Spark Plasma Sintering of Multilayer Ceramics – Case Study of Al2O3-Mg(Ca)TiO3 Sandwich
Spark plasma sintering enables very rapid fabrication of bulk ceramic materials. Suitability of this technique for preparing of multilayer ceramic discs is up to now relatively seldom reported. Our work is focused on a bi-layered disc consisting of thick Al2O3 layer and comparably thick Mg (Ca)TiO3 (MCT) layer sintered in one run. Al2O3 powder was nanometric (less than 40 nm) and composed of the hexagonal α-phase whereas MCT is a solid solution of two orthorombic perovskites. Pre-sintered and crushed MCT powder was coarser than alumina, up to 125 μm. The purpose of this material combination was creating of dielectric sandwich consisting of capacitor MCT material and resistor nanoalumina material. Spark plasma sintering run was done at 1200 °C, using pressure 80 MPa and dwell time only 2 min. Resulting sandwich was subjected to microstructural observations and cross sectional measurement of microhardness. On the border between Al2O3 and MCT the microhardness was higher than in MCT but has markedly higher dispersion than in the individual components. The MCT material exhibits birefringence in the polarized light [1]. We attempted to correlate the microhardness of individual MCT grains to their orientation indicated by birefringence.