Laminated alumina/zirconia ceramic composites prepared by electrophoretic deposition

The electrophoretic deposition of alumina and zirconia powders from isopropanolic suspension in the presence of monochloroacetic acid was studied in the constant-current regime. The different levels of electric current during deposition from 250 μA to 48 mA were used. The green density of the deposit depends on the current density and then on the particle velocity during deposition, reaching values from 58% to 61% according to the electric current used. It was found that the lower the green density of the green deposit, the larger the pores. The low green density led to low final fired density and subsequently to the low Vickers hardness HV5 ranging from 2000 to 1650 depending on electric current used. Based on these findings microlaminates having various thickness ratios to achieve different residual stress levels were prepared consisting of alternating layers of alumina and zirconia.