A study in the mechanical milling of alumina powder

Abstract The mechanical milling of alumina in order to reduce grain sizes to ≤100 nm has been proposed as a means of reducing sintering temperatures and improving pressureless sintered density, particularly as a means of allowing co-firing with metallic components for biomedical implants. There is a persistent problem with contamination from the milling media, usually hardened steel which can be only partially alleviated by acid leaching. We have explored the use of alternative milling media with a view to reducing the levels of contamination. Alumina powders were milled with hardened steel, tungsten carbide, alumina and zirconia milling media under identical conditions of ball mass:powder mass ratio 10:1 and target milling times of 32 h. All of the milling media were found to cause unacceptable levels of contamination. Zirconia media gave the lowest contamination (3–4%) and in some circumstances, the addition of a small amount of zirconia may lead to increased toughness without loss of bio-compatibility.