Fabrication of super-high-strength microchanneled Al2O3–ZrO2 ceramic composites with fibrous microstructure

Continuously porous Al2O3–(monolinic-ZrO2)/tetragonal-ZrO2 ceramic composites with tailored fine-scale fibrous microstructure was fabricated by a multipass extrusion process. Precise control of the microstructure was achieved, giving Al2O3–(m-ZrO2) fibrous phase (3.5 μm) in the t-ZrO2 phase (1.5 μm thickness). The pore size and porosity was 175 μm and 36%. The rounded microchannels and fine geometric control of the fibrous microstructure result in composites with a remarkably high bending strength value of 588 MPa which is 2- to 6-fold higher than their monolithic counterparts.