Microstructure and properties of zirconia-alumina composites fabricated via powder injection molding

Nalattaporn SAELEE; Nutthita CHUANKRERKKUL; Panitarn WANAKAMOL

doi:10.55713/jmmm.v31i1.1019

Authors

Nalattaporn SAELEE Department of Materials Science, Srinakharinwirot University, 114 Sukhumvit 23, Wattana, Bangkok, 10110, Thailand
Nutthita CHUANKRERKKUL Metallurgy and Materials Science Research Institute, Chulalongkorn University, Soi Chulalongkorn 12, Wang Mai, Pathum Wan, Bangkok, 10330, Thailand
Panitarn WANAKAMOL Department of Materials Science, Srinakharinwirot University, 114 Sukhumvit 23, Wattana, Bangkok, 10110, Thailand

DOI:

https://doi.org/10.55713/jmmm.v31i1.1019

Keywords:

Powder injection molding, Zirconia, Flexural test, X-ray diffraction

Abstract

This study aimed to fabricate zirconia-alumina composites via powder injection molding and investigated the effects of alumina addition on microstructure as well as physical properties of the composites. Zirconia-alumina composites were prepared using polyethylene glycol (PEG) and polyvinyl butyral (PVB) as binders. The powder loading was fixed at 38 vol%, and PEG: PVB binder weight ratio was fixed at 80:20. Alumina content within ceramic component was varied at 0, 10, 20, 30, 40 and 50 vol% to observe the effect of alumina on the composite structures and properties. The injection molding was done at 190℃ followed by water debinding of PEG at 40℃. Thermal debinding of PVB at 450℃ was performed prior to sintering at 1450℃. From the density measurement via Archimedes’ method, the relative density of sintered samples was found to be highest at 10 vol% alumina and gradually lower at higher alumina content. The condition with highest density yielded the highest flexural modulus and flexural strength. XRD indicated that tetragonal zirconia phase coexisted with alumina when alumina was added. Above 20 vol% alumina, monoclinic zirconia was also detected. The increased porosity in samples with high alumina content, as confirmed in SEM morphological observation, correlated with lower flexural strength and lower flexural modulus. The results illustrated the feasibility of powder injection molding in the production of zirconia-alumina composites and the optimum condition in this study was 10 vol% alumina.

Downloads

Download data is not yet available.

References

J. Wang, and M.J. Edirisinghe, "Ceramic Injection Molding," in Reference Module in Materials Science and Materials Engineering: Elsevier, 2016. DOI: https://doi.org/10.1016/B978-0-12-803581-8.03574-8

J. Chevalier, "What future for zirconia as a biomaterial?," Biomaterials, vol. 27(4), pp. 535-543, 2006. DOI: https://doi.org/10.1016/j.biomaterials.2005.07.034

M. Fornabaio, P. Palmero, R. Traverso, C. Esnouf, H. Reveron, J. Chevalier, and L. Montanaro "Zirconia-based composites for biomedical applications: Role of second phases on composition, microstructure and zirconia transformability," Journal of the European Ceramic Society, vol. 35(14), pp. 4039-4049, 2015. DOI: https://doi.org/10.1016/j.jeurceramsoc.2015.04.027

S. Pieralli, R.-J. Kohal, E. Lopez Hernandez, S. Doerken, and B. C. Spies, "Osseointegration of zirconia dental implants in animal investigations: A systematic review and meta-analysis," Dental Materials, vol. 34(2), pp. 171-182, 2018. DOI: https://doi.org/10.1016/j.dental.2017.10.008

K. Sivaraman, A. Chopra, A. I. Narayan, and D. Balakrishnan, "Is zirconia a viable alternative to titanium for oral implant? A critical review," Journal of Prosthodontic Research, vol. 62(2), pp. 121-133, 2018. DOI: https://doi.org/10.1016/j.jpor.2017.07.003

