International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

www.elsevier.com/locate/ijrmhm

Development of yttria and ceria toughened alumina composite

for cutting tool application
A. Senthil Kumar
a

a,

, A. Raja Durai b, T. Sornakumar

Department of Production Engineering, Sethu Institute of Technology, Pulloor, Kariapatti 626 106, Tamilnadu, India
b
Department of Production Engineering, MIT Campus, Anna University, Chennai 600 044, India
c
Department of Mechanical Engineering, Thiagarajar College of Engineering, Madurai 625 015, India
Received 18 February 2006; accepted 10 May 2006

Abstract
Yttria and ceria toughened alumina (YCTA) ternary ceramic composite were developed for cutting tool application. Alumina, ceria
and yttria powders were mixed with polyvinyl alcohol and uniaxially pressed. The green compacts were sintered, subsequently hot isostatically pressed (HIPed) and Wnish machined in the form of cutting tool inserts. The densities of the green compacts and the sintered and the
HIPed specimens of YCTA were evaluated. The mechanical properties of the sintered and the HIPed specimens of YCTA were also evaluated. Machining studies were conducted using the newly developed YCTA inserts on grey cast iron work piece. For comparison, the
commercially available zirconia toughened alumina (ZTA) inserts and silicon carbide whisker reinforced alumina (SCWRA) inserts were
also used for the machining studies. The performance of YCTA inserts is compared with that of the ZTA and SCWRA inserts.
2006 Elsevier Ltd. All rights reserved.
Keywords: Oxide ceramics; X-ray diVraction; Hardness; Fracture toughness; Machining

1. Introduction
The advances in ceramic composites have resulted in the
emergence of newer materials. Control of microstructure
has led to the development of ceramic composite cutting
tool materials like titanium carbide added alumina, zirconia toughened alumina and silicon carbide whisker reinforced alumina which are successfully used for cutting tool
application. Apart from binary ceramicceramic composites, it is possible to develop advanced ternary ceramic
ceramic composites for cutting tool applications using the
combination of diVerent ceramic materials. Aluminium
oxide has exceptionally good properties like high hardness,
chemical inertness, melting point and wear resistance. How-

Corresponding author. Tel.: +91 452 2530461.

E-mail address: asenthil123@yahoo.com (A. Senthil Kumar).

0263-4368/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijrmhm.2006.05.002

ever, alumina is a brittle ceramic material and it is strengthened by the addition of secondary phase ceramic particles,
Wbers and whiskers in the alumina matrix [1]. Yttrium oxide
is the most thermodynamically stable oxide available.
Yttrium oxide based materials are used as thermal barrier
coatings [2]. Yttrium oxide is used as an additive to stabilize
zirconia and by the addition of yttria the fracture toughness
of the composite is increased [3]. Aluminayttria composite
has three diVerent phases: YAM (Y4Al2O9, yttrium aluminum monoclinic), YAP (YAlO3, yttrium aluminum perovskite) and YAG (Y3Al5O12, yttrium aluminum garnet) [4].
Tseng and Lo [5] studied about phase development in aluminayttria system synthesized by solgel method and the
formation of YAG, YAP and YAM was observed in the
XRD analysis. Patankar et al. [6] reported about the processing of polycrystalline yttriumaluminium garnet
(YAG) via mechanical alloying. Hongzhi Wang et al. [7]
prepared Al2O35 vol% YAG composites and reported that
the bending strength and the fracture toughness are 604 MPa

