A new synthetic route to MgO–MgAl₂O₄–ZrO₂ highly dispersed composite material through formation of Mg₅Al_2.4Zr_1.7O₁₂ metastable phase: synthesis and physical properties

Abstract

Mg₅Al_2.4Zr_1.7O₁₂ metastable phase was successfully synthesized from analytical-grade MgO, α-Al₂O₃, MgAl₂O₄, and ZrO₂ under an N₂ atmosphere. The sintering temperature was varied from 1650 to 1780°C, and the highest amount of Mg₅Al_2.4Zr_1.7O₁₂ appeared in the composite material when the sintering temperature was 1760°C. According to our research of the formation mechanism of Mg₅Al_2.4Zr_1.7O₁₂, the formation and growth of MgAl₂O₄ dominated when the temperature was not higher than 1650°C. When the temperature was higher than 1650°C, MgO and ZrO₂ tended to diffuse into MgAl₂O₄ and the Mg₅Al_2.4Zr_1.7O₁₂ solid solution was formed. When the temperature reached 1760°C, the formation of Mg₅Al_2.4Zr_1.7O₁₂ was completed. The effect of MgAl₂O₄ spinel crystals was also studied, and their introduction into the composite material promoted the formation and growth of Mg₅Al_2.4Zr_1.7O₁₂. A highly dispersed MgO–MgAl₂O₄–ZrO₂ composite material was prepared through the decomposition of the Mg₅Al_2.4Zr_1.7O₁₂ metastable phase. The as-prepared composite material showed improved overall physical properties because of the good dispersion of MgO, MgAl₂O₄, and ZrO₂ phases.

Keywords

metastable phases / formation mechanisms / composite materials / refractory materials / synthesis / physical properties

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