Journal of the American Ceramic Society, Vol.87, No.7, 1265-1273, 2004
Critical factors affecting the wettability of alpha-alumina by molten aluminum
The wetting behaviors of alpha-Al2O3 single crystals with three different faces-R(01 (1) over bar2), A(011 (2) over bar0), and C(0001)-and polycrystals (PC) by molten aluminum were studied over a wide temperature range using both a conventional and an improved sessile-drop method. The critical factors affecting the wettability, such as temperature, atmosphere, substrate surface roughness, and crystallographic orientation, and the influence from the experimental technique, were thoroughly investigated. The results show that the aluminum surface oxidation and the thickness of the oxide film have a pronounced effect on the wettability, especially at low temperatures. To eliminate this effect, the experimental temperature must be over a critical value. Vacuum favors lowering this value compared with atmosphere, and the improved sessile-drop method, particularly using an impingement-dropping mode (I-mode), helps to weaken this effect by mechanical disruption and removal of the oxide film. However, the dropping distance and the dropping force must be controlled to prevent a receding contact angle. The effects of the substrate surface roughness and temperature are not significant in the case of a clean and a fine-prepared aluminum surface. On the other hand, the effect of the aluminum crystallographic orientation is noticeable and the wettability is in the order of R > A > PC > C. The intrinsic contact angles of the Al/alpha-Al2O3 system in the temperature range 1000degrees-1500degreesC were estimated to be 76degrees-85degrees for the R and A faces, 88degrees-100degrees for the C face, and 77degrees-90degrees for the polycrystal, depending on the temperature.