Alumina (Al₂O₃) and zirconia (ZrO₂) have good overall properties and thus are widely used oxide technical ceramics. The biggest drawback of Al₂O₃ is its low fracture toughness. In contrast, ZrO₂ is relatively tough, but is also much more expensive. In order to improve the alumina toughness, composite ceramics are being developed. Slip casting technology has economic advantages over the conventional hot isostatic pressure technology, but problems may arise when preparing stable highly-concentrated suspensions (slip) for filling the mold. The purpose of this study is to prepare aqueous suspensions using 70 wt. % α-Al₂O₃, with 0, 1, 5 and 10 wt. % of added t-ZrO₂. Suspensions were electrosterically stabilized using the ammonium salt of polymethylacrylic acid, an alkali-free anionic polyelectrolyte dispersant. Also, magnesium oxide in form of magnesium aluminate spinel (MgAl₂O₄) was used to inhibit the abnormal alumina grain growth during the sintering process. Minimum viscosities were used as stability estimators, where an increase in ZrO₂ content required adding more dispersant. After sintering, the Vickers indentation test was used to determine the hardness and the indentation fracture toughness from the measurement of the crack length. Also, the brittleness index (B_i, μm^−1/2) was calculated from values of Vickers hardness and the Vickers indentation fracture toughness. It was found that with increasing ZrO₂ content the fracture toughness increased, while the hardness as well as the brittleness index decreased. Zirconia loading reduces the crystallite sizes of alumina, as confirmed by the X-ray diffraction analysis. SEM/EDS analysis showed that ZrO₂ grains are distributed in the Al₂O₃ matrix, forming some agglomerates of ZrO₂ and some pores, with ZrO₂ having a smaller grain size than Al₂O₃.

In the present work, alumina (Al₂O₃) foam was prepared by the replica method where a polyurethane (PU) foam (30 pores per inch (ppi)) template was impregnated with a 60 wt.% Al₂O₃ suspension. Sintered Al₂O₃ foam was used as substrate for the deposition of sol-gel derived titania (TiO₂) film using dip coating. For the preparation of TiO₂ sol, titanium(IV) isopropoxide (Ti-iPrOH) was used as the precursor. The common problem of qualification and quantification of a crystalline coating on a highly porous 3D substrate with an uneven surface was addressed using a combination of different structural characterization methods. Using Powder X-ray Diffraction (PXRD) and synchrotron Grazing Incidence X-ray Diffraction (GIXRD) on bulk and powdered Al₂O₃ foam and TiO₂-coated Al₂O₃ foam samples, it was determined Al₂O₃ foam crystallizes to corundum and coating to anatase, which was also confirmed by Fourier Transformed Infrared Spectroscopy (FTIR). Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM/EDS) revealed the structural and microstructural properties of the substrate and coating. Differential Thermal Analysis (DTA) and Thermogravimetric Analysis (TGA) were used to clarify the evolution of the porous microstructure. The Al₂O₃-TiO₂ composite was evaluated as a photocatalyst candidate for the degradation of the micropollutant medication memantine. The degradation rate was monitored using a light-emitting diode (LED) lamp operating at electromagnetic (EM) wavelength of 365 nm. The photocatalytic activity of sol-gel-derived TiO₂ film immobilized on the Al₂O₃ foam was compared with commercially available TiO₂ nanoparticles, P25-Degussa, in the form of a suspension. The levels of memantine were monitored by High-Performance Liquid Chromatography–Tandem Mass Spectrometry (HPLC–MS/MS). The efficiency and rate of the memantine photodegradation by suspended TiO₂ nanoparticles is higher than the TiO₂-coated Al₂O₃ foam. But, from the practical point of view, TiO₂-coated Al₂O₃ foam is more appropriate as a valuable photocatalytic composite material.

In this work, alumina (Al₂O₃) ceramics were prepared using an environmentally friendly slip casting method. To this end, highly concentrated (70 wt.%) aqueous suspensions of alumina (Al₂O₃) were prepared with different amounts of the ammonium salt of a polycarboxylic acid, Dolapix CE 64, as an electrosteric dispersant. The stability of highly concentrated Al₂O₃ aqueous suspensions was monitored by viscosity measurements. Green bodies (ceramics before sintering) were obtained by pouring the stable Al₂O₃ aqueous suspensions into dry porous plaster molds. The obtained Al₂O₃ ceramic green bodies were sintered in the electric furnace. Analysis of the effect of three sintering parameters (sintering temperature, heating rate and holding time) on the density of alumina ceramics was performed using the response surface methodology (RSM), based on experimental data obtained according to Box–Behnken experimental design, using the software Design-Expert. From the statistical analysis, linear and nonlinear models with added first-order interaction were developed for prediction and optimization of density-dependent variables: sintering temperature, heating rate and holding time.

Choosing the appropriate cutting tool material is essential for enhancing machining processes because it directly affects product quality, surface finish, dimensional accuracy, tool longevity, and overall efficiency. Different materials are used for cutting tools, i.e., for cutting inserts. Due to their high hardness and high temperature resistance, ceramics cutting inserts allow for increased cutting speeds, resulting in shorter manufacturing times and reduced costs, despite being pricier than traditional cemented carbide and facing certain technical challenges due to their brittleness. Alumina-based ceramics dominate the market, accounting for about two-thirds of usage, followed by silicon nitride and zirconia. This paper provides a comprehensive overview of recent advances in alumina ceramic materials used as cutting inserts, focusing on research conducted in the last five years to optimize static and dynamic mechanical and thermal properties, wear resistance, density, etc. They ways in which the properties are altered through the incorporation of whiskers, nanoparticles, or nanotubes; the modification of the structure; the optimization of sintering parameters; and the application of advanced sintering techniques are demonstrated. The paper also addresses sustainability, environmental impact, and the management of critical raw materials associated with cutting inserts, which pertains to the future development of cutting insert materials.