Alumina-mullite-zirconia composites obtained by reaction sintering: Part I. Microstructure and mechanical behaviour

Zirconia particles can be added to the matrix to overcome the brittleness inherent in ceramic materials, thereby strengthening the material through tetragonal-monoclinic phase transformation of the zirconia. This work focuses on the effect of the percentage of zirconia and mullite in the mechanical and thermomechanical properties of alumina-mullite-zirconia composites that were obtained by reaction sintering of alumina and zircon. Different samples were processed, resulting in composites with an alumina matrix, which was always volumetrically predominant. A percentage of alumina and mullite with maximized mechanical and thermomechanical properties was observed. This maximization is discussed in terms of the microstructure obtained for the composites mentioned above. The toughening mechanisms provided by zirconia and mullite inclusions, based not only on the R-curve behaviour but also on the analysis of the fracture surface, are also discussed in this report. An additional paper will be forthcoming, containing detailed discussions concerning the R-curve behaviour of the same composites.