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<p>This study presents the fabrication of α-Al<sub>2</sub>O<sub>3</sub>-based nanocomposites reinforced with <i>amorphous Si</i><sub><i>3</i></sub><i>N</i><sub><i>4</i></sub> nanoparticles through a carefully engineered processing route. The slurry preparation involved Dolapix CE64 as a dispersant, magnetized water, and ultrasonic wave vibration (UWV), followed by a shear force–thin-layer drying stage to achieve uniform nanoparticle dispersion. Consolidation was carried out via Spark Plasma Sintering (SPS) at 1550&#xa0;°C under 100&#xa0;MPa for 10&#xa0;min. An L25 Taguchi design was applied to optimize the processing parameters and minimize experimental variability. The optimized composition—Sample 25 (0.1 wt% amorphous Si<sub>3</sub>N<sub>4</sub> + 2 wt% Dolapix CE64, magnetized water, UWV, and shear force–thin-layer processing)—achieved a remarkable improvement in densification and mechanical reliability. Compared with monolithic α-Al<sub>2</sub>O<sub>3</sub>, the optimized nanocomposite exhibited a substantial increase in relative density (92.9% → 99.6%) and Weibull modulus (5.22 → 14.2), indicating enhanced structural integrity and uniformity. Microstructural analyses (FE-SEM, EDS mapping, and XRD) confirmed homogeneous dispersion of Si<sub>3</sub>N<sub>4</sub> and refined grain morphology, directly correlating with the observed mechanical response. Importantly, the optimized sample demonstrated greater deformation tolerance prior to fracture, reflecting a pronounced reduction in brittleness while maintaining competitive strength. These results reveal that the synergistic use of amorphous Si<sub>3</sub>N<sub>4</sub> nanoparticles, magnetized water, and ultrasonic-assisted dispersion in the SPS process can yield dense, tough, and damage-tolerant alumina nanocomposites, offering new opportunities for advanced structural and wear-resistant applications.</p>

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Effect of amorphous Si3N4 nanoparticles, dispersing agents and magnetized water on the mechanical properties of α-Al2O3

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Mahdi Darabi,
  • Ehsan Mohammad Sharifi,
  • Reza Vafaei,
  • Akbar Eshaghi,
  • Mohammad Reza Loghman-Estarki

摘要

This study presents the fabrication of α-Al2O3-based nanocomposites reinforced with amorphous Si3N4 nanoparticles through a carefully engineered processing route. The slurry preparation involved Dolapix CE64 as a dispersant, magnetized water, and ultrasonic wave vibration (UWV), followed by a shear force–thin-layer drying stage to achieve uniform nanoparticle dispersion. Consolidation was carried out via Spark Plasma Sintering (SPS) at 1550 °C under 100 MPa for 10 min. An L25 Taguchi design was applied to optimize the processing parameters and minimize experimental variability. The optimized composition—Sample 25 (0.1 wt% amorphous Si3N4 + 2 wt% Dolapix CE64, magnetized water, UWV, and shear force–thin-layer processing)—achieved a remarkable improvement in densification and mechanical reliability. Compared with monolithic α-Al2O3, the optimized nanocomposite exhibited a substantial increase in relative density (92.9% → 99.6%) and Weibull modulus (5.22 → 14.2), indicating enhanced structural integrity and uniformity. Microstructural analyses (FE-SEM, EDS mapping, and XRD) confirmed homogeneous dispersion of Si3N4 and refined grain morphology, directly correlating with the observed mechanical response. Importantly, the optimized sample demonstrated greater deformation tolerance prior to fracture, reflecting a pronounced reduction in brittleness while maintaining competitive strength. These results reveal that the synergistic use of amorphous Si3N4 nanoparticles, magnetized water, and ultrasonic-assisted dispersion in the SPS process can yield dense, tough, and damage-tolerant alumina nanocomposites, offering new opportunities for advanced structural and wear-resistant applications.