Full metal-ceramic composite beads containing different amounts of niobium and alumina, particularly 100 vol% alumina, 100 vol% niobium, and 95/5 vol% niobium/alumina, were produced by the alginate gelation process. The suspension for bead fabrication contained sodium alginate as gelling agent and was added dropwise into a calcium chloride solution to trigger the consolidation process. After debinding in air, sintering of the composite beads was performed under inert atmosphere. Samples in green and sintered state were analyzed by digital light microscopy and scanning electron microscopy equipped with energy dispersive X-ray spectroscopy. Investigations by mercury intrusion porosimetry revealed that pure alumina beads featured smaller pores compared to composite beads, although the open porosities were comparable. The fracture strength was evaluated on single beads. Contrary to the pure alumina, the composite beads showed a clear plastic deformation. Pure niobium beads showed a ductile behavior with very large deformations. XRD analyses revealed the presence of calcium hexaluminate and beta-alumina as minor phases in the alumina beads, while the composite ones contained about 25 wt% of impurities. The impurities comprised NbO arising from the oxidation, and β-Nb2C, from the reaction with the residual sodium alginate.
Keywords: alginate gelation; computed tomography; metal-ceramic composites; niobium; refractory metals.