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Original Article
Article history: This work analysed the effect of the addition of rare-earth mixed oxide (RE2O3), a solid
Received 27 October 2021 solution of Y2O3 and other rare earths benefited from a Brazilian natural ore called Xen-
Accepted 25 November 2021 otime, on the sintering and properties of a commercial nanopowder composed of Ce-
Available online 4 December 2021 tetragonal polycrystal zirconia (TZP) þ 15 wt.% Al2O3. Powder mixtures were prepared,
adding 10 wt.% of Y2O3 or 10 wt.% RE2O3 in Ce-TZP/Al2O3 powder, which were compacted
Keywords: and sintered at 1500 C for 2 h. Sintered samples were characterized by X-ray diffraction,
Ce-TZP/Al2O3 composites scanning electron microscopy, and relative density. Structural analyses and phase quan-
Rare-earth oxides tification were performed using the Rietveld refinement method. Mechanical character-
YAG - Y3Al5O12 ization - Vickers hardness and fracture toughness - of the samples was carried out by
Characterization Vickers indentation. The results indicated that the RE2O3 is composed of a solid Y2O3 so-
Mechanical properties lution with lattice parameters slightly lower than those of pure Y2O3 due to the presence of
Brazilian xenotima other oxides such as Yb2O3 (19.7%), Er2O3 (13.9%), or Dy2O3 (10.2%). During sintering, the
oxides added to the composite were completely consumed by the Ce-TZP/Al2O3 matrix to
form two different crystalline phases: ZrO2-Cubic and Y3Al5O12. As a consequence, multi-
phase composites with relative density of 93.8 ± 1.2 (Y2O3 reinforced) and 94.5 ± 1.7
(RE2O3 reinforced), average hardness in the order of 10.5 GPa, and fracture toughness of 7.1
e8.5 MPa m1/2 were obtained. The high fracture toughness observed was a consequence of
* Corresponding author.
E-mail address: sousalima@ime.eb.br (E.S. Lima).
https://doi.org/10.1016/j.jmrt.2021.11.141
2238-7854/© 2021 Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/
licenses/by-nc-nd/4.0/).
452 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0
the presence of different coupled toughening mechanisms resulting from the multiphase
characteristic of these composites.
© 2021 Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
a
Not determined.
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0 453
2.3. Characterization
Table 2 e Crystallographic characteristics of the Y2O3, RE2O3 oxides and (Ce,Y)-TZP/Al2O3 composite from XRD analysis.
Parameters Y2O3 RE2O3 (Ce,Y)-TZP/Al2O3
Present phase Y2O3 Y2O3 (solid solution) ZrO2-m ZrO2-t CeO2 Al2O3
Percentage (%) 100 100 77.1 4.3 4.4 14.2
System Cubic Cubic Monoclinic Tetragonal Cubic Hexagonal
Space group Ia e3 (n 206) Ia e3 (n 206) Not evaluated
a (
A) 10.6079 (3) 10.588 (1)
Rp (%)/Rwp (%)/Rexp (%) 9.2/15.4/11.3 11.3/14.0/10.9
c2 1.88 1.66 1.78
454 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0
Fig. 2 e a) XRD patterns of Ce-TZP/Al2O3 doped with 10% Y2O3 and 10% RE2O3 after sintering at 1500 C for 2 h; b) expanded 2
q (38 ~ 42 ); c) expanded 2 q (65 ~ 75 ).
3.1. Characterization of the starting powders 3.2. Characterization of the sintered specimens
Table 3 e Rietveld refinement of sintered ceramic composites doped with 10% Y2O3 or 10% RE2O3.