A. Senthil Kumar et al. / International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

and 5.0 MPa m1/2, respectively. The formation of YAG in

the alumina matrix improved the mechanical properties
composite. Ceria is widely used in polishing of optical glass,
arts and crafts. Ceria is also used as an additive, to stabilize
zirconia and by the addition of ceria the fracture toughness
of the composite is increased [8]. Ceria is used to stabilize
the alumina in gamma phase and helps to retain a higher
surface area eVectively up to a temperature of 1000 C
under reducing condition. Aluminaceria composites are
widely used in catalytic converter. Alessandro Piras et al. [9]
reported that ceria was ineVective as a stabilizing agent for
-alumina under oxidizing conditions. However, alumina
ceria composite containing -alumina can be developed, by
high temperature sintering in oxidizing or atmospheric
environment. Senthil Kumar et al. [10] developed the aluminaceria ceramic tool inserts and reported that they
exhibited better mechanical properties than the pure alumina inserts. In the present work, the development of
ceramic composite cutting tool based on alumina, yttria
and ceria is discussed.
2. Experimental procedure
Aluminium oxide powder 90 wt% with an average particle size of 1.2 m was mixed with 5 wt% of yttrium oxide
powder with an average particle size of 2 m and 5 wt% of
cerium oxide powder with an average particle size of 5 m.
The blended powders were mixed with polyvinyl alcohol
and uniaxially cold pressed to a rhombic shaped compacts
at a pressure of 200 MPa. The green compacts were sintered
at 1600 C in air for 2.5 h. The sintering was carried out at a
heating rate of 10 C per minute from room temperature to
600 C and at this stage the binder material was removed
from the compacts. Then, the sintering was carried out at a
heating rate of 15 C per minute from 6001600 C. The sintered specimens were slowly cooled in the furnace to atmospheric temperature. Some of the sintered specimens were
subsequently HIPed at 1470 C and 190 MPa for 2.5 h. Both

215

the sintered and the HIPed specimens were Wnish machined

in a grinding machine using diamond grinding wheel. The
Wnal shape and size of the inserts were brought to the speciWcation of CNGN 12 07 08 (rhombic nose angle D 80;
rhombic inscribed circle diameter D 12.70 mm; thickness D
7.94 mm and corner radius D 0.8 mm). The XRD analysis
was carried out using a computer controlled diVractometer,
JEOL Model 8030 using Cu K radiation (wavelength
1.5406 ). The densities of the specimens were determined
using the Archimedes principle method for 10 samples in
each type and the average values of densities were evaluated. The hardness of the inserts were evaluated using a
Vickers Hardness Tester Machine with a load of 294 N, for
10 samples in each type and the average values of hardness
were evaluated. The fracture toughness was evaluated using
indentation method with various loads of 49, 98, 196, 294
and 490 N and the average values of the fracture toughness
were evaluated. The performance of the YCTA ceramic
cutting tool was evaluated by conducting machining studies
on grey cast iron (170 BHN) work piece in a precision lathe.
Flank wear of the cutting tool insert and the surface roughness measurements of the machined work piece were
observed. The Xank wear of the inserts were measured
using a toolmakers microscope. The surface roughness of
the machined work piece was measured using a surface
roughness meter. For comparison the machining tests were
also conducted using commercial ZTA and SCWRA
inserts. ZTA insert contains 96.5 wt% of alumina and
3.5 wt% of zirconia. SCWRA insert contains 80 vol% of alumina and 20 vol% of silicon carbide whiskers. Grey cast
iron was chosen for machining, since ceramics are generally
used to machine cast iron [11]. The machining tests were
conducted at cutting speeds of 120 m/min, 170 m/min and
270 m/min; at a constant feed rate of 0.12 mm/rev and at a
constant depth of cut of 0.5 mm for a period of 15 min
under dry condition. The photograph showing the sintered
and the HIPed YCTA ceramic cutting tool inserts after
machining 15 min is presented in Fig. 1.

Fig. 1. Photograph of sintered and HIPed YCTA ceramic composite insert after machining for 15 min: (a) sintered and (b) HIPed.

216

A. Senthil Kumar et al. / International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

3. Results and discussion

Table 1
Mechanical properties of cutting tool inserts

3.1. Properties of YCTA cutting tools

S. No.

Cutting tool

Hardness (HV)

Fracture toughness
(MPa m1/2)

The green compacts of YCTA inserts have 62.5% of the

theoretical density, whereas the sintered specimen and the
HIPed specimen have 96.5% and 99% of theoretical density,
respectively. The mechanical properties like hardness and
fracture toughness of the sintered and the HIPed inserts are
presented and compared with ZTA and SCWRA inserts in
Table 1. It can be noted that the improvement in hardness
and fracture toughness after HIPing is marginal. As the sintered specimens have already attained densities nearer to
their theoretical densities, it is only possible for a small
increase in their densities during HIPing and hence the
increase in mechanical properties is also marginal. Lalande
et al. [17] reported that Al2O3/ZrO2/Ag composite was sintered in air for 2 h at 1550 C and there was no improvement in fracture toughness by post-HIPing. Jeong and

