiN whiskers and TiCN whiskers are used either singularly or in combination of two or more, if necessary. Such whiskers are dispersed at a ratio of 5-70 vol.%, preferably 5-60 vol.%, as against the total volume. If the volume of the dispersed whiskers is less than 5 vol.%, the effect of improving the fracture toughness achieved by the incorporation thereof is little, while the sinterability of the whole system declines if the ratio exceeds 70 vol.%. In view of the acceptable mechanical properties and ease of sintering, the quantity of incorporated whiskers is preferably 25-45 vol.%, or most desirably 30-40 vol.%. The aforementioned whiskers is in either single crystal form or polycrystal form, and preferably has a particle size of 10 µm (microns) or less, particularly 0.5-2.0 µm (microns). The reason for this is that if the average particle size of whiskers exceeds 10 µm (microns), breakage develops from thick whiskers to remarkably impair the strength of the sintered body thereby obtained and it becomes difficult to achieve uniform (homogeneous) mixing of whiskers in the matrix in the manufacturing step, whereby variances are liable to occur in the strength and fracture toughness of the obtained product and furthermore the degree of phase abrasion on the flank increases in case the sintered body thereby obtained is used as a cutting tool. On the other hand, if the aspect ratio, which represents the length-to-diameter ratio of a unit whisker, is excessively small, a high fracture toughness is hardly ensured, since such small aspect ratio reduces the effect of fibers reinforcement. By contrast, if the aspect ratio is excessively large, it is difficult to secure a high fracture toughness, since the handling of the raw material becomes difficult and such whiskers can not be dispersed evenly. For the aforementioned reason, whiskers having an average aspect ratio of 3-100, particularly 10-30, are preferably used. Ti-based whiskers such as mentioned above are synthesized by carbonization, nitrogenization or the chemical vapor deposition (CVD) method. The whiskers-reinforced ceramics consisting of either one of the aforementioned components under the present invention have a bending strength of 588.2 MPa (60 kg/mm²) or more, particularly 686.3 MPa (70 kg/mm²). Furthermore, a third component such as a boron-containing metal compound, silicon carbide granules and carbon granules is be compounded with the whiskers-reinforced ceramics of the present invention. For example, by compounding a boron-containing metal compound, whiskers-reinforced ceramics having high fracture toughness and hardness can be obtained. There can be mentioned as examples of such boron-containing metal compounds borides of metals of Groups 4a, 5a or 6a Group in Periodic Table such as AlB₁₂, ZrB₂, TiB₂, TaB, WB, NbB₂ and LaB₆ or borates containing Al such as Al₁₈B₄O₃₃ whiskers. Among the aforementioned compounds, boric acids such as AlB₁₂, ZrB₂, TiB₂, WB, NbB₂ and Al₁₈B₄O₃₃ are preferred in view of the sinterability and fracture toughness. Particularly, those consisting of rod-like crystal having an aspect ratio of 1.5 or more are preferred for Al-containing boric acids. It is desirable that those boron-containing metal compounds are compounded generally at a ratio of 0.02 to 40 weight%, particularly 0.5 to 10 weight%. If the quantity of the same is less than 0.02 weight%, the effect of improving the fracture toughness and hardness imparted is not sufficient, while if it is compounded in a quantity exceeding 40 weight%, the sinterablility is deteriorated. Besides, granular silicon carbide (SiC) is compounded with the intent to have it inhibit the reactivity with ferrous material and furthermore contribute to improvement of mechanical properties such as the fracture toughness. Particularly, it is co-used with TiC whiskers. For such granular SiC, the one having an average particle size of 1 µm (micron) or less, particularly 0.5 µm (micron) or less, is preferred, while it is desirable that it is compounded at a ratio of 3 to 30 vol.%, particularly 5 to 15 vol.%. If the quantity of SiC is less than 3 vol.%, the effect achievable from the incorporation of SiC particles, namely, the effect of inhibiting the grain growth of Al₂O₃, is lost; and if it exceeds 30 vol.%, the sinterablility declines and furthermore the Ti-based whiskers react with SiC to produce a chemical compound, and thus it is no longer possible to obtain good sintered bodies. Moreover, the abrasion resistance of the sintered body prepared into a cutting tool notably declines. Carbon, too, is co-used with TiC whiskers as is the case with granular SiC with the result of contributing to improvement of mechanical properties of the sintered body obtained therefrom. Such carbon may be either carbon powder having an average particle size of 1 micron or less, particularly 0.5 µm (micron) or less, carbon in such organic compound as phenolic resin capable of releasing carbon in the sintering step or carbon coated onto the surface of TiC whiskers beforehand. Such carbon is used at a ratio of 0.05 to 2 weight% of the total quantity, particularly 0.5 to 1 weight%. If the amount of carbon added is less than 0.05 weight%, the effect of improving the fracture toughness is little, and as it exceeds 2 weight%, the sinterability and hardness and strength of the sintered body decline. Alumina powder is activated by the addition of said carbon powder, silicon carbide or a boron-containing compound, limitation of the oxygen content of whiskers and dry milling of alumina powder. The preparation of fibers-reinforced ceramics As the alumina powder to be used for the preparation of the aforementioned whiskers-reinforced ceramics of the present invention, the one having a purity of 99% or more, particularly 99.5% or more and having an average particle size of 3 microns or less is preferably used. Above all, it is essential that alumina powder which has been activated is used. Such activation treatment is performed by means of dry milling. Specifically, any conventional method including rotary mill, vibrating mill, jet mill and attrition mill may be used, while a higher effect of activation is achieved by a highly efficient pulverization. Such pulverization treatment may be carried out on the alumina powder by itself or together with additives. The sinterability of alumina powder by itself can be increased by the aforementioned activation treatment. While the Ti-based whiskers used in combination with the aforementioned alumina powder in the present invention contains oxygen as an impurity, it is desirable that Ti-based whiskers having an oxygen content of 3 weight% or less be used in the preparation of the fibers-reinforced ceramics of the present invention. Although the sinterability is improved with an increase in the oxygen content, the hardness and sinterability of the sintered body decreases, since the presence of such oxygen accelerates the grain growth of alumina. The desirable level of the oxygen content depends on the specific properties required of the sintered body. In cases where a high fracture toughness is desirable, the oxygen content is preferably 0 to 0.3 weight%. In case where a high hardness is desired, the oxygen content is preferably 0.2 to 2 weight%. In cases where ease of fabrication is desirable, the oxygen content is preferably 2 to 3 weight%. With view to ensuring an overall balance among the strength, hardness and fracture toughness, the preferable oxygen content is between 0.1 and 1.5 weight%. In cases where ceramics for cutting tool use is prepared, the oxygen content is preferably 0.05 to 0.2 weight%. In the preparation of the whiskers-reinforced ceramics of the present invention, it is desirable that an oxide of at least one kind of element selected from among Mg, Ni, Co, Cr, Ca, Sr, Si and the elements of Group 3a in the Periodic Table be used as an auxiliary sintering aid, since the addition of such agent enhances the sinterability of the matrix composition and improves properties of the ceramics thereby obtained. The dosage of this auxiliary sintering aid varies with the kind of the third component used. For example, in cases where the aforementioned boron-containing metal compound is added, it is desirable that such auxiliary sintering aid is added by 0.02 to 8 weight%, particularly 0.5 to 5 weight%. In other cases, it is appropriate that it be added at a ratio of 0.5 to 2 weight%. If the amount of the auxiliary sintering aid is used in a quantity less than the aforementioned level, the effect of improving the sinterability achieved is not sufficient. In cases where it is used in a quantity exceeding the aforementioned level, the fracture toughness of the ceramics thereby obtained is low. As examples of the elements of Group 3a in the Periodic Table, there can be mentioned Yb, Nd, Er, Ce, Sm, Y, Gd, Dy and La. In case a boron-containing metal compound is used in the present invention, MgO, CaO, SiO₂ and oxides of elements of Group 3a are suitably used among the aforementioned auxiliary sintering aids. Moreover, in cases where a boron-containing metal compound is not used, oxides of Mg, Co, Cr, Ni and rare earth elements are suitably used as an auxiliary sintering aid. The whiskers-reinforced ceramics of the present invention is obtained after subjecting a mixture of alumina powder and, if necessary, a third component, and an auxiliary sintering aid to a treatment for activation of alumina powder by means of the aforementioned dry milling by the process whereby Ti-based whiskers are admixed to said mixture, and the obtained mixture is molded into the desired shape by any selected molding process, such as compression molding, extrusion, injection molding and hydrostatic cold molding, whereupon the molded part is sintered. The whiskers-reinforced ceramics of the present invention is obtained after subjecting a mixture of alumina powder and, if necessary, a third component, and an