Ce-TZP/Al2O3/Y2O3
Al2O3 (Corundum) Y3Al5O12 (YAG) t- ZrO2 c- ZrO2
Crystalline composition (%) 46.4 t-ZrO2
37.3 c-ZrO2
12.7% - Al2O3
3.6% - YAG
Crystalline structure Rhombohedral Cubic Tetragonal Cubic
Space group R-3cH Ia-3d P42/nmcZ e
^
Lattice parameters (A) a ¼ 4.755 a ¼ 12.011 a ¼ 3.608 e
c ¼ 12.956 c ¼ 5.191
Phase density (g/cm3) 4.002 4.555 6.053 e
Crystallite size (nm) 326.641 93.834 72.226 e
Ce-TZP/Al2O3/RE2O3
Fig. 3 presents the results of phase quantification in the sin- composite doped with 10% RE2O3 (34%). On the other hand,
tered samples. The Rietveld refinement results are presented there is a great difference between Al2O3 and Y3Al5O12, which
in Table 3. results from the greater propensity of RE2O3 to form REAG
Figure 2 (a) shows the presence of tetragonal (t-ZrO2) and (Y(ss)2Al5O12) compared with Y2O3, according to reaction 4.
cubic (c-ZrO2) zirconia regardless of the use of Y2O3 or RE2O3.
In addition, difference in intensity between the crystalline ZrO2 (m) þ CeO2 / ZrO2 (t) (3)
peaks can be noticed: the ceramic composite doped with 10
wt.% Y2O3 presents more intense cubic phase (c-ZrO2) peaks, 3/2 Y(ss)2O3 þ 5/2 Al2O3 / Y(ss)3Al5O12 (4)
whereas the ceramic composite doped with 10 wt.% RE2O3
shows more intense Y3Al5O12 peaks, as shown in magnifica- Assuming that, the use of Y2O3 as a dopant facilitates for-
tions of the diffractograms in Fig. 2 (b-c). An associated anal- mation of the c-ZrO2 phase (Eq. (5)); the original alumina
ysis of Fig. 2 and Fig. 3 shows that both materials have a quantifications are maintained with a little YAG formation in
considerable amount of t-ZrO2 after sintering, in the order of the structure, with excess Y2O3.
47%, from the reaction between monoclinic zirconia and
cerium oxide present in the starting powder, reaction 3. ZrO2 (m) þ Y2O3 / ZrO2 (c) (5)
Considerable differences are observed in the quantification of
the c-ZrO2 phase, where the composite doped with 10% Y2O3 Thus, when RE2O3 is used to dope the ceramic composite,
(37.3%) presented larger amount of cubic phase than the there is greater presence of YAG in the overall composition of the
Fig. 4 e SEM micrographs of the sintered (Ce,Y)-TZP-Al2O3 composite highlighting hexaluminate platelets (magnification -
10,000£).
456 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0
sintered composite and, consequently, smaller fractions of The addition of Y2O3 (Fig. 5) or RE2O3 (Fig. 6) inhibits the
cubic phase ZrO2-(c) and Al2O3 are observed. This occurs because formation of hexaluminate platelets, therefore platelets are
RE2O3 is a mixture of oxides that presents greater atomic dis- not observed in these composites. Furthermore, the insertion
order, increasing the reactivity of the powder. In this case, the of Y2O3 as an additive promotes an increase in the number of
associated energy is greater and, therefore, the reactions in the c-ZrO2 grains in a behaviour predicted by Li et al. [40] in
solid state begin at temperatures lower than those of the high ZrO2eCeO2eY2O3 system, whose microstructure presents
purity oxides. In Table 1, the mean grain size of RE2O3 is on the grains remarkably larger than the tetragonal (t-ZrO2) grains.
order of 0.8 mm, but the FWHM of the XRD peak in Fig. 1 is large, Furthermore, a microstructural heterogeneity due to prefer-
although it is a true solid solution. As the RE2O3 particles are ential growth of cubic c-ZrO2 phase grains is observed. The use
formed from fine crystallite aggregates, they will have excellent of RE2O3 as a dopant favoured the formation of large YAG
reactivity, which justifies the clear XRD peaks of Y3Al5O12 (Y3Al5O12) grains, Fig. 6(c), characterized by the absence of
observed in the sample with the addition of RE2O3. alumina grains in the vicinity due to having been consumed
Figure 4 Present micrographs obtained by SEM of the according to the reaction (4), and in agreement with the re-
composite without additions of Y2O3 or RE2O3, indicating the sults X-ray diffraction, Fig. 3, It is also noted that the residual
presence of submicrometric equiaxed grains of zirconia (light alumina present in this composite is composed of equiaxed
phase) and alumina (dark phase). Some platelets larger than grains of submicrometric size, as indicated in Fig. 6(a,b).
