Fabrication of reaction-bonded Cr₂O₃ ceramics

Reaction-bonding to form Cr₂O₃ can be achieved by gaseous oxidation of a Cr phase. The reaction-bonding process is best conducted by complete oxidation before sintering. Below ≈800°C, the activation energy for oxidation is 220kJmol^-1, indicating the predominance of Cr³⁺ outward diffusion along high diffusivity paths, e.g., grain boundaries and dislocations. At higher temperatures, the activation energy is reduced to 52kJmol^-1 as a result of oxygen transport along lower-energy paths, e.g., along microcracks, and the internal and external surfaces. In spite of the decrease in activation energy, the access of oxygen to the inside of the powder compact is hindered by the progressive densification of the oxidizing powder compacts. Maximum densification is achieved for fully oxidized Cr/Cr₂O₃ compacts when the oxygen partial pressure is close to that of the Cr-Cr₂O₃ equilibrium. 0.1wt% MgO addition increases the density and reduces the grain size of the reaction-bonded Cr₂O₃ samples due to the possible formation of the spinel phase MgCr₂O₄. ZrO₂ and MgO additions improve the fracture strength and toughness of conventionally sintered Cr₂O₃ and change its fracture mode from intergranular to intragranular. For reaction-bonded Cr₂O₃ samples with or without MgO addition, their fracture strength and toughness data are roughly the same as those of sintered Cr₂O₃ doped with ZrO₂ and MgO and their fracture surfaces are predominantly intragranular.