auxiliary sintering aid to a treatment for activation of alumina powder by means of the aforementioned dry milling by the process whereby Ti-based whiskers are admixed to said mixture, and the obtained mixture is molded into the desired shape by any selected molding process, such as compression molding, extrusion, injection molding and hydrostatic cold molding, whereupon the molded part is sintered. Processes adopted for the sintering step include conventional sintering, the hot pressing method and the hot isostatic pressing method (HIP). The sintering is carried out at a temperature of 1650 to 1850 °C in an inert atmosphere of Ar or He, or in an reductive atmosphere in the presence of carbon, etc. under either a pressurized condition or under reduced pressure for 0.5 to 6 hours. Particularly, for the purpose of obtaining a high density sintered body, a sintered body having a density of 96% as against the theoretical density by the conventional sintering or by the hot isostatic pressing method (HIP), and then the obtained sintered body is subjected to a hydrostatic hot sintering step additionally. By adopting the aforementioned sintering step, the sintering step is accomplished by a temperature level lower than in case of the conventional sintering by 50 to 100 °C, owing to the improved sinterability of alumina itself which is achieved by the activation treatment of alumina powder. By the aforesaid sintering process, the average particle size of alumina crystal in the finally obtained sintered body can be controlled to 3 µm (microns) or less, particularly, 1.5 µm (microns) or less. Accordingly, various properties of the ceramics, particularly, bending strength, can be largely improved. More specifically, the properties as evaluated in the 3 points bending strength are improved to 588.2 MPa (60 kg/mm²) or higher, particularly 686.3 MPa (70 kg/mm²) as is obvious from the Examples cited hereunder. The particle size of whiskers in the sintered body remains at a level of 10 µm (microns) or less, since it undergoes hardly any change from that of its raw material. The following Examples illustrate the present invention specifically. Comparative Example After weighing out Al₂O₃ powder having an average particle size of 1 micron or less and a purity of 99.9% or higher and, if necessary, the auxiliary sintering aid in the powder form as set forth in Table 1, the powder was subjected to dry milling for 12 hours by either one of the ball mill, vibrating mill, attrition mill and jet mill methods. A specified quantity of TiC whiskers with an average particle size (the transverse diameter) of 1 µm (micron), an aspect ratio of 10-30 and an oxygen content of 0.3 weight% was added to the mixed powder. The obtained powder was enclosed in a sealed nylon pot together with nylon balls and was mixed by the ball mill for 12 hours. The slurry obtained after the mixing step was dried and used as the slip to be processed by hot pressing. The aforesaid slip was filled in a carbon mold and was sintered by hot pressing at a specified temperature for 1 hour under the pressure of 29.4 MPa (300 kg/cm²)so that test specimens for breaking strength test conforming the JIS Standard may be fabricated. (Test Specimen Nos. 1 to 15.) Whiskers, however, were not added to Test Specimen No. 9. Each test specimen was polished and tested for the 3-point bending strength and Vickers hardness; and the fracture toughness (K₁₀) was measured by the IM method with test specimens polished to mirror finish. The average crystal particle size of alumina was measured by observation of microscopic photographs. Test results are set forth in Table 1. More test specimens were prepared in the same manner as mentioned above except that instead of TiC whiskers, TiN whiskers and TiCN whiskers having an oxygen content of 0.3 weight%, an average particle size (the transverse diameter) of 1.5 µm (microns) and an aspect ratio of 20, respectively, and their properties were measured in the same manner as adopted for the test specimens prepared with TiC whiskers. Test results of said tests are set forth in Table 1. (Test specimens No. 16 and 17.) According to Table 1, it was necessary for Test Specimen No. 1, for which the wet mixing was adopted to mix alumina powder, to set the sintering temperature as high as 1850 °C, and the particle size of alumina amounted to as large as 5 µm (microns) due to the grain growth of alumina in the sintered body. On account of the large alumina particle size, its bending strength was as low as 343.1 MPa (35 kg/mm²). On the contrary, the test specimens which have undergone the dry milling step in accordance with the method described in the present invention permitted sintering at a low sintering temperature of 1600 to 1850 °C in either case. The sintered body thereby obtained has such a micro structure as has an average particle size of alumina of 3 µm (microns) or less and a bending strength 588.2 MPa (60 kg/mm²) or higher. Furthermore, there