A new synthetic route to MgO-MgAl₂O₄-ZrO₂ highly dispersed composite material through formation of Mg₅Al_2.4Zr_1.7O₁₂ metastable phase:synthesis and physical properties

Mg₅Al_2.4Zr_1.7O₁₂ metastable phase was successfully synthesized from analytical-grade MgO, α-Al₂O₃, MgAl₂O₄, and ZrO₂ under an N₂ atmosphere. The sintering temperature was varied from 1650 to 1780℃, and the highest amount of Mg₅Al_2.4Zr_1.7O₁₂ appeared in the composite material when the sintering temperature was 1760℃. According to our research of the formation mechanism of Mg₅Al_2.4Zr_1.7O₁₂, the formation and growth of MgAl₂O₄ dominated when the temperature was not higher than 1650℃. When the temperature was higher than 1650℃, MgO and ZrO₂ tended to diffuse into MgAl₂O₄ and the Mg₅Al_2.4Zr_1.7O₁₂ solid solution was formed. When the temperature reached 1760℃, the formation of Mg₅Al_2.4Zr_1.7O₁₂ was completed. The effect of MgAl₂O₄ spinel crystals was also studied, and their introduction into the composite material promoted the formation and growth of Mg₅Al_2.4Zr_1.7O₁₂. A highly dispersed MgO-MgAl₂O₄-ZrO₂ composite material was prepared through the decomposition of the Mg₅Al_2.4Zr_1.7O₁₂ metastable phase. The as-prepared composite material showed improved overall physical properties because of the good dispersion of MgO, MgAl₂O₄, and ZrO₂ phases.