ISSN 0020-1685, Inorganic Materials, 2012, Vol. 48, No. 3, pp. 313–317. © Pleiades Publishing, Ltd., 2012.
Original Russian Text © A.I. Orlova, A.K. Koryttseva, A.E. Kanunov, V.N. Chuvil’deev, A.V. Moskvicheva, N.V. Sakharov, M.S. Boldin, A.V. Nokhrin, 2012, published
in Neorganicheskie Materialy, 2012, Vol. 48, No. 3, pp. 372–377.
313
INTRODUCTION
Phosphates isostructural with NaZr
2
(PO
4
)
3
(NZP)
constitute a family of structural analogs owing to the
characteristic features of their structure and their abil-
ity to accommodate cations differing in nature
(charge, ionic radius, electronegativity, and electronic
structure) in various combinations and ratios. Calcu-
lated possible compositions of such phosphates were
reported by Orlova [1], who considered the principles
of modeling the chemical composition of such com-
pounds using information about the crystal-chemical
properties of cations and the distinctive features of the
structure of interest. Experimental studies demon-
strate that the NZP phosphates may contain cations of
s-, p-, d-, and f-block elements in oxidation states
from 1+ to 5+.
The NaZr
2
(PO
4
)
3
-type phosphates typically have
high thermal stability (1200–1700°С), low or near-
zero thermal expansion, and high radiation resistance
(external radiation (gamma) doses, up to 5 × 10
8
Gy;
internal radiation (alpha) exposures, up to 10
18
alpha-
particles per gram). These materials do not degrade in
water (tests at 200°С and 60 MPa for two years), have
low corrosion rates (leaching rates of the most mobile
cations, down to 10
–6
to 10
–5
g/(cm
2
day)), are cata-
lytically active, and offer ionic conductivity [1].
Crystalline materials with such properties are of
interest for laser and space applications; nuclear engi-
neering; the fabrication of chip substrates, catalyst
supports, and phosphors; medical applications; and
the development of stable ceramic radioactive waste
forms.
The use of such materials is highly dependent on
the ability to produce dense ceramics uniform in
microstructure.
Such ceramics can be produced by cold uniaxial
and isostatic pressing, followed by sintering [2–14];
hot pressing [5, 6]; and microwave sintering [15]
(table). The relative densities reached range from 76.2
to 98.8%. These techniques, however, require consid-
erable energy, in particular, because long sintering
times are needed. For example, Limaye et al. [9]
obtained materials with a 98.3% relative density using
a two-step process: pressing and sintering at 1200°С
for 24 h.
To raise the density of NZP-type ceramic materials
and minimize the sintering time, we used high-speed
pulsed electric current sintering, also known as spark
plasma sintering (SPS).
In this method, a material and die are rapidly
heated by high-power millisecond dc current pulses
[16, 17]. The benefits of the SPS process include rapid
heating, vacuum, and hydrostatic pressure. These fac-
tors are capable of increasing the sintering rate, as
demonstrated by decades of application. Munir et al.
[18] cite many studies in which the SPS process was
successfully used to produce high-density ceramics
and ceramic-matrix composites with improved physi-
comechanical properties.
The SPS process was used earlier to produce mate-
rials with increased density: metals, multilayer sys-
tems, and ceramics, including Al
2
O
3
–SiC [19] and
W–Co [20, 21].
Ceramics based on NASICON-type Li com-
pounds can also be produced by SPS [22].
Fabrication of NaZr
2
(PO
4
)
3
-Type Ceramic Materials
by Spark Plasma Sintering
A. I. Orlova
a
, A. K. Koryttseva
a
, A. E. Kanunov
a
, V. N. Chuvil’deev
b
, A. V. Moskvicheva
b
,
N. V. Sakharov
b
, M. S. Boldin
b
, and A. V. Nokhrin
b
a
Lobachevsky State University, pr. Gagarina 23, Nizhni Novgorod, 603950 Russia
b
Research Institute of Physics and Technology, Lobachevsky State University,
pr. Gagarina 23/3, Nizhni Novgorod, 603950 Russia
e-mail: albina.orlova@inbox.ru
Received July 18, 2011
Abstract—Ceramic materials based on Ca
0.5
Zr
2
(PO
4
)
3
and NaFeNb(PO
4
)
3
, structural analogs of
NaZr
2
(PO
4
)
3
(NZP), were prepared by spark plasma sintering. At sintering temperatures of 1100–1200 and
880°C and sintering times of 12 and 3 min, the relative densities reached were 99.1 and 99.9%, respectively.
According to X-ray diffraction data, the sintering process caused no changes in phase composition. The
ceramics had a dense, homogeneous microstructure and ranged in grain size from 0.5 to 2.5 μm.
DOI: 10.1134/S002016851202015X