One-step synthesis and low-temperature rapid sintering of alumina-zirconia ceramics by flash sintering combined with phase transformation

High-performance alumina-zirconia ceramics are generally sintered above 1500 °C and consume lots of energy; rapid sintering at low temperature is an ideal technique due to its economy and low-energy consumption. For the first time, flash sintering combined with phase transformation-assisted sintering techniques was reported in this work. The alumina-zirconia amorphous precursor powder was used to replace the final product powder for ceramic processing, and the one-step synthesis and rapid sintering densification of alumina-zirconia ceramics at low temperature of 849 °C for 60 s were realized. The effects of electric field on the low-temperature sintering of amorphous powders are summarized into three aspects. Firstly, the electric field reduces the viscosity of the amorphous powder and promotes liquid phase sintering. Secondly, the electric field promotes the phase transition of the amorphous powder from metastable to stable phase, and accelerates the atomic migration. Thirdly, Joule heating and defect generation in the flash sintering promotes more effective material transport. Overall, this work reduces the energy for calcination of amorphous powders, reduces the sintering temperature of ceramics, well hinders the grain coarsening and shows excellent mechanical properties.