Fabrication of fine-grained alumina ceramics by a novel process integrating stereolithography and liquid precursor infiltration processing

Abstract In this study, we report a novel approach, integrating stereolithography and liquid precursor infiltration techniques, to fabricate fine-grained alumina ceramics. The XRD patterns of the sample immersed with Zr 4+ or Zr 4+ (Y 3+ ) show that the sintered body contains Al 2 O 3 and t-ZrO 2 as the major phase and minor phase, respectively. Moreover, the t-ZrO 2 phase in the sample immersed with Zr 4+ (Y 3+ ) shows intense peaks compared to the composite immersed with Zr 4+ . On the other hand, the sample immersed with Mg 2+ contained Al 2 O 3 and MgAl 2 O 4 as the major phase and minor phase, respectively. The microstructure of the sample immersed with Zr 4+ shows that ZrO 2 particles are homogeneously distributed in the Al 2 O 3 matrix, thus inhibiting the grain growth of alumina particles. Moreover, the sample immersed with Mg 2+ shows a more dense and fine-grained structure. Compared to the non-infiltrated sample, the average grain size of the alumina sample immersed with Zr 4+ or Mg 2+ decreased. The sample infiltrated with Zr 4+ (Y 3+ ) had the smallest alumina average grain size of 1.14 µm. The ceramics prepared by infiltration showed a higher hardness (19.54 GPa), but a slightly lower fracture toughness (4.02 MPa m 1/2 ) compared to the samples (17.2 GPa, 4.13 MPa m 1/2 ) without infiltration.