1
2
3
4

Sintered YCTA inserts

HIPed YCTA inserts
ZTA inserts
SCWRA inserts

1675
1710
1730
2000

4.9
5
4.5
8

Niihara [18] reported that Al2O3/SiC nanocomposites were

pressureless sintered with additives MgO and Y2O3 and
obtained over 98% of theoretical density and HIPing did
not improve fracture strength.
3.2. XRD and SEM analysis
The XRD pattern and peak table and are presented in
Fig. 2. From the XRD pattern, the presence of -Al2O3
(Corundum), CeO2(Cerianite) can be observed and yttria in

Fig. 2. XRD pattern of sintered YCTA insert, using Cu K radiation.

A. Senthil Kumar et al. / International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

217

Table 2
Properties of alumina, yttria and ceria ceramic materials [2529]

Fig. 3. SEM micrograph of the sintered YCTA ceramic cutting tool.

the alumina matrix has transformed to YAP, YAG and

YAM. Initially, YAM and YAP are formed and the formation of YAG occurs after prolonged heat treatments at
temperatures around 1600 C [12]. However, the presence of
YAM and YAP are also observed after heat treatments at
1600 C [13]. The addition of rare earth oxide like cerium
oxide promotes the formation of YAG in the composite
[14]. The formation of YAG, YAM and YAP promotes
bonding between alumina and yttria, which also has a contributing eVect on the improvement of the mechanical
properties of the composite. Moreover, the sintering at
1600 C for 2.5 h promotes grain growth and it can be noted
from the SEM micrograph of the sintered YCTA cutting
tool presented in Fig. 3. At this temperature grain growth
occurs resulting in a dense compact [15]. The densiWcation
rate is greatly dominated by the green density. The dominant mechanisms of densiWcation in the initial stage of sintering at 700800 C are particle rearrangement, lattice
diVusion and grain boundary diVusion. The densiWcation at
latter stages at 14001600 C proceeds with grain growth.
The porosity during the sintering decreases by mass transport through the lattice diVusion with grain growth [16].
The decrease in porosity leads to achievement of good sintered density in the YCTA tools.
3.3. Toughening mechanism of the YCTA composite
The various mechanisms for toughening of the ceramic
composites are crack deXection, microcracking, transformation toughening, crack branching and crack bridging.
All of these mechanisms essentially redistribute stress at the
crack tip and increase the energy needed to propagate a
crack through the composite material, thereby resulting in
improved toughening [19]. Particulate toughening is commonly adopted to strengthen the ceramicceramic composites. Dieter [20] explained the strengthening mechanisms
about the dispersion of soft particles in the hard matrix.

Property

Unit

Alumina

Yttria

Ceria

Youngs modulus [E]

CoeYcient of thermal
expansion []
Poissons ratio []

