Peculiarities of the Phase Formation during Electroconsolidation of AlO-SiO-ZrO Powders Mixtures.

This paper is devoted to the sintering process of AlO-SiO-ZrO ceramics. The studied method was electroconsolidation with directly applied electric current. This method provides substantial improvements to the mechanical properties of the sintered samples compared to the traditional sintering in the air. The research covered elemental and phase analysis of the samples, which revealed phase transition of high-alumina solid solutions into mullite and corundum. Zirconia was represented mainly by tetragonal phase, but monoclinic phase was present, too. Electroconsolidation enabled samples to reach a density of 3.0 g/cm at 1300 °C, while the sample prepared by traditional sintering method obtained it only at 1700 °C. For the composite AlO-20 wt.% SiO-10 wt.% ZrO fabricated by electroconsolidation, it was demonstrated that fracture toughness was higher by 20-30%, and hardness was higher by 15-20% compared to that of samples sintered traditionally. Similarly, the samples fabricated by electroconsolidation exhibited elastic modulus higher by 15-20%. The hypothesis was proposed that the difference in mechanical and physical properties could be attributed to the peculiarities of phase formation processes during electroconsolidation.