A novel processing procedure for significantly suppressing grain growth in submicrometer alumina compacts has been developed and implemented with the intent of ultimately using the same processing route to control grain size in nanophase alumina compacts. In this study, partially sintered alumina pellets made from 0.5 µm starting powders are altered by the chemical infiltration of Si 3 N 4 . The control and infiltrated pellets are then heated to 1650°C for 4 h. The fully sintered pellets are approximately 97% dense. Suppressed grain growth is observed in the infiltrated pellets. The average grain size in the control pellets after densification is 4.2 and 1.2 µm in the infiltrated pellets. Depth of infiltration is measured using transmission electron microscopy (TEM) and scanning electron microscopy (SEM).Depending on the specific infiltration conditions used, the outer 15-50% of the infiltrated pellets exhibit a graded microstructure consisting of a region of abnormal grain growth and a region of suppressed grain growth. Abnormal grain growth is visible on the outer surfaces of the infiltrated pellets where a relatively high ratio of Si to N is present. Further into the pellet, after some depletion of the Si source gas has occurred, regions of suppressed grain growth are apparent. Based on these results, an infiltration profile is determined. A mathematical model is developed to describe the infiltration process and to determine optimal infiltration conditions. High-resolution electron microscopy (HREM), energy dispersive spectroscopy (EDS), electron energy loss spectroscopy (EELS), and X-ray photoelectron spectroscopy (XPS) are used to study the infiltrated samples.
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