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Microstructural and mechanical characterization of ceria-stabilized tetragonal zirconia/alumina composites produced through a segregated-network approach for ceramic bushing applications

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Abstract

The aim of this study was to develop ceramic bushings used in automotive engineering. To achieve this, 12 mol% ceria (CeO2)-stabilized tetragonal polycrystalline zirconia (12Ce-TZP)/10–20 wt% alumina (Al2O3) composites were designed by using a segregated-network approach. They were subsequently produced by wet-mixing, cold isostatic pressing (CIP), computer numerical control (CNC) machining, binder burnout, and sintering at 1550–1600 °C for 1–3 h. Physical, mechanical, and microstructural properties of 12Ce-TZP/Al2O3-sintered composites were characterized using the Archimedes’ principle, Vickers hardness (HV), indentation fracture toughness (KIc), flexural strength (σ), X-ray diffraction (XRD), ultra-high-resolution scanning electron microscopy (UHR-SEM), and energy-dispersive X-ray spectroscopy (EDX) analyses. According to the overall results, 12Ce-TZP/Al2O3 composites were sintered up to 99.5% of theoretical density, when sintering temperature and dwell time were increased. 12Ce-TZP/10 wt% Al2O3/1600 °C/2 h composite, showing high mechanical properties in HV = 9.52 ± 0.09 GPa, KIc = 15.44 ± 0.15 MPa m1/2, and σ = 955.41 ± 15 MPa, was considered the most appropriate composition for ceramic bushing production. XRD analyses indicated that 12Ce-TZP/Al2O3 composites consisted of tetragonal zirconia (t-ZrO2) and corundum (α-Al2O3) phases, while 12Ce-TZPs were found to contain only t-ZrO2 phase with no trace of monoclinic zirconia (m-ZrO2). UHR-SEM investigations revealed that the microstructural evolution of 12Ce-TZP/Al2O3 composites was observed as an interpenetrated intragranular-type through the formation of a segregated-network structure. In addition, energy-absorbing mechanisms, i.e., crack propagation hindrance, crack blunting, crack bridging, crack deflection, and stress-induced t-ZrO2 → m-ZrO2 phase transformation were seen to govern the enhancement of mechanical properties. It is thought that results presented herein are also significant for new commercial applications of 12Ce-TZP/Al2O3 composites rather than other biomaterials.

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Data availability

The data that support the findings of this research are available from the corresponding author, A.Y., upon reasonable request.

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Acknowledgments

The author would like to thank Associate Professor Dr. Hilmi Yurdakul for allowing the Teknoceram Co. (Kutahya, Turkey) infrastructure to be used for ceramic bushing production. The author also wishes to express her sincere gratitude to Professor Dr. Servet Turan (Eskisehir Technical University, Turkey) for providing the opportunity to use electron microscopy and mechanical test facilities. The author would like to also thank the Kutahya Dumlupinar University Advanced Technologies Research Center (DPU-ILTEM) for UHR-SEM examinations, Associate Professor Dr. Rasim Ceylantekin (DPU, Kutahya/Turkey) for his invaluable support on the XRD Rietveld refinement analyses, and Research Assistant Ercan Sener (Alanya Alaaddin Keykubat University, Alanya-Antalya/Turkey) for data processing.

Funding

This study was funded by Alanya Alaaddin Keykubat University (ALKÜ) Scientific Research Projects Unit (BAP) with the Project No: 2018-02-03-MAP01.

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  1. Rafet Kayis Faculty of Engineering, Department of Metallurgical and Materials Engineering, Alanya Alaaddin Keykubat University, Kestel Campus, University Street, Alanya, 07450, Antalya, Turkey

    Arife Yurdakul

  2. Department of Hand Arts, Kutahya Vocational School of Fine Arts, Kutahya Dumlupinar University, Germiyan Campus Afyon Road 7. Km, 43100, Kutahya, Turkey

    Arife Yurdakul

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Correspondence to Arife Yurdakul.

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Yurdakul, A. Microstructural and mechanical characterization of ceria-stabilized tetragonal zirconia/alumina composites produced through a segregated-network approach for ceramic bushing applications. J Aust Ceram Soc 57, 379–398 (2021). https://doi.org/10.1007/s41779-020-00558-x

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