Residual stresses in alumina/zirconia composites: Effect of cooling rate and grain size

Alumina/zirconia composites with various compositions at the zirconia-rich part of the phase diagram have been prepared with various grain sizes of the starting alumina powders. After firing under identical conditions, the pellets have been cooled systematically, changing the cooling rates from 0.5 to 8000 K/min. Subsequently, the residual stresses in alumina have been determined by monitoring the frequency shifts of the R-2 luminescence line of alumina (14 430 cm(-1)). The data indicate that the stress in alumina is compressive in all cases, with increasing absolute values of the stress with decreasing alumina content. Within the same composition, the residual stress as a function of the cooling rate presents a minimum for values between 10 and 100 K/min, with no clear dependence on the alumina or zirconia grain size. An interpretation of the experimental data in terms of a Coble-type diffusional relaxation applies for intermediate cooling rates (from 10 to 800 K/min), but it fails to account for the large stresses at low cooling rates. The width of the stress distribution is narrow (similar to 150 MPa) and constant for all compositions and grain sizes at low cooling rates, but it increases for cooling rates > 10 K/min, depending on the grain size but not on the composition. For fast cooling rates, a correlation is found when reporting the average width of the stress distribution as function of the average sintered grain-size distribution of alumina. Overall, zirconia grain size seems to influence the average stress, whereas alumina grain size determines the stress distribution.