2 mm are also seen. These platelets are formed during sinter- Figure 7 (a) shows that the sintered composite doped with
ing, by the solid state reaction of alumina contained in the Y2O3 has a large population of zirconia grains with average
initial powder mixture and cerium oxide, forming hex- size <1 mm. Moreover, a population of zirconia grains with
aluminates, and are indicated as reinforcements for these Ce- exaggerated growth is identified and, finally, the larger grains
TZP-Al2O3 composites [39]. Fig. 5 and Fig. 6 present the SEM (3.1e4.9 mm) are characteristic of Y3Al5O12. The use of RE2O3 as
micrographs of composites containing 10 wt.% Y2O3 and a dopant also allows the grains of the zirconia matrix to
10 wt.% RE2O3 respectively. Furthermore, Fig. 7 (a-c) shows the remain with submicrometric characteristics, with sizes be-
average grain size of the samples containing 10 wt.% Y2O3 and tween 0.1 and 0.7 mm, with a small population of larger cubic
10 wt.% RE2O3. It is possible to observe a zirconia matrix with grains in addition to YAG grains >2 mm (Fig. 7 (b)). The analysis
submicrometric characteristics, as well as equiaxial alumina also showed that the Al2O3 grains, regardless of their average
grains (Al2O3) distributed throughout the zirconia matrix, size, do not present significant variations as a function of the
which are preferentially found in triple junctions. type of dopant used in the mixture (Fig. 7 (c)).
Fig. 5 e SEM micrographs of the sintered (Ce,Y)-TZP-Al2O3 composite containing 10 wt.% Y2O3: a) 5000 x; b) 10,000 x. Arrows
indicate equiaxed grains of Al2O3 (dark phase, Fig. 5(b), and grown grains of ZrO2-Cubic, Fig. 5(c).
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0 457
Fig. 6 e SEM micrographs of the sintered (Ce,Y)-TZP-Al2O3 composite containing 10 wt.% RE2O3: a) 10,000 x; b) 40,000 x; c)
10,000 x (highlighting gray YAG grains with no black Al2O3 grains on their boundaries).
3.3. Mechanical properties which associated with densification, enabled fracture tough-
ness values in the order of 7.1 ± 0.4 MPa m1/2.
The hardness and fracture toughness values of the samples As the densification and mechanical properties of the
sintered at 1500 C determined at room-temperature are original commercial composite without the addition of Y2O3
summarized in Table 4. or RE2O3 oxides are slightly superior to doped composites,
Results of the mechanical properties are probably corre- even without the presence of hexaluminate platelets, new
lated with material densification. The composite doped with sintering conditions involving higher final temperatures or
Y2O3 had a relative density of 93.8 ± 1.2%, while the composite prolonged isothermal holding times may be suggested for
doped with RE2O3 presented a slightly higher density value future investigations, aiming to improve densification and
(94.5 ± 1.7%) and were thus considered statistically similar. mechanical properties, adjusting their properties to the
The microstructural and crystallographic configuration pre- intended final application of this composite.
sented by the materials, as well as the residual porosity in the Figure 8 (a) shows the Vickers indentation and 8(b), the
order of 5.5e5.2%, after sintering, led to mean Vickers hard- radial cracks developed.
