Various supraparticles have been extensively studied owing to their excellent catalytic properties that are attributed to their inherent porous structure; however, their mechanical properties have not garnered attention owing to their less dense structure. We demonstrate a rational approach for fabricating assembled supraparticles and, subsequently, highly dense microspheres. In addition, 3 mol % yttria-stabilized zirconia (3YSZ) and alumina particles were selected as building blocks and assembled into higher-order architectures using a droplet-based template method (spray drying) for validation with proof-of-concept. Moreover, structural features such as density, size, sphericity, and morphology of supraparticles were controlled by adjusting the competing kinetics occurring between the assembly of building blocks and evaporation of the solvent in the droplets. The preparatory aqueous suspension and process parameters were optimized as well. A detailed understanding of the formation mechanism facilitated the yield of tailor-made supraparticles and, thereafter, highly dense microspheres (approximate relative density = 99%) with excellent sphericity (>98%) via heat treatment. The microspheres displayed highest hardness (26.77 GPa) and superior elastic modulus (210.19 GPa) compared with the mechanical properties of the 3YSZ samples reported to date. Ultimately, the proposed supraparticle engineering provided insight for controlling the structural features and resultant micromechanical properties, which widely extends the applicability of supraparticle-based functional materials for practical purposes that require materials with high density and excellent mechanical properties.
Keywords: 3YSZ; assembly; building block; mechanical properties; microsphere; spray drying; supraparticle.