A. Celli, A. Tucci, L. Esposito, and C. Palmonari, "Fractal analysis of cracks in alumina–zirconia composites," Journal of the European Ceramic Society, vol. 23(3), pp. 469-479, 2003. DOI: https://doi.org/10.1016/S0955-2219(02)00148-6

S. Sequeira, M. H. Fernandes, N. Neves, and M. M. Almeida, "Development and characterization of zirconia–alumina composites for orthopedic implants," Ceramics International, vol. 43(1), Part A, pp. 693-703, 2017. DOI: https://doi.org/10.1016/j.ceramint.2016.09.216

F. Kern, and R. Gadow, "Alumina toughened zirconia from yttria coated powders," Journal of the European Ceramic Society, vol. 32(15), pp. 3911-3918, 2012. DOI: https://doi.org/10.1016/j.jeurceramsoc.2012.03.014

A. Nevarez-Rascon, A. Aguilar-Elguezabal, E. Orrantia, and M.H. Bocanegra-Bernal, "Compressive strength, hardness and fracture toughness of Al2O3 whiskers reinforced ZTA and ATZ nano-composites: Weibull analysis," International Journal of Refractory Metals and Hard Materials, vol. 29(3), pp. 333-340, 2011. DOI: https://doi.org/10.1016/j.ijrmhm.2010.12.008

H.L.C. Pulgarin, and M.P. Albano, "Sintering, microstrusture and hardness of different alumina–zirconia composites," Ceramics International, vol. 40(4), pp. 5289-5298, 2014. DOI: https://doi.org/10.1016/j.ceramint.2013.10.102

H.L.C. Pulgarin, and M.P. Albano, "Three different alumina–zirconia composites: Sintering, microstructure and mechanical properties," Materials Science and Engineering: A, vol. 639, pp. 136-144, 2015. DOI: https://doi.org/10.1016/j.msea.2015.05.010

B. Stawarczyk, M. Özcan, L. Hallmann, A. Ender, A. Mehl, and C. Hämmerlet, "The effect of zirconia sintering temperature on flexural strength, grain size, and contrast ratio," Clinical oral investigations, vol. 17, 2012. DOI: https://doi.org/10.1007/s00784-012-0692-6

F. Allaire, B. R. Marple, and J. Boulanger, "Injection molding of submicrometer zirconia: blend formulation and rheology," Ceramics International, vol. 20(5), pp. 319-325, 1994. DOI: https://doi.org/10.1016/0272-8842(94)90049-3

S. Chauoon, M. Meepho, N. Chuankrerkkul, S. Chaianansutcharit, and R. Pornprasertsuk, "Fabrication of yttria stabilized zirconia thin films on powder-injected anode substrates by electrophoretic deposition technique for solid oxide fuel cell application," Thin Solid Films, vol. 660, pp. 741-748, 2018. DOI: https://doi.org/10.1016/j.tsf.2018.03.082

A. Faes, H. Girard, A. Zryd, Z. Wuillemin, and J. Van herle, "Fabrication of structured anode-supported solid oxide fuel cell by powder injection molding," Journal of Power Sources, vol. 227, pp. 35-40, 2013. DOI: https://doi.org/10.1016/j.jpowsour.2012.11.016

R. Martin, M. Vick, M. Kelly, J.P. de Souza, R.K. Enneti, and S. V. Atre, "Powder injection molding of a mullite–zirconia composite," Journal of Materials Research and Technology, vol. 2(3), pp. 263-268, 2013. DOI: https://doi.org/10.1016/j.jmrt.2013.03.014

L. Liu, X.L. Ni, H.Q. Yin, and X.H. Qu, "Mouldability of various zirconia micro gears in micro powder injection moulding," Journal of the European Ceramic Society, vol. 35(1), pp. 171-177, 2015. DOI: https://doi.org/10.1016/j.jeurceramsoc.2014.07.027

