Effects of Residual Stresses on Strength and Crack Resistance in ZrO2 Ceramics with Alumina Coating

doi:10.15541/jim20210412

Abstract

Abstract:

By covering a thin Al₂O₃ coating on ZrO₂ substrate, compressive stress caused by the mismatch of thermal expansion coefficients between the coating and substrate was introduced in the surface layer of Al₂O₃-ZrO₂ pre-stressed ceramics (marked as A_CZ_S pre-stressed ceramics). Vickers indentation test was carried out to check the crack resistance in the surface layer and substrate influenced by the residual stresses. The enhancement of the crack resistance in surface layer results in a high flexural strength and excellent damage tolerance. Both theoretical analysis and experimental results show that the compressive stress and crack resistance in the surface layer increase with the increasing ratio of the cross-sectional area of ZrO₂ substrate to Al₂O₃ coating. Due to the residual compressive stress existing in Al₂O₃ coating, a high flexural strength of (1207±20) MPa was measured for ZrO₂ specimens coated with 40 μm Al₂O₃. The flexural strength is 32% higher than that of monolithic ZrO₂, and about triple of the value of Al₂O₃. Meanwhile, compared to ZrO₂, the A_CZ_S pre-stressed ceramics exhibit superior thermal shock resistance.

Key words: Al₂O₃-ZrO₂ pre-stressed ceramics, compressive stress, flexural strength, damage tolerance

CLC Number:

TQ174

LI Haiyan, HAO Hongjian, TIAN Yuan, WANG Changan, BAO Yiwang, WAN Detian. Effects of Residual Stresses on Strength and Crack Resistance in ZrO₂ Ceramics with Alumina Coating[J]. Journal of Inorganic Materials, 2022, 37(4): 467-472.

Figures/Tables 8

Fig. 1 (a) Schematic diagram of the ACZS pre-stressed ceramics; (b) SEM image of interface between ZrO2 substrate and Al2O3 coating

Fig. 2 (a) Typical Vickers indentation of ZrO2 ceramics; (b) Optical photograph of the indentation morphology for ZrO2 ceramics without residual stress

Fig. 3 Optical photographs of the indentation morphologies for ACZS pre-stressed ceramics with different ratios of the cross-sectional areas, showing the effects of the compressive stresses in the coating and tensile stresses in the substrate

Table 1 Parameters used in formulas and the results of the experiment and simulation

		Elasticity modulus, E/GPa	p/N	a/μm	c/μm	H_V/GPa	K_I,_IFR/(MPa·m^1/2)
ZrO₂	ZrO₂	220	19.62	26.80	35.20	12.66	9.10
A_CZ_S with 40 μm coating	Al₂O₃-40	350	4.91	11.25	47.50	17.98	1.52
A_CZ_S with 40 μm coating	ZrO₂-40	220	19.62	26.16	36.88	13.28	8.33
A_CZ_S with 30 μm coating	Al₂O₃-30	350	4.91	11.09	44.38	18.49	1.67
A_CZ_S with 30 μm coating	ZrO₂-30	220	19.62	26.08	36.05	13.37	8.59
A_CZ_S with 20 μm coating	Al₂O₃-20	350	4.91	10.94	25.00	19.02	3.89
A_CZ_S with 20 μm coating	ZrO₂-20	220	19.62	26.01	35.87	13.44	8.64

Fig. 4 Stress state and Vickers indentation of ACZS pre-stressed ceramics hs and hc: the thicknesses of substrate and coating

Fig. 5 Calculated residual stress in the Al2O3 coating and ZrO2 substrate of ACZS pre-stressed ceramics, as the function of the ratio of cross-sectional area of ZrO2 substrate to Al2O3 coating

Fig. 6 SEM images of the fracture surfaces for monolithic ZrO2 ceramics (a, b) and ZrO2 substrate of ACZS pre-stressed ceramics (c, d) fabricated by the hot-pressing sintering method

Fig. 7 Residual strength of ACZS pre-stressed ceramics and ZrO2 ceramics, after quenching at different thermal shock temperatures

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Effects of Residual Stresses on Strength and Crack Resistance in ZrO₂ Ceramics with Alumina Coating

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