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Materials 2013, 6(11), 5382-5397; doi:10.3390/ma6115382

Optimized Slurries for Spray Drying: Different Approaches to Obtain Homogeneous and Deformable Alumina-Zirconia Granules

1,* , 3,4
1 Department of Applied Science and Technology, INSTM R.U. PoliTO, LINCE Lab., Politecnico di Torino, Corso Duca degli Abruzzi, 24, 10129 Torino, Italy 2 Now at Materials Science Division, Lawrence Berkeley National Laboratory, Berkeley, CA 94720, USA 3 Université de Lyon, INSA de Lyon, MATEIS UMR CNRS 5510, Bât. Blaise Pascal 7, Av. Jean Capelle, 69621 Villeurbanne, France 4 Institut Universitaire de France, 103 bd Saint-Michel, 75005 Paris, France
* Author to whom correspondence should be addressed.
Received: 8 July 2013 / Revised: 26 October 2013 / Accepted: 12 November 2013 / Published: 21 November 2013
(This article belongs to the Section Advanced Composites)
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Spray drying is widely used for producing granulated feed materials for compaction process, which is the current industrial method for manufacturing alumina-zirconia femoral heads. The optimization of the granules compaction behavior requires the control of the slurry rheology. Moreover, for a dual-phase ceramic suspension, the even phase distribution has to be kept through the atomization step. Here we present two approaches addressing the key issues involved in the atomization of a composite system. Alumina-10 vol % zirconia powders were prepared by either a powder mixing route, or by the surface modification of a commercial α-alumina powder with a zirconium salt. Slurries from both powders were spray dried. The correlation between slurry rheology and pH, granules morphology and sintered microstructures was here investigated and discussed on the ground of the two feed materials characteristics. The processing conditions were optimized to obtain dense and homogeneous alumina-zirconia micro-nano composites by both processing routes.
Keywords: Al2O3-ZrO2; slurry optimization; spray drying; granules morphology Al2O3-ZrO2; slurry optimization; spray drying; granules morphology
This is an open access article distributed under the Creative Commons Attribution License (CC BY 3.0).

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Naglieri, V.; Gutknecht, D.; Garnier, V.; Palmero, P.; Chevalier, J.; Montanaro, L. Optimized Slurries for Spray Drying: Different Approaches to Obtain Homogeneous and Deformable Alumina-Zirconia Granules. Materials 2013, 6, 5382-5397.

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