J. Xiao, W. Cai, J. Liu, and M. Liu, "A novel low-pressure injection molding technique for fabricating anode supported solid oxide fuel cells," International Journal of Hydrogen Energy, vol. 39(10), pp. 5105-5112, 2014. DOI: https://doi.org/10.1016/j.ijhydene.2014.01.079

F. Mohd Foudzi, N. Muhamad, A. Bakar Sulong, and H. Zakaria, "Yttria stabilized zirconia formed by micro ceramic injection molding: Rheological properties and debinding effects on the sintered part," Ceramics International, vol. 39(3), pp. 2665-2674, 2013. DOI: https://doi.org/10.1016/j.ceramint.2012.09.033

J. He, Z. Shao, D.F. Khan, H. Yin, S. Elder, Q. Zheng, and X. Qu, "Investigation of inhomogeneity in powder injection molding of nano zirconia," Powder Technology, vol. 328, pp. 207-214, 2018. DOI: https://doi.org/10.1016/j.powtec.2017.12.075

J. Wen, W. Liu, Z. Xie, C. Lou, and X. Yang, "Effects of the binder compositions on the homogeneity of ceramic injection molded compacts," Ceramics International, vol. 44(3), pp. 3218-3225, 2018. DOI: https://doi.org/10.1016/j.ceramint.2017.11.093

S. Md Ani, A. Muchtar, N. Muhamad, and J. A. Ghani, "Fabrication of zirconia-toughened alumina parts by powder injection molding process: Optimized processing parameters," Ceramics International, vol. 40(1), Part A, pp. 273-280, 2014. DOI: https://doi.org/10.1016/j.ceramint.2013.05.134

N. Chuankrerkkul, K. Somton, T. Wonglom, K. Dateraksa, and P. Laoratanakul, "Physical and mechanical properties of zirconia toughened alumina (ZTA) composites fabricated by powder injection moulding," Chiang Mai Journal of Science, vol. 43, pp. 375-380, 2016.

F. Sommer, H. Walcher, F. Kern, M. Maetzig, and R. Gadow, "Influence of feedstock preparation on ceramic injection molding and microstructural features of zirconia toughened alumina," Journal of the European Ceramic Society, vol. 34(3), pp. 745-751, 2014. DOI: https://doi.org/10.1016/j.jeurceramsoc.2013.09.020

N. Chuankrerkkul, R. Charoenkijmongkol, P. Somboonthanasarn, C. Auechalitanukul, and R.C. McCuiston, "Microstructure and properties of zirconia toughened alumina fabricated by powder injection moulding," Key Engineering Materials, vol. 659, pp. 116-120, 2015. DOI: https://doi.org/10.4028/www.scientific.net/KEM.659.116

V.A. Krauss, A.A.M. Oliveira, A.N. Klein, H.A. Al-Qureshi, and M.C. Fredel, "A model for PEG removal from alumina injection moulded parts by solvent debinding," Journal of Materials Processing Technology, vol. 182(1), pp. 268-273, 2007. DOI: https://doi.org/10.1016/j.jmatprotec.2006.08.004

X. Yang, Z. Xie, G. Liu, and Y. Huang, "Dynamics of Water Debinding in Ceramic Injection Moulding," Advances in Applied Ceramics - ADV APPL CERAM, vol. 108, pp. 295-300, 2009. DOI: https://doi.org/10.1179/174367608X362430

W. Liu, J. Wen, Z. Xie, and X. Yang, "Powder modification mechanism, effects of binder compositions on the thermal behavior, and the mechanical properties of the ceramic injection molded system," Ceramics International, vol. 44(5), pp. 5646-5651, 2018. DOI: https://doi.org/10.1016/j.ceramint.2017.12.213

Z. Xie, J. Luo, X. Wang, J. Li, and Y. Huang, "The effect of organic vehicle on the injection molding of ultra-fine zirconia powders," Materials & Design, vol. 26(1), pp. 79-82, 2005. DOI: https://doi.org/10.1016/j.matdes.2004.03.011