Method of pressureless sintering production of densified ceramic composites
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United States of America Patent
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Aug 14, 2012
Grant Date -
May 27, 2010
app pub date -
Jul 23, 2009
filing date -
Jul 24, 2008
priority date (Note) -
Expired
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Abstract
Methods of making and compositions of dense sintered ceramic nano- and micro-composite materials that are highly stable in a variety of conditions and exhibit superior toughness and strength. Liquid feed flame spray pyrolysis techniques form a plurality of nanoparticles (e.g., powder), each having a core region including a first metal oxide composition comprising Ce and/or Zr or other metals and a shell region including a second metal oxide composition comprising Al or other metals. In certain aspects, the core region comprises a partially stabilized tetragonal ZrO2 and the shell region comprises an α-Al2O3 phase. The average actual density of the ceramic after sintering is greater than 50% and up to or exceeding 90% of a theoretical density of the ceramic.
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