Abstract:Zirconia-mullite nano-composite ceramics were fabricated by in-situ controlled crystallization of Si-Al-Zr-O amorphous bulk, which were first treated at 900−1 000 ℃ for nucleation, then treated at higher temperature for crystallization to obtain ultra-fine zirconia-mullite composite ceramics. The effects of treating temperature and ZrO2 addition on mechanical properties and microstructure were analyzed. A unique structure in which there are a lot of near equiaxed t-ZrO2 grains and fine yield-cracks has been developed in the samples with 15% zirconia addition treated at 1 150 ℃. This specific microstructure is much more effective in toughening ceramics matrix and results in the best mechanical properties. The flexural strength and fracture toughness are 520 MPa and 5.13 MPa•m1/2, respectively. Either higher zirconia addition or higher crystallization temperature will produce large size rod-like ZrO2 and mullite grains, which are of negative effect on mechanical properties of this new composite ceramics.

Key words: Si-Al-Zr-O amorphous bulk; crystallization; zirconia-mullite composite; structure