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Novel process of preparation of Yttria stabilized ZrO2 small sizes beads using sol-gel method combined with spray granulation technology

Abstract

In this work, based on the sol-gel method combined with spray granulation technology, a novel process method to prepare Yttria stabilized ZrO2 beads with 5–50 µm diameter, 123 nm grains size, few pores, solid internal structure and well spherical type is proposed. These advantages can greatly improve the beads density, and decline the sintering temperature. The optimum preparation parameters, including sol and spray parameters, baking and sintering conditions, are obtained through the investigation of experimental conditions. The SEM test results of the surface and cross section morphologies show that the beads have solid structure and there is good consistency between the surface and interior of the beads. The average grain size of test results is about 123 nm. The XRD test results demonstrate that no monoclinic phase exists in the beads. The sintering temperature of the new process is only 1200 °C.

In this work, based on the sol-gel method combined with spray granulation technology, a novel process method to prepare Yttria stabilized ZrO2 beads with 5–50 µm diameter, 123 nm grains size, few pores, solid internal structure and well spherical type is proposed. These advantages can greatly improve the beads density, and decline the sintering temperature. The processes of the method mainly contain: sol preparation, spray forming process, organic compound discharging and sintering. The optimum preparation parameters, including sol and spray parameters, baking and sintering conditions, are obtained through the investigation of experimental conditions. The tested density result of the prepared beads is about 6.024 g/cm3 which is higher than for the traditional process. The SEM test results show that the diameter of the prepared Yttria stabilized ZrO2 beads is range from 5 to 50 µm with good sphericity. The surface and cross section morphologies show that the beads have solid structure and there is good consistency between the surface and interior of the beads. The average grain size is about 123 nm, no pores between grains. The XRD test results demonstrate that no monoclinic phase exists in the beads. The sintering temperature of the new process is only 1200 °C.

Highlights

  • A novel method to prepare Yttria stabilized ZrO2 beads with 5–50 µm diameter is proposed.

  • The optimum parameters of experiment conditions are studied and obtained.

  • The beads have characteristics of few pores, solid internal structure and well spherical type.

  • This process has low sintering temperature that is only 1200 °C.

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Acknowledgements

We gratefully acknowledge the financial support from the Quanzhou science and Technology Bureau. We also thank the status of the Quanzhou Yunjian Measurement Control and Perception Technology Innovation Research Institute who gave much assistance for the paper’s experiments.

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Correspondence to Xiaodong Wang or Yanchao Ren.

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Peng, D., Wang, X., Ren, Y. et al. Novel process of preparation of Yttria stabilized ZrO2 small sizes beads using sol-gel method combined with spray granulation technology. J Sol-Gel Sci Technol 103, 62–73 (2022). https://doi.org/10.1007/s10971-022-05782-4

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  • DOI: https://doi.org/10.1007/s10971-022-05782-4

Keywords

  • Yttria stabilized ZrO2 beads
  • Micron size and small grains solid
  • Internal structure
  • Low sintering temperature
  • Sol-gel and spray granulation technology