Abstract:
The sol-gel process for forming dense alumina based cermics or dense ceramics with alumina as a sintering additive, the process comprising the steps of: preparing polymeric alumina sol by hydrolysis of Al (O--iBu)3 with a strong acid; preparing the ceramic dispersion in the alumina sol; gelling the dispersion; drying the gel dispersion to form a solid; calcining the solid; and sintering the calcined solid.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the production of dense ceramic materials which require alumina as either a densification aid or a matrix, and more particulary to the use of polymeric aluminum containing sols as coating material for ceramic powder as to the means of at least in partial process which resulted in green compacts with better microstructural homogeneity and excellent reproducibility. 
     2. Description of the Prior Art 
     Efforts have been focussed on preparing green compacts with microstructural homogeneity. It has been carried out through milling, dispersing, or spray-drying, and followed by forming green compacts by means of dry pressing, slip casting, or colloid pressing. Such prepared green compacts are subjected to densification by hot press, hot isostatic press, pressure or pressureless sintering. Alumina is added in the process of preparing green compacts as a powder or a colliodal sol wherein high purity submicron sized alumina is preferred. 
     Colloidal alumina sol or gel is disclosed by Yoldas in U.S. Pat. No. 3,944,658 (1976) and thereafter a few methods of preparing peptizable alumina are disclosed. In U.S. Pat. Nos. 4,574,003 (1986) and 4,801,399 (1989) water soluble inorganic salts (e.g. aluminum nitrate or zirconium nitrate) are disclosed as peptizing agents, herein colloidal sol is used for preparing alumina monoliths, alumina-based ceramic abrasive grains, or composites. The ceramic material which results from most, if not all, of these processes is well below its theoretical density. 
     SUMMARY OF THE INVENTION 
     According to this invention, the formation of dense alumina based ceramics or dense ceramic materials with an alumina as a sintering additive by a sol-gel process, the process comprising the steps of: preparing polymeric alumina sol by hydrolysis of Al(O--iBu)3 with a strong acid; preparing the ceramic dispersion in the alumina sol; gelling the dispersion; drying the gel dispersion to form a solid; calcining the solid; and sintering the calcined solid; results in a ceramic material with a higher density and a better microstructure than those prepared without the use of the polymeric alumina sol. As a result, the ceramic materials prepared by this invention generally demonstrate greater bending strength, greater hardness and greater fracture toughness. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The preparation of alumina-based ceramic materials or ceramics with alumina as a sintering additive from a sol-gel process usually begins with the preparation of a proper alumina sol. 
     In the present invention the alumina sol is prepared by hydrolysis of aluminum alkoxides in hot strong acidic water in 2-3 hours. Such prepared sol can be concentrated by removing excess liquid with a rotary evaporator. The sol is stable for several weeks at room temperature. The sol can be diluted or concentrated as needed. 
     If an alumina can be introduced to coat ceramic particles, such prepared powder would sinter at a lower temperature and to a higher density. If a slurry in an alumina sol can be controlled not to segregate or agglomerate prior to gelation of the green body can be assumed to consist of alumina matrix upon calcination, i.e. the particles are coated with alumina. Such prepared alumina sol starts to gel around pH 3.5 and most of nitride, oxide or carbide ceramic powders show higher pH than 3.5 in its aqueous slurry. Therefore the sol slowly begins to gel on the surface of the particle upon mixing. The mixing is usually performed for 10 to 30 minutes with a magnetic stirrer or by a ball milling for about an hour. Gelling of the dispersion may be accelerated by removing solvent slowly. The slurry is then gelled by casting into moulds of the plaster of Paris. The cost materials are dried at room temperature and calcined between 500° and 600° C. The calcined powder was screened through a 200 mesh sieve, and pelletized under  10,000 psi and cold isostatically pressed under between 20,000 and 40,000 psi. The green compact is then sintered by heating with appropriate heating rate to appropriate temperature and soaking at that temperature for 2-3 hours under proper sintering atmosphere. 
    
    
     The following examples are illustrative of certain specific embodiments of the invention; however, these examples are for illustrative purpose only and are not to be construed as limitations of the invention. 
     EXAMPLES 
     Example 1 
     Preparation of TiN/Al2O3/TiAlON composites. 
     Alumina sol was prepared by the dropwise addition of 23.22 g of Al (O--iBu)3 (95%) to an admixture of 90.0 mL of deionized water and 10.0 mL of formic acid (88%) at 70°-80° C. under refluxing for 3 hours. To this alumina sol, 29 g of AlN and 28 g of TiN was added with vigorous stirring. The mixed slurry was then cast in molds of plaster of Paris. The cast samples were dried at 80° C. in an oven overnight and calcined at 600° C. for 5 hours. Green bodies were prepared by screening to minus 200 mesh, pressing pellets at 10 Kpsi and isostatically pressing them at 40 Kpsi. The green bodies were sintered between 1500° C. and 1800° C. for 2 hours under 5 psi of N2. Composites with different ratios of AlN to TiN ranging from 0.83 to 2.0 were prepared as described above. The effects of the mole ratios of AlN to TiN and alumina added on densification are summarized in Table 1. 
     
