Alumina (Al2O3) and zirconia (ZrO2) have good overall properties and thus are widely used oxide technical ceramics. The biggest drawback of Al2O3 is its low fracture toughness. In contrast, ZrO2 is relatively tough, but is also much more expensive. In order to improve the alumina toughness, composite ceramics are being developed. Slip casting technology has economic advantages over the conventional hot isostatic pressure technology, but problems may arise when preparing stable highly-concentrated suspensions (slip) for filling the mold. The purpose of this study is to prepare aqueous suspensions using 70 wt. % α-Al2O3, with 0, 1, 5 and 10 wt. % of added t-ZrO2. Suspensions were electrosterically stabilized using the ammonium salt of polymethylacrylic acid, an alkali-free anionic polyelectrolyte dispersant. Also, magnesium oxide in form of magnesium aluminate spinel (MgAl2O4) was used to inhibit the abnormal alumina grain growth during the sintering process. Minimum viscosities were used as stability estimators, where an increase in ZrO2 content required adding more dispersant. After sintering, the Vickers indentation test was used to determine the hardness and the indentation fracture toughness from the measurement of the crack length. Also, the brittleness index (Bi, μm−1/2) was calculated from values of Vickers hardness and the Vickers indentation fracture toughness. It was found that with increasing ZrO2 content the fracture toughness increased, while the hardness as well as the brittleness index decreased. Zirconia loading reduces the crystallite sizes of alumina, as confirmed by the X-ray diffraction analysis. SEM/EDS analysis showed that ZrO2 grains are distributed in the Al2O3 matrix, forming some agglomerates of ZrO2 and some pores, with ZrO2 having a smaller grain size than Al2O3.

In the present work, alumina (Al2O3) foam was prepared by the replica method where a polyurethane (PU) foam (30 pores per inch (ppi)) template was impregnated with a 60 wt.% Al2O3 suspension. Sintered Al2O3 foam was used as substrate for the deposition of sol-gel derived titania (TiO2) film using dip coating. For the preparation of TiO2 sol, titanium(IV) isopropoxide (Ti-iPrOH) was used as the precursor. The common problem of qualification and quantification of a crystalline coating on a highly porous 3D substrate with an uneven surface was addressed using a combination of different structural characterization methods. Using Powder X-ray Diffraction (PXRD) and synchrotron Grazing Incidence X-ray Diffraction (GIXRD) on bulk and powdered Al2O3 foam and TiO2-coated Al2O3 foam samples, it was determined Al2O3 foam crystallizes to corundum and coating to anatase, which was also confirmed by Fourier Transformed Infrared Spectroscopy (FTIR). Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM/EDS) revealed the structural and microstructural properties of the substrate and coating. Differential Thermal Analysis (DTA) and Thermogravimetric Analysis (TGA) were used to clarify the evolution of the porous microstructure. The Al2O3-TiO2 composite was evaluated as a photocatalyst candidate for the degradation of the micropollutant medication memantine. The degradation rate was monitored using a light-emitting diode (LED) lamp operating at electromagnetic (EM) wavelength of 365 nm. The photocatalytic activity of sol-gel-derived TiO2 film immobilized on the Al2O3 foam was compared with commercially available TiO2 nanoparticles, P25-Degussa, in the form of a suspension. The levels of memantine were monitored by High-Performance Liquid Chromatography–Tandem Mass Spectrometry (HPLC–MS/MS). The efficiency and rate of the memantine photodegradation by suspended TiO2 nanoparticles is higher than the TiO2-coated Al2O3 foam. But, from the practical point of view, TiO2-coated Al2O3 foam is more appropriate as a valuable photocatalytic composite material.

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In this work, alumina (Al2O3) ceramics were prepared using an environmentally friendly slip casting method. To this end, highly concentrated (70 wt.%) aqueous suspensions of alumina (Al2O3) were prepared with different amounts of the ammonium salt of a polycarboxylic acid, Dolapix CE 64, as an electrosteric dispersant. The stability of highly concentrated Al2O3 aqueous suspensions was monitored by viscosity measurements. Green bodies (ceramics before sintering) were obtained by pouring the stable Al2O3 aqueous suspensions into dry porous plaster molds. The obtained Al2O3 ceramic green bodies were sintered in the electric furnace. Analysis of the effect of three sintering parameters (sintering temperature, heating rate and holding time) on the density of alumina ceramics was performed using the response surface methodology (RSM), based on experimental data obtained according to Box–Behnken experimental design, using the software Design-Expert. From the statistical analysis, linear and nonlinear models with added first-order interaction were developed for prediction and optimization of density-dependent variables: sintering temperature, heating rate and holding time.

The present study examines the potential of microwave heating as an emerging and innovative energy-efficient alternative to conventional heating techniques used for different materials, with a focus on the processing of ceramic materials. Modern ceramics are studied extensively, and their use and different applications are wide due to many advantages of these materials. The most important factor in microwave sintering which differentiates it from conventional heating techniques is a unique heat transfer mechanism. Microwave energy is absorbed by the material, hence the transfer of energy takes place at the molecular level. This way, the heat is generated throughout the material, i.e. on the inside as well on the outside. This allows a very low temperature gradient throughout the material cross section. When conventional sintering is used, typically at high heating rates, high temperature gradients pose a problem. The accelerated microwave heating occurs through the whole volume, so the heating is uniform, which limits the grain growth and coarsening, and leads to a uniform and fine microstructure. The densification is accelerated as well during the unique heat transfer mechanism of microwave sintering, which enhances the mechanical properties of the sintered materials.This paper discusses the use of microwave sintering in the manufacturing of different modern technical materials, namely ceramics, composites, metals and alloys, and glasses. The improvement of different properties is described using the available literature.