were achieved in the sintered body a fracture toughness of 4.0 MPam 1/2 or more and a Vickers hardness of 17150 MPa (1750 kg/mm²) or higher. On the other hand, in the case of Test Specimen No. 9 fabricated without any whiskers incorporated, it is totally impossible to achieve an improved fracture toughness, although its bending strength is increased by carrying out the dry pulverization step. Moreover, when the amount of whiskers incorporated exceeded 70 volume%, the sinterability of Test Specimen No. 15 decreased notably while other properties could not be measured. By measuring properties in the same manner as mentioned above of test specimens fabricated in the same manner as used for Test Specimen No. 1 except that TiC whiskers whose oxygen content exceeds 3 weight% was used, it was determined that the test specimens thus fabricated were inferior to those used in Test Specimen No. 1 with respect to the bending strength and fracture toughness. Example 1 After weighting out Al₂O₃ powder having an average particle size of 1 micron or less and a purity of 99.9% or higher and either metal compound identified in Table 2 and Table 3, the powder was mixed and milled in an attrition mill for 12 hours. To this mixture were added Titanium-based whiskers having an average particle size of 0.8 µm (micron), an oxygen content of 0.1 to 1.0 weight%, and an aspect ratio of 30-50 by each amount set forth in Table 2 and Table 3. The obtained powder was enclosed in a sealed nylon pot together with nylon balls and was mixed by the ball mill for 12 hours. The slurry obtained after the mixing step was dried and used for hot pressing. The aforementioned material was placed in a carbon mold and was sintered by hot pressing at a specified temperature for 1 hour under a pressure in the range of 2940 to 4900 MPa (300 to 500 kg/mm²) so that a test specimen for breaking strength test may be prepared in the same manner as in the Comparative Example. (Test Specimen Nos. 18 to 51.) Rod-shape aluminum borate with an aspect ratio of 30-50 was, however, used as a boron-containing metal compound for Test Specimen No. 36. Measurements were taken of the aforementioned specimens in the same manner as in Comparative Example. Test results are set forth in Table 4 and Table 5. Test Specimen No. Vickers Hardness (kg/mm²) Fracture Toughness (MPa·m 1/2 ) Breaking Strength (Kg/mm²) Average Crystal Diameter of Alumina (µm) 18 1700 4.5 65 4.0 19 1710 4.8 70 3.0 20 1980 5.5 80 2.0 21 2150 6.5 120 1.8 22 2150 7.0 100 1.5 23 1800 6.0 85 1.5 24 2100 6.5 110 1.8 25 2100 6.5 120 1.8 26 2030 6.2 118 2.0 27 2080 6.3 115 1.8 28 2200 7.0 110 1.8 29 2100 6.0 90 1.0 30 1850 5.0 80 1.0 31 2150 6.5 115 1.5 32 2150 6.5 100 1.5 33 2150 6.5 100 1.5 34 2200 6.5 118 1.5 35 2150 6.5 120 1.5 Test Specimen No. Vickers Hardness (kg/mm²) Fracture Toughness (MPa·m 1/2 ) Breaking Strength (Kg/mm²) Average Crystal Diameter of Alumina (µm) 36 2000 6.5 100 2.5 37 1950 6.5 100 1.8 38 2000 6.0 95 1.4 39 2000 6.0 95 1.4 40 2150 6.5 120 1.4 41 2100 6.5 115 1.4 42 2100 6.5 110 1.4 43 2200 6.5 115 1.4 44 2100 6.5 110 1.4 45 1650 4.5 50 1.5 46 2100 5.9 90 1.5 47 2170 6.5 120 1.5 48 2100 6.6 115 1.8 49 2000 6.5 115 1.8 50 1700 5.5 90 2.5 51 1650 4.5 60 3.5 Example 2 After weighing out Al₂O₃ powder having an average particle size of 1 µm (micron) or less and a purity of 99.9% or higher, SiC powders with an average particle size of 0.5 µm (micron), and, if so desired, oxides (auxiliary sintering aid) identified in Table 6, the powder was wet mixed and milled in ball mill for 12 hours. To this mixture was added TiC whiskers with an average diameter of 1.0 µm (microns), an oxygen content of 0.1 to 1.0 weight% and an aspect ratio of 10-30 by the specified amount. The obtained powder was mixed by the rotary mill for 12 hours. The slurry obtained after the mixing step was dried and used for hot pressing. Using the aforementioned material, test specimens for fracture test were fabricated in the same manner as in Comparative Example. (Test Specimen Nos. 52-81). Measurements were taken in the same manner as in Comparative Example. The micro structure of each specimen was observed on the basis of microscopic photographs for the purpose of evaluation of the sinterability. Test results are set forth in Table 6. However, Test Specimen No. 81 was obtained as a sintered body in the same manner as the other specimens from a mixture of Al₂O₃ added with SiC whiskers. Example 3 The material for hot pressing was prepared according to the composition set forth in Table 7 in the same manner as in Example 2, and test specimens for fracture test were fabricated similarly (Test Specimen No. 82 to 107). Those test specimens were tested in the same manner as in Examples 2. Test results are set forth in Table 7. Test Specimens No. 102 to 107, however, were prepared with TiC whiskers coated with carbon equivalent in quantity to 1 weight% of the substrate whiskers instead of the carbon powder which was used elsewhere.

