Deformation and fracture behaviour of alumina-zirconia multi-material nanocomposites reinforced with graphene and carbon nanotubes

An effort to improve the low fracture toughness of monolithic alumina (Al2O3) ceramic demands microstructural manipulation with nanostructured materials such as zirconia (ZrO2), Graphene (GN) and Carbon Nanotubes (CNTs). Despite these attempts, the fundamental understanding of the mechanical properties and deformation behaviour of multiple combinations of these second-phase additives within the advanced Al2O3 structure are still being explored. In this respect, Al2O3-based nanocomposites reinforced with optimum amounts of ZrO2(10 wt%), GN(0.5 wt%) and CNTs(2 wt%) were evaluated via hot-pressing at 1600 °C, preceding colloidal mixing of the Al2O3 matrix and nanostructured additives. Mechanical properties such as fracture toughness (KIC) and bending strength (σf) measured using three-point bending techniques including single edge notched beam (SENB) test, and direct crack measurement (DCM) methods were calculated from the near-dense fabricated multi-material nanocomposites and benchmarked against the monolithic Al2O3 material under similar experimental conditions. From the conventional SENB test, the fracture toughness values increased by up to 60% on the addition of only 10 wt%ZrO2 to the monolithic Al2O3, whilst a drastic increase by up to 159% was achieved with the incorporation of both GN and CNTs within the Al2O3–ZrO2 structure, as compared to the monolithic Al2O3. The KIC values obtained from SENB tests were typically lower than the DCM method, but similar trend in the toughness behaviour were realized regardless. Bending strength of the prepared monolithic Al2O3 was also increased by up to 46% with the combined additions of ZrO2, GN and CNTs. Toughening and strengthening mechanisms including pull-outs by GN and CNTs, crack arrest and cack bridging were identified as the main source of enhancement in the mechanical properties of the multi-material nanocomposites. The addition of carbon additives also influenced monoclinic and tetragonal ZrO2 phase transformations, which also contributed to the overall mechanical behaviour of the Al2O3-10 wt%ZrO2 nanocomposites. •Al2O3 matrix with 10 wt%ZrO2, 0.5 wt%GN and 2 wt%CNTs were mixed and hot-pressed.•Combined additions of ZrO2, GN and CNTs refined grain structure of the Al2O3 matrix.•Fracture toughness and bending strength enhanced due to active mechanisms.•Crack bridging and arrest mechanisms operative in the multi-material nanocomposites.