Journal of the American Ceramic Society, Vol.97, No.11, 3442-3451, 2014
Phase Evolution in the Transformation of Atomically Mixed Versus Ball-Milled Mixtures of Nanopowders in the Formation of Composite MO center dot 3Al(2)O(3) Spinels: Bottom-Up Processing is Not Always Optimal
Liquid-feed flame spray pyrolysis (LF-FSP) provides atomically homogeneous mixed metal powders with 30-40nm average particle sizes, often producing kinetic phases due to the high quench rate As produced LF-FSP Al2O3-rich spinels, such as MgO3Al(2)O(3), form an Al2O3-rich metastable single-phase spinel. On heating, the powders phase separate to form MAl2O4 and -Al2O3. Compacts of MO3Al(2)O(3) (M=Co, Ni, Mg) were produced and sintered to evaluate the final duplex microstructure. The same composition was also approached from stoichiometric LF-FSP MAl2O4 nanopowders ball-milled with Al2O3 nanopowders in an attempt to evaluate how the initial length scale of mixing affected the final microstructure. Contrary to traditional sintering, we observe two distinct mechanisms. At 1000 degrees C-1200 degrees C, cation diffusion appears to control densification as a consequence of high vacancy concentrations and atomic mixing where traditionally expected site inversion plays less of a factor given the high quench rates. The second mechanism follows -Al2O3 exsolution and densification occurs via oxygen diffusion and -Al2O3 grain growth. When sintering the duplex MAl2O4/-Al2O3 compacts to at least 95% theoretical density, we find final microstructures that do not reflect the initial degrees of mixing. That is, the atomically mixed MgO3Al(2)O(3) does not does not offer an advantage over the submicron length scale of mixing in the ball-milled samples.