Processing and Characterization of Interpenetrating Ni-ZrO2 Composites

Abstract

This thesis describes the processing and characterization of uniform, interpenetrating, nickel-cubic stabilized zirconia composites. This work was performed in support of future development in the study and modelling of Metal-Ceramic (M/C) Functionally Graded Materials. Since it is of fundamental interest to understand the relationship between microstructure and behaviour in these materials, the characterization has focused on uniform composites. To minimize experimentation while maximizing productivity, the material grades selected for this study include M:C ratios by volume of 25:75, 50:50, and 75:25, along with the elemental materials (i.e. 100% nickel and 100% cubic zirconia). Solid state powder processing was developed including the steps: colloidal processing (by tape casting), lamination, organic burnout, hydrogen reduction of metal oxides, and hot press consolidation. These techniques support the even distribution of phases and yield high density composites (>98% of theoretical). Unfortunately the nickel powder used in this study produced atypical properties which complicated the analysis of mechanical behaviour. Composite thermal dilation, elastic, and mechanical properties were determined. Through analysis of residual stresses and fracture behaviour ideas regarding the modelling of M/C composites and FGMs are addressed. Continuum modelling approaches seem appropriate.