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Mechanical Properties of Ceramics and Composites

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120

Chapter 2

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206.A Ghosh, KW White, MG Jenkins, AS Kobayashi, RC Bradt. Fracture resistance of a transparent magnesium aluminate spinel. J Am Cer Soc 74(7):1624–1630, 1991.

207.KW White, GP Kelkar. Evaluation of the crack bridging mechanism in a MgAl2O4spinel. J Am Cer Soc 74(70):1732–1734, 1991.

208.JC Hay, KW White. Grain-bridging mechanisms in monolithic alumina and spinel. J Am Cer Soc 76(7):1849–1854, 1993.

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214.RW Steinbrech, O Schmenkel. Crack-resistance curves of surface cracks in alumina. J Am Cer Soc 71(5):C-271–273, 1988.

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224.BA Chandler, EC Duderstadt, JF White. Fabrication and properties of extruded and Sintered BeO. J Nuc Mat 8(3):329–347, 1963.

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226.JA Salem, JL Shannon, Jr., RC Bradt. Crack growth resistance in textured alumina. J Am Cer Soc 72(1):20–27, 1989.

227.M Iwasa, EC Liang, RC Bradt. Fracture of isotropic and textured Ba Hexaferrite. J Am Cer Soc 64(7):390–393, 1981.

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230.FF Lange. Relation between strength, fracture energy, and microstructure of hotpressed Si3N4. J Am Cer Soc 56(10):518–522, 1973.

231.FF Lange. Fracture toughness of Si3N4 as a function of the initial α-phase content. J Am Cer Soc 62(7–8):428–430, 1979.

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3

Grain Dependence of Ceramic

Tensile Strengths at 22°C

I.INTRODUCTION

A.Background

It has been known for years that grain effects play an important role in the tensile, hence flexure, strength (σ) of ceramics. Since grain size (G) is the most important and pervasive variable in both improving and understanding tensile strength, various G functions have been used to show strength decreases with increasing G. Some investigators opted for log σ vs. log G plots, e.g. Knudsen [1] but this compresses data at large G (obscuring important σ–G changes there). An inverse G function is preferred, since this allows use of data for all grain sizes, including single crystals (G = ∞), though with some large-G data compression. For mechanistic reasons discussed below, plotting σ vs. G-1/2 has become standard, but there is still some confusion and uncertainty concerning specific parameters and interpretations. Related issues of using average or maximum G values and branch intersections and slopes, particularly at finer G, whose clarification [2, 3] is addressed later, need broader recognition and use. The volume fraction porosity (P) and the shape and spatial variations of porosity, grains, and other phases can be important, particularly in view of the challenge of obtaining a significant range of specimens in which G is the primary factor determining σ.

Before proceeding to discussing mechanisms and presentation and evaluation of data it is useful to consider briefly the history of investigating and understanding grain size effects on the strength behavior of ceramics. To obtain reasonable data several limitations had to be overcome, often in an iterative fash-

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ion, namely effects of second, e.g. glassy, phases in many oxide ceramics such as Al2O3, and varying pore and flaw populations, and their interactions, and limitations and variations of grain size, shape, and orientation. Problems of these limitations were compounded by many studies focusing on one particular mechanism or one particular aspect of a variable, e.g. G distribution, often with a limited range of testing and evaluation, and failing to apply some necessary basic tools, especially fractography. An important step was sorting out the main porosity effects [1–6], thus enhancing identification of grain size effects.

Another major help was improvements in raw materials and processing, especially the introduction and increasing use of hot pressing, to give bodies with little or no porosity and second phases with either finer or larger G [7–11], thus better defining both branches (Fig. 3.1). Larger G behavior generally approximated a G -1/2 dependence of strength, suggesting grains being the flaws (recognizing that flaw size, c, is measured by a radius and G by a diameter). However, this relation must be limited, since it implies strength extrapolating to 0 at G = ∞, neglecting single crystal strengths generally being similar to many, and higher than some, polycrystalline bodies, as is discussed later. Finer grain samples typically showed some, but much less, grain size dependence than larger grain samples, i.e. laying mostly or completely along the finer grain branch (Fig. 3.1), hence projecting to a positive strength intercept at G = ∞ (i.e. G-1/2 = 0), commonly of the order of magnitude as for single crystal specimens with the same surface finish. The combination of such a positive intercept along with increasing observations of slip or twinning on a micro-, or in some cases a macro-, scale suggested possible microplastic crack nucleation, growth, or both. Carniglia’s surveys [8, 9] showed that when a sufficient G range was covered, both regimes of behavior were typically observed as a continuous function of G, showing finer G strengths decreasing with increasing G, extrapolated to σ > 0 at G = ∞, i.e. at G-1/2 = 0. Intermediate to large G samples showed greater σ decrease with increasing G, generally indicating extrapolation to σ 0 at G -1/2 = 0.

Carniglia suggested that the failure mechanism for the finer grain branch was microplasticity, hence referring to this as the Petch or Hall–Petch regime, and that for the large G branch it was Griffith flaw failure with the flaw dimensions being those of the grain size. The change between mechanisms was attributed to stresses for failure from flaws being higher than the stresses to activate microplastic failure at fine G, until G became sufficiently large to allow flaw failure at stresses below those needed for microplasticity. This provided not only a possible explanation for the two-branch character of the σ – G-1/2 plots commonly observed but also for variability in the intersection of the σ – G-1/2 branches. Thus, as the quality of surface finish improved in specimens lacking other major sources of flaws e.g., pores, the larger G branch would extend to finer G before microplasticity took over. A few investigators, such as Kirchner and Gruver [10] and Rice [3, 11–13], suggested contributions of other intrinsic

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129

FIGURE 3.1 Schematic of the preexisting flaw model showing the larger G branch with strengths decreasing rapidly with increased G, falling below single crystal strengths followed by (test and specimen dependent) variable reversal toward single crystal strengths. Finer G branches have lower slopes, giving less strength increases with decreasing G, and meet the larger G branch when c G/2. Since the finer G branch has flaws > G, i.e. not constrained by G, it can be more variable, e.g. wider, or may consist of different flaw populations, hence separate branches. Microcrack and microplastic variations shown illustrate similar rates of σ changes, e.g. an initially rapid decrease with the onset of substantial microcracking and then saturation. However, both models are shown at arbitrary strength levels relative to the preexisting flaw model.