Spark Plasma Sintered Zirconia Ceramic Composites with Graphene-Based Nanostructures

The addition of graphene-based nanostructures (GBNs) can improve the inherent fragility of ceramics and provide them with improved electrical and thermal conductivities. However, both the starting material (ceramic matrix and GBNs) and the processing/sintering approach are crucial for the final composite microstructure and properties. This work focuses on the influence of the content and dimensions of the GBN filler (10 and 20 vol%; 3 and ~150 layers), the powder-processing conditions (dry versus wet), and the homogenization method (ultrasound sonication versus high-energy planetary ball milling) on GBN/tetragonal zirconia (3YTZP) composites. The microstructure and electrical properties of the spark plasma sintered (SPS) composites were quantified and analyzed. The highest microstructural homogeneity with an isotropic microstructure was achieved by composites prepared with thicker GBNs milled in dry conditions. A high content (20 vol%) of few-layered graphene as a filler maximizes the electrical conductivity of the composites, although it hinders their densification.