GPa
106 K1

386
8

158
7.9

172
13

0.22

0.29

0.29

The dislocation can cut and deform the soft particles, however, the particles cannot be easily sheared due to the
strengthening mechanisms such as coherency strains, stacking fault energy, ordered structure, modulus eVect, interfacial energy and lattice friction stress eVect. Due to these
strengthening mechanisms, an additional expenditure of
energy is required, in order to propagate the crack through
the particles. Hyoun-Ee Kim et al. [21] explained the
strengthening mechanism by the compressive thermal residual stresses. These stresses are developed due to the diVerence between the properties like thermal expansion
coeYcients and elastic moduli of matrix and particles and
they reduce the stress intensity factor at the crack tip. The
residual thermal stresses are developed during the cooling
of the compacts, after sintering or HIPing. These stresses
are formed around the dispersed particles [22]. The thermal
residual stresses depend on the thermal expansion coeYcients of the particle and the matrix and these thermal
residual stresses are of suYcient magnitude to generate lattice defects such as dislocations around the particle even in
ceramic materials. The thermal residual stresses also
depend on the change in temperature, Poissons ratio and
Youngs modulus of the particle and the matrix [23,24].
During cooling the temperature reduces and it induces thermal residual stresses. Table 2 shows the relevant properties
of alumina, yttria and ceria ceramics [2529]. From the
table, it can be noted that there is a signiWcant diVerence in
the coeYcients of thermal expansion of alumina and ceria.
There are also notable diVerences between the Youngs
moduli of the particles (yttria and ceria) and the matrix
(alumina). A small diVerence exists between the Poissons
ratios of the ceramic materials. Thermal residual stresses
are likely to be developed due to the diVerences in these
properties. These residual stresses inXuence in the pinning
of crack propagation initiated in the matrix by reducing the
stress intensity factor at the crack tip [30]. So, the addition
of yttria and ceria particles in the alumina matrix introduces particulate toughening eVect and increases the fracture toughness of the composite. The fracture toughness
values of the sintered and the HIPed YCTA ceramic composite inserts are slightly higher than that of commercial
ZTA. The above toughening mechanism contributes to the
better fracture toughness of the YCTA ceramic composite
inserts than that of ZTA insert.
3.4. Machining performance of YCTA tool
Flank wear is the dominant tool wear among the diVerent forms of tool wear, as it aVects the dimensional tolerance

218

A. Senthil Kumar et al. / International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

0.17

Flank wear (mm)

Flank wear (mm)

0.12

0.1

0.08

0.13

0.09

0.06
4

10

12

14

16

0.05
100

Time (min)

150

200

250

300

Cutting speed (m/min)

Sintered YCTA

ZTA

HIPed YCTA

SCWRA

Sintered YCTA

ZTA

HIPed YCTA

SCWRA

Fig. 4. Flank wear vs. machining time of the ceramic inserts at 170 m/min.

Srface roughness Ra (m)

of the work piece [31]. The variation of Xank wear of the

ceramic cutting tool inserts with respect to machining time is
shown in Fig. 4. From the Wgure it can be noted that the
Xank wear of sintered YCTA insert is slightly higher than
ZTA and SCWRA inserts whereas Xank wear of HIPed
YCTA insert is slightly lower ZTA and SCWRA inserts. It
can also be noted that the Xank wear of the ceramic inserts
progresses steadily with respect to time. The growth of the
Xank wear with machining time can be divided into three
regions such as initial wear region, steady wear region and
rapid wear region. When machining begins, the sharp edge
of the tool rapidly breaks down, may be due to plastic deformation of the cutting edge and the initial wear happens. In
the steady wear region, the cutting wedge assumes a stable
conWguration hence the wear progress is more or less uniform and it progresses slowly and steadily. In the rapid wear
region, the growth of wear occurs rapidly and the cutting
tool fails very soon. From Fig. 4, it can be noted that the
Xank wear of the cutting tools is in the steady state region
and hence the wear pattern is uniform and steady. The lower
Xank wear of the HIPed YCTA insert than that of the ZTA
insert can also be attributed to the equivalent mechanical
properties to that of ZTA insert. Though SCWRA insert
has better mechanical properties than the YCTA inserts the
Xank wear resistance of the HIPed YCTA insert are better
than that of the SCWRA inserts. The reason is mainly due
to the presence of thermodynamically stable yttria in the
alumina matrix whereas the chemical aYnity of silicon carbide towards iron aVects the performance of SCWRA insert
[2,32]. The thermodynamic stability of yttria and the abrasive characteristic of ceria enhance the Xank wear resistance
of the YTCA insert. The variation of Xank wear with respect
to cutting speed is presented in Fig. 5. The Xank wear of the
ceramic cutting tools increases with cutting speed. As the
cutting speed increases, adhesive and abrasive wear increase
for two reasons: (i) the sliding distance of cutting tool
increases with increase in cutting speed for a given time and
(ii) the cutting temperature increases with increase in cutting
speed [11]. As the cutting speed increases the HIPed YCTA
exhibits lower Xank wear than the ZTA and SCWRA

Fig. 5. Flank wear vs. cutting speed of the ceramic inserts after 15 min of
machining.