Claims: An alumina ceramic material, reinforced by the incorporation of whiskers characterized in that it comprises: a matrix consisting principally of alumina having 3 µm or less of average particle size, whiskers at a ratio of 5 to 70 % by volume, said whiskers being selected from at least one kind from titanium carbide whiskers, titanium nitride whiskers and titanium carbo-nitride whiskers, and one component selectecd from the group consisting of (a) a boron-containing metal compound at a ratio of 0,02 to 40 % by weight, (b) silicon carbide particles at a ratio of 3 to 30 % by volume, and (c) carbon at a ratio of 0,05 to 2 % by weight, with the proviso that where (b) or (c) is selected as the component, the whiskers incorporated in the ceramic material are titanium carbide. The alumina ceramic material according to claim 1, which has a bending strength of 588.2 MPa (60 kg/mm²) or higher. The alumina ceramic material according to claims 1 or 2, wherein the boron-containing metal compound includes at least one element selected from the group consisting of metals in the periodic table groups 4a, 5a and 6a, aluminum and oxygen. The alumina ceramic material according to one of claims 1 to 3, wherein the material further includes 0,02 to 8 % by weight of a sintering aid selected from the group consisting of an oxide of an element selected from Mg, Ca, Si and the periodic table group 3a. The alumina ceramic material according to claim 4, wherein the elements are selected from the periodic table group 3a consisting of Yb, Nd, Er, Ce, Sm, Y, Gd, Dy and La. A process for the preparation of a sintered whiskers-reinforced ceramic material, comprising the steps of: activating alumina with an average particle size of 3 µm or less; mixing the alumina with 5 to 70 % by volume of whiskers selected from the group consisting of titanium carbide, titanium nitride and titanium carbo-nitride; mixing the alumina with a boron-containing metal compound which is 0,02 to 40 % by weight, and molding and sintering the mixture. The process according to claim 6, wherein the whiskers have an oxygen content of 3 % by volume or less. The process according to claim 6 wherein the material further includes 0,02 to 8 % by weight of a sintering aid selected from the group consisting of an oxide of an element selected from Mg, Ca, Si and the periodic table group 3a. The process according to claim 6, wherein the boron-containing metal compound includes an element selected from the group consisting of metals in the periodic table groups 4a, 5a, 6a, aluminum and oxygen. A process for the preparation of a sintered whiskers-reinforced ceramic material, comprising the steps of: activating alumina with an average particle size of 3 µm or less; mixing the alumina with 5 to 70 % by volume of titanium carbide whiskers; mixing the alumina with 3 to 30 % by volume of silicon carbide particles, and molding and sintering the mixture. A process for the preparation of a sintered whiskers-reinforced ceramic material, comprising the steps of: activating alumina with an average particle size of 3 µm or less; mixing the alumina with 5 to 70 % by volume of titanium carbide whiskers; mixing the alumina with carbon which is 0,05 to 2 % by weight, and molding and sintering the mixture.

Inventors: HAYASHI KATSURA C O KYOCERA CO, SAKAUE KATSUSHI C O KYOCERA CO, HAYASHI, KATSURA C/O KYOCERA CORP., SAKAUE, KATSUSHI C/O KYOCERA CORP.
Applicants: KYOCERA CORP, KYOCERA CORPORATION
Application year: 1991
Main classification: C04B35
IPC codes: C04B35