ness values of 9.8 ± 1.2 GPa (Y2O3) and 10.1 ± 1.7 GPa (RE2O3), as Results of the microstructural analysis suggest that the
shown in Table 4. use of rare-earth oxides enables greater refinement of the
The composites developed in this work showed that the Ce-TZP grain, responsible for the toughening of the material
use of 10 wt.% Y2O3 induces the formation of the cubic phase due to toughening mechanisms by phase transformation. It
ZrO2-(c) as well as of the ZrO2-(t) phase stabilized with ceria is known that tetragonal zirconia with average grain size
(Ce-TZP), an amount of Al2O3 close to the original proportion, <0.8 mm has higher toughening capacity than zirconia with
and a small fraction of transformed YAG. This complex larger grain size [35]. This toughening mechanism by phase
microstructural configuration, allowed high fracture tough- transformation is more relevant when using CeO2 as a
ness values (8.5 ± 0.9 MPa m1/2). In contrast, the composite dopant in substitution for the traditional Y2O3 (Y-TZP)
doped with 10 wt.% RE2O3 induces formation of four distinct [35,36]. Therefore, the shielding zone at the tip of the crack
phases: Ce-TZP (majority), cubic-ZrO2, Al2O3, and Y3Al5O12, in Ce-TZP is higher than in Y-TZP, thus inducing greater
458 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0
Fig. 7 e Grain size distribution analysis of: a) Ce-TZP/Al2O3 doped with 10 wt.% Y2O3; b) Ce-TZP/Al2O3 doped with 10 wt.%
RE2O3; c) Al2O3 grains.
crack locking and more effective reduction of crack multiphase materials can be calculated using the mathemat-
propagation. ical approximation given in the Equations (6)e(8) [37,38]:
The Al2O3 grains present in the matrix are considered a
sb ¼ Eb , ða ab Þ,DT (6)
secondary toughening mechanism that generates residual
stress around the ZrO2 matrix. Thus, during crack propagation
in biphasic regions of the composite, higher fracture energies sm ¼ Em , ða am Þ,DT (7)
are necessary for the crack to continue propagating. In addi-
tion, the presence of a third phase in greater quantity, when ab Cb Eb þ ac Cc Ec þ am Cm Em
a¼ (8)
using RE2O3, favours the appearance of residual thermal ten- Cb Eb þ Cc Ec þ Cm Em
sions in the material. As Al2O3 is preferentially found in triple Considering the Young's modulus of the ZrO2, Al2O3 and
junctions, spontaneous crack locking is obtained considering Y3Al5O12 phases as 190 GPa, 390 GPa and 300 GPa, respectively,
that, as the cracks are intergranular, they are located along the and their respective thermal expansion coefficients (a) as
grain boundaries. Theoretically, residual thermal stresses in 10.5 106 K1, 8.5 106 K1, 6.2 106 K1, the residual
stresses in each phase for the ATZ-Y2O3 composite are esti-
mated to be sZrO2 ¼ 182.1 MPa, sAl2O3 ¼ 776.6 MPa, and
sY3Al5O12 ¼ 1615 MPa, whereas the ATZ-Re2O3 composite pre-
Table 4 e Properties of the ceramic composites doped sents calculated residual stresses of sZrO2 ¼ 257,8 MPa,
with Y2O3 or RE2O3. sAl2O3 ¼ 621.3 MPa, and sY3Al5O12 ¼ 1495 MPa.
Sample Relative Vickers Fracture Reflections of these thermal stresses distributed among
density Hardness toughness the phases present in the composites contribute to generate
(%) HV98N KIC 98 N stress fields that act to hinder crack propagation in a stable
(GPa) (MPa.m1/2) way. This reduced crack propagation, in combination with the
(Ce,Y) - TZP/Al2O3 95.2 ± 0,7 11.3 ± 1.4 8.6 ± 0.7 shielding zones around the major phase of ZrO2-(t) grains (Ce-
Ce-TZP/Al2O3/10%Y2O3 93.8 ± 1.2 9.8 ± 1.2 8.5 ± 0.9 TZP), hinder crack growth and provide the material with high
Ce-TZP/Al2O3/10%RE2O3 94.5 ± 1.7 10.1 ± 1.7 7.1 ± 0.4 fracture toughness.
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 2 ; 1 6 : 4 5 1 e4 6 0 459
Fig. 8 e a) Example of Vickers indentation (magnification 1000£); b) emphasis on the propagation of cracks and their
behaviour (magnification near to 17,000£).
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