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A series of ZrO2–MgAl2O4 ceramics with additions of 0; 2.5; 5.0; and 7.5 wt. % nano-ZrO2 were successfully fabricated at 1580°C for 4 h from powders of commercial Al2O3 and calcined MgO by single-stage solid state reaction sintering (SRS) method. Effects of nano-ZrO2 additive on the phase compositions, microstructures and bulk density of the ceramics were investigated. Nano-ZrO2 additive was found to remarkably promote the sintering densification and improve the microstructure of the ceramics. Uniform, dense and fine microstructures are obtained, and the mean grain size of MgAl2O4 particles is about 2 μm. The as-prepared ceramics mainly consist of MgAl2O4 and c-ZrO2 (cubic-Ca0.15Zr0.85O1.85), due to the reaction between Al2O3 and MgO as well as the nano-ZrO2 additive and CaO stabilizer. The formation process of the ceramics mainly includes the synthesis of MgAl2O4 and the conversion process of m-ZrO2 to c-ZrO2 under the stabilizing action of CaO.

EFFECTS OF NANO-ZrO₂ ADDITIVE ON THE PHASE TRANSFORMATION AND DENSIFICATION OF ZrO₂-MgAl₂O₄ CERAMICS PREPARED BY SINGLE-STAGE SRS PROCESS