Transmission electron microscopy study of zirconia-alumina nanolaminates grown by reactive sputter deposition. Part I: zirconia nanocrystallite growth morphology

Pure zirconia films and zirconia-alumina nanolaminate films grown by reactive sputter deposition are studied by high resolution transmission electron microscopy (HRTEM) and electron energy loss spectroscopy (EELS). The phase composition and morphology associated with zirconia crystallite growth are investigated by examining films containing zirconia layers of varying thickness. These studies, performed at room temperature, suggest that the zirconia crystallites initially grow in the tetragonal phase to a critical size of 6.0 +/- 0.2 nm, in agreement with a value of 6.2 nm predicted by end-point thermodynamics. Past the critical size, incorporation of additional zirconia molecules into the zirconia layers is accomplished predominantly by transformation of the growing crystallites to the monoclinic phase, and less frequently by deposition of amorphous zirconia. Transformation to the monoclinic phase is accompanied by a highly faulted intermediary phase. The subsequent growth behavior of monoclinic crystallites is consistent with a three-dimensional intrface-controlled, diffusion-limited growth process with a growth exