Facile method for preparing lamellar structured alumina-zirconia ceramics with high toughness

This study describes a facile and effective method for fabricating alumina-zirconia composites with innovative lamellar structure as well as outstanding mechanical strength/toughness. To this end, the particle-stabilized foam method has been utilized to synthesize alumina ceramic foams built by single-layer pore wall firstly, providing the basic lamellar structure for the subsequently mixing with zirconia particles and hot-press sintering to achieve robust alumina-zirconia ceramics. The unique lamellar microstructure is composed of alumina sheets and zir-conia grain layers alternated consistently, resulting in superior fracture toughness of 9.38 MPa m1/2, high flexural strength of 1.01 GPa and Vickers hardness of 17.04 GPa at the relative density of 99.63%. This approach opens up new possibilities for creating alumina-zirconia ceramics with exceptional mechanical performance.