Revisiting 1 GPa alumina ceramics

Sintering is the proof test of ceramic processing. So is flaw-sensitive flexural strength. The calibration and optimization of processing are critical to the further development of ceramic science and technology. Chasing ultra-strength in brittle ceramics such as alumina is thus significant in the sense that it best illustrates how one can eliminate flaws via powders, forming, and sintering. Previous reports in high-strength alumina with three-point-bending strengths above 1 GPa are rare, while some cause confusion and suspicion. Here, we revisited the processing of 1 GPa alumina ceramics via accessible processing route of mild-speed centrifugal casting and pressureless two-step sintering. We demonstrated a high green body density of 63%, a low pressureless sintering temperature of 1175 °C, a high sintering density of 99.2%, a fine grain size of 0.52 μm, and a high flexural strength of 1036±32 MPa (three-point-bending over a 20 mm span length). We hope our study could set down the questioning on 1 GPa alumina: it is doable and can be done better.