                       TABLE 1______________________________________EFFECTS OF MOLE RATIOS OF AlN TO TiN ANDALUMINA ADDED ON DENSIFICATIONAlN/TiN  Alumina* (wt %)               T (°C.)/t (h)                          Density                                 (g/cm3)______________________________________0.83   4.1          1,600/1.0  3.0               1,600/1.0  4.20               1,680/1.5  4.40               1,680/2.0  melt  7.15         1,580/1.5  3.65               1,630/1.5  4.17               1,650/1.5  4.151.0    9.2          1,600/2.0  3.15               1,630/2.0  3.80,  3.87               1,650/1.0  3.88,  3.841.2    8.8          1,650/1.0  4.16  7.5          1,600/2.0  3.70               1,650/1.0  3.981.33   3.0          1,650/1.5  4.17               1,700/0.5  4.351.55   3.0          1,600/1.0  3.61               1,650/1.0  4.29               1,650/1.5  4.31,  4.38               1,650/2.0  4.38               1,680/2.0  4.38  7.0          1,500/2.0  3.02               1,500/4.0  3.17               1,500/2.0  3.66               1,630/2.0  4.30,  4.21               1,650/1.5  4.33               1,650/2.0  4.41,  4.36               1,700/2.0  4.18               1,800/2.0  3.86  11.0         1,650/1.5  2.38               1,680/1.5  2.47  20.0         1,650/1.0  2.39______________________________________ *Alumina was added as alumina sol. 
    
     Example 2 
     Preparation of Sintered Silicon Nitride (5.0 wt % Y2O3, 5.5 wt % Al 2  O 3 ) 
     The alumina sol was prepared by hydrolysis of 60.90 g Al (O--iBu)3 (95%, Alfa Products) in an admixture of 270 ml of distilled water and 30 ml of formic acid between 70° and 90° C. To 20 ml of the alumina sol (containing 1.11 g Al 2  O 3 ) 18.09 g of silicon nitride (SN-E10, Ube) and 1.01 g yttria (the finest, H. C. Starck) were added with vigorous stirring. The well mixed slurry was poured into molds of the plaster of Paris. The cast samples were dried at 70° C. in an oven overnight and calcined at 650° C. for 3 h. Green compacts were prepared by screening the powder to minus 200 mesh, and pressing pellets at 10 Kpsi and isostatically at 40 Kpsi. The pellets were packed in a mixture of silicon nitride and boron nitride bed. Sintering was conducted under 5 psi of high purity nitrogen atmosphere by heating at a rate of 20° C./min to 1750° C. and holding for 2.5 h. The sintered density was over 99% of the theoretical density. 
     A silicon nitride was prepared from Si 3  N 4  (SN-E10, Ube), Y2O3 (5.0 wt %), AlN (1.49 wt %, Grade B, H.C. Starck) and alumina sol (3.66 wt % as alumina) in the same way as described above to give rise a density greater than 99%. Their XRD showed over 99% of β-Si 3  N 4 . 
     Several silicon nitrides were prepared with different amount of additives via the same procedure as described earlier and the results are summarized in the table 2. The densities of commercial Si 3  N 4  range from 2.7 to 3.3 g/cm 3 . 
     
                                           TABLE 2__________________________________________________________________________Influence of AlN additions on sintered density of Si.sub.3 N.sub.4 fromdifferent sources.                        SINTERING,                                DENSITY,                                      MOR   KlcSOURCE Y2O3 (wt %)         Al2O3 (wt %)                 AlN (wt %)                        T (°C.)/t (hr)                                (g/cm3)                                      (Ksi) (Mpa · m1/2)__________________________________________________________________________Ube    5.0    5.5     0      1750/1.0                                3.04                        1750/2.5                                3.22  122 ± 6  5.0    5.5     1.5    1750/1.0                                3.18                        1750/2.5                                3.23  122 ± 10Ube    6.0    2.0     0      1750/1.0                                NA                        1750/2.5                                3.22  101 ± 3                                            5.89 ± 0.02  6.0    1.4     0.5    1750/1.0                                3.02                        1750/2.5                                3.24   105 ± 0.8                                            6.79 ± 0.08H. C. Starck  5.0    5.5     0      1750/2.5                                3.00                        1780/2.5                                2.96  5.1    11.5    0      1750/2.5                                3.19                        1780/2.5                                3.25__________________________________________________________________________ 
    
     Example 3 
     Preparation of Sialons 
     Three sialon compositions were prepared as described in example 1. The XRD study showed only β-Si 3  N 4  for the 5/1/1 and 5.5/0.5/0.5 systems, and β&#39;-Si 3  Al 3  O 3  N 5  for the 1/1/1 system. Conditions and properties are listed below: 
     
