Effect of mullite additions on the fracture mode of alumina

This work analyses the effect of mullite additions on the fracture mode of alumina. Mullite is proposed as an alternative to SiC for the second phase particles because the thermal expansion mismatch between alumina and mullite is of the same sign and order as that between alumina and SiC. Three alumina–5 vol.% mullite composites formed by alumina matrices with similar average grain sizes in the micrometric range (≈1 μm) and second phase sub-micrometric (50–350 nm) and nanometric mullite (<50 nm) particles located at grain boundaries and triple points were prepared. The fracture mode of the alumina matrix changed from predominantly intergranular to predominantly transgranular. This change became more significant as the size of the sub-micrometric fraction of mullite particles decreased.