Effect of grain morphology and interface on the toughness of nacre-like aluminas

Ceramic composites that are both tough and strong are needed for extreme environments, ranging from aerospace and nuclear, to medical applications. Bioinspired ceramic composites tackle this challenge by mimicking tough natural structures. Nacre-like aluminas (NLAs) are ceramics processed using advanced colloidal techniques to obtain a microstructure resembling the brick-and-mortar structure of nacre. NLAs can achieve flexural strengths up to 600 MPa and fracture toughnesses ranging from 5 MPa.m^1/2 up to 16 MPa.m^1/2 after crack propagation. These high values mainly rely on deflection mechanisms; these can operate at temperatures up to 1200°C and under impact testing. The fracture properties have been found to be highly dependent on the mortar composition and processing technique used. However, we still don't know how far we can extend the structural properties of NLAs by changing their mortar strength and brick morphology. In this study, we combine mode I wedge splitting testing and in situ synchrotron X-ray microtomography of mixed-mode SENB fracture testing along with a kinked crack analytical formulation to study the microstructure-properties relationship in NLAs having two mortar compositions/morphologies. We compare the toughness values obtained in mode I and II with deflection models and study the effect of mode-mixity on the NLA toughness. Our findings show the grain morphology strongly influences the fracture behaviour, with the longer grain material showing longer stable crack deflection which could be further optimised going forwards. By contrast the mortar properties which provide deflection and local toughening mechanisms may be nearing their optimal strength.