         __________________________________________________________________________STARTING MATERIAL       SINTERING              Klc(mole ratio)    Y2O3 (wt pct)                   (°C/h) 5 psi N2                           d(g/cm3)                                H(DPN)                                     MOR  (MPa · √m)__________________________________________________________________________Si3N4/*AlN/Al2O3(1/1/1)           5.0     1,650/2.0                           3.16 1447                   1,700/0.5                           3.23 1514Si3N4/*AlN/Al2O3(5/1/1)           5.1     1,650/2.0                           3.16 1499                   1,680/2.0                           3.24 1594Si3N4/*AlN/Al2O3(5.5/0.5/0.5)           5.0     1,700/0.5                           3.21 1622                   1,750/2.5                           3.22      99 ± 10                                          5.09 ± 0.37__________________________________________________________________________ *AlN (H. C. Starck, B grade) 
    
     The densities of commercial sialon range from 3.1 to 3.25 g/cm 3 , which sintered at temperature of about 1,800° C. before being allowed to cool gradually. 
     Example 4 
     Preparation of 15 vol % Zirconia-Alumina Composite 
     Zirconia toughened alumina composite was prepared by mixing 100 g of alumina (Sumitomo, AKP-30) with 108.6 ml of zirconia sol (Remet Chem. Co, 25 wt % nitrate stabilized), and followed by adding 30 ml of the alumina sol (2.93 g as Al2O3) as described in example 1. The green compacts were sintered at 1550° for 2h in air to give rise densities greater than 99% of the theoretical density. The bending strength was 95.1±2.1 Ksi and the fracture toughness was 5.15±0.24 MPa·√m. Its x-ray diffraction study showed over 99% tetragonal phase. 
     Example 5 
     Preparation of 3 mol pct Y2O3-Zirconia -5.5 wt pct Alumina Composite 
     Zirconia 27.63, (Aldrich Chemicals, d=5.5 g/cm 3 ) and 1.58 g of yttria (the finest, Herman C. Starck) were thoroughly mixed in 35 ml of the alumina sol (1.70 g as alumina) as prepared in example 1. The green compacts were prepared as described in Example 1. The pellets were sintered under 5 psi of high purity argon atmosphere at 1,400° C. for 2h and 1,500° C. for 2.5h. The densities were 5.14 g/cm 3  and 5.74 g/cm 3 , respectively. 
     Example 6 
     Preparation of Alumina-Titanium Nitride Composites 
     Aluminum nitride (64 mmol, H.C.) and titanium oxide (48 mmol) were thoroughly mixed in 60 ml of the alumina sol (2.0 g alumina) prepared as in example 1. The green compacts were prepared as described in example 1. The pellets were sintered under 5 psi of high purity N2 at 1,650° C. for 1.5 h. The density was 4.245 g/cm 3  and its XRD showed only TiN and 00-Al2O3. The powder mixtures were hot pressed at 1,450° C. for one hour at 35 MPa nominal stress in graphite dies. The density was 4.27±0.1 g/cm 3  and its fracture toughness at 3.3±0.3 MPa·m1/2 measured using a 10 kg indentor. 
     Example 7 
     Preparation of TiN/Al2O3/TiAlON--SiC Whisker Composites 
     Silicon carbide whisker (5.0 g) was added to 31 ml of the alumina sol (4.8 g Al2O3) as prepared in example 1. After 10 min aluminum nitride (17.0) and titanium nitride (21.0 g) were added and vigorously stirred for an additional 20 min. The green compacts were prepared as described in example 1. The pellets were sintered at 1,680° C. for 2 h, and 1,780° C. for 3.0 h. Under nitrogen atmosphere the densities were found 2.51 and 4.46 g/cm 3 , respectively. 
     Example 8 
     Preparation of Alumina-Silicon Carbide Powder Composites 
     Silicon carbide (5.0 g, H.C. Starck, 3-25 m) was added to 50 ml of alumina sol (5.90 g alumina) as prepared in example 1 and stirred for 15 min, then alumina (39.1 g, Baikowski) was added with vigorous stirring. The slurry was poured into molds of the plaster of Paris. The green compacts were prepared as described in example 1. The pellets were sintered under 5 psi of argon atmosphere at 1,550° and 1,700° C. for 2 h, the densities were 3.49, and 3.51 g/cm 3 , respectively. The values are comparable to those obtained by Bowen&#39;s &#34;disappearing&#34; polymer coating. 
     Example 9 
     Preparation of Alumina-silicon Carbide Whisker Composites 
     Silicon carbide whiskers (2.0 g, American Matrix, 5-60 μm) were dispersed in 17 ml of the alumina sol (2.0 g alumina), and alumina (16.0 g, Baikowski, 2.5 μm) was added and stirred for 20 min. The green compacts were prepared as described in example 1. Sintering was conducted under 5 psi of argon atmosphere at 1,700° C. for 2 h, the density was 3.28 g/cm 3 . 
     Although the invention has been described through the preceeding exmples, these examples are for the purpose of illustration only. Variations and modifications can be made without departing from the spirit and scope of the invention as described in the accompanying claims.