6.5

5.5

5
100

150

200

250

300

Cutting speed (m/min)

Sintered YCTA

ZTA

HIPed YCTA

SCWRA

Fig. 6. Surface roughness (Ra) vs. cutting speed after machining for 15 min.

inserts. As in the case of other ceramic cutting tools the

Xank wear of YCTA ceramic cutting tool insert is also progressive and severe wear patterns are not observed during
machining grey cast iron in the given machining conditions.
The surface roughness largely depends upon the form stability of the cutting nose. An ideal tool in turning is one, which
replicates its nose well on the work surface [33]. Hence, the
surface quality of the turned work surfaces is largely dependent on the form stability of the cutting nose. Fig. 6 shows
the surface roughness (Ra) vs. cutting speed after machining
for 15 min using the ceramic cutting tool inserts. It can be
noted that HIPed YCTA produced lower surface roughness
than ZTA and SCWRA inserts. The HIPed YCTA ceramic
cutting tool insert exhibits better surface Wnish on the
machined work piece than ZTA and SCWRA inserts
because of the better form stability of the cutting nose.
4. Conclusion
YCTA insert has been developed using alumina, yttria
and ceria and its machining performance on grey cast iron is

A. Senthil Kumar et al. / International Journal of Refractory Metals & Hard Materials 25 (2007) 214219

evaluated. The sintered YCTA has slightly lower machining

performance than the ZTA and SCWRA inserts. The
mechanical properties of HIPed YCTA is equivalent to the
ZTA. The formation of YAG, YAM and YAP was
observed during XRD analysis. The machining performance
of HIPed YCTA insert is comparable to that of ZTA and
SCWRA inserts. In conclusion, the newly developed YCTA
composite material can be used for cutting tool applications.
References
[1] Sornakumar T. Advanced ceramicceramic composite tool materials
for metal cutting applications. Key Eng Mater 1996;114:17388.
[2] Kyongjun An, Kakkaveri Ravichandran S, Dutton Rollie E, Semiatin
SL. Microstructure, texture, and thermal conductivity of single-layer
and multilayer thermal barrier coatings of Y2O3-stabilized ZrO2 and
Al2O3 made by physical vapour deposition. J Am Ceram Soc 1999;
82(2):399406.
[3] Casellas Daniel, Feder Adrian, Llanes Luis, Anglada Marc. Fracture
toughness and mechanical strength of Y-TZP/PSZ ceramics. Scripta
Mater 2001;45:21320.
[4] Huh Young-Duk, Cho Young-Shik, Do Young Rag. The optical
properties of (Y1xGdx)3z(Al1yGay)5O12:Cez phosphors for white
LED. Bull Korean Chem Soc 2002;23(10):14358.
[5] Tseng TY, Lo JR. Phase development and activation energy of the
Y2O3Al2O3 system by a modiWed solgel process. Mater Chem Phys
1998;56(1):5662.
[6] Patankar SN, Zhang D, Adam G, Sam Froes FH. Processing of
yttriumaluminum garnets under non-equilibrium conditions. J Alloy
Compd 2003;353(12):3079.
[7] Wang Hongzhi, Gao Lian, Shen Zhijian, Nygren Mats. Mechanical
properties and microstructures of Al2O35 vol.% YAG composites. J
Eur Ceram Soc 2001;21(6):77983.
[8] Annamalai VE, Gokularathnam CV, Krishnamurthy R. On sintering
behaviour of 12% mol ceria stabilized zirconia. J Mat Sci Lett 1992;
11:6424.
[9] Piras Alessandro, Trovarelli Alessandro, Dolcetti Giuliano. Remarkable stabilization of transition alumina operated by ceria under reducing and redox conditions. Appl Catal B: Environ 2000;28(2): L7781.
[10] Senthil Kumar A, Rajadurai A, Sornakumar T. Development of aluminaceria ceramic composite cutting tool. Int J Refract Metals Hard
Mater 2004;22:1720.
[11] Bhattacharyya SK, Ezugwu EO, Jawaid A. The performance of ceramic
tool materials for the machining cast iron. Wear 1989;135: 14759.
[12] Kinsman KM, McKittrick J, Sluzky E, Hesse K. Phase development
and luminescence in chromium-doped yttrium aluminum garnet
(YAG:Cr) phosphors. J Am Ceram Soc 1994;77(11):286672.
[13] Ohno K, Abe T. EVect of BaF2 on the synthesis of the single-phase
cubic Y3Al5O12. J Electrochem Soc: Solid-State Sci Technol 1986;
133(3):63843.
[14] Garskaite Edita, Jasaitis Darius, Kareiva Aivaras. Solgel preparation and electrical behaviour of Ln:YAG (Ln D Ce, Nd, Ho, Er). J
Serb Chem Soc 2004;68(89):67784.

219

[15] Hoghooghi B, Healey L, Powell S, McKittrick J, Sluzky E, Hesse K.

Synthesis of YAG:Cr phosphors by precipitation from aluminum and
yttrium sulfate solutions. Mater Chem Phys 1994;38:17580.
[16] Sameshima Soichiro, Higashi Kenji, Hirata Yoshihiro. Sintering and
grain growth of rare-earth-doped ceria particles. J Ceram Process Res
2000;11:2733.
[17] Lalande J, Scheppokat S, Janssen R, Claussen N. Toughening of alumina/zirconia ceramic composites with silver particles. J Eur Ceram
Soc 2002;22(13):216571.
[18] Jeong YK, Niihara K. Microstructure and mechanical properties of
pressureless sintered Al2O3/SiC nanocomposites. Nano-struct Mater
1997;9(18):1936.
[19] Dutta Sunil. Fracture toughness and reliability in high-temperature
structural ceramics and composites: prospects and challenges for the
21st Century. Bull Mater Sci 2001;24(2):11720.
[20] Dieter GE. Mechanical metallurgy. Singapore: McGraw-Hill Book
Company (SI Metric Edition); 1988.
[21] Kim Hyoun-Ee, Moorhead AJ, Sang-Hak Ki. Strengthening of alumina by formation of a mullite/glass layer on the surface. J Am
Ceram Soc 1997;80(7):187780.
[22] Awaji Hideo, Choi Seong-Min, Yagi Eisuke. Mechanisms of toughening and strengthening in ceramic-based nanocomposites. Mech Mater
2002;34(7):41122.
[23] Bhattacharya Sandeepan, Jakus Karl. Hot pressing of annular
aluminazirconia composites. J Am Ceram Soc 1998;81(3):4604.
[24] Hwang HJ, Sekino T, Ota K, Niihara K. Perovskite-type BaTiO3
ceramics containing particulate SiC, Part I: structure variation and
phase transformation. J Mater Sci 1996;31:461724.
[25] Morrell R. Handbook of properties of technical and engineering
ceramics, Part 2: data reviews, Section I: high alumina ceramics. London: Her Majestys Stationery OYce; 1985.
[26] Morrell R. Handbook of properties of technical and engineering
ceramics, Part 2: data reviews, Section I: high alumina ceramics. London: Her Majestys Stationery OYce; 1987.
[27] Manning WR, Hunter Jr O, Powell Jr BR. Elastic properties of polycrystalline yttrium oxide, dysprosium oxide, holmium oxide, and
erbium oxide: room temperature measurements. J Am Ceram Soc
1969;52(8):43642.
[28] Yeheskel O, Tevet O. Elastic moduli of transparent yttria. J Am
Ceram Soc 1999;82(1):13644.
[29] Cao XQ, Vassen R, Stoever D. Ceramic materials for thermal barrier
coatings. J Eur Ceram Soc 2004;24(1):110.
[30] Ohji T, Jeong Y-K, Choa Y-H, Niihara K. Strengthening and toughening mechanisms of ceramic nanocomposites. J Am Ceram Soc 1998;
81(6):145360.
[31] Kalpakjian Serope, Schmid Steven R. Manufacturing engineering and
technology. New Delhi: Addison Wesley Longman Private Limited;
2000.
[32] Stachowiak Gwidon W, Stachowiak Grazyna B. Wear behaviour of
ceramic cutting tools. Key Eng Mater 1994;96:37164.
[33] Sornakumar T, Gopalakrishnan MV, Krishnamurthy R, Gokularathnam CV. Development of alumina and Ce-TTZ ceramicceramic
composite (ZTA) cutting tool. Int J Refract Metals Hard Mater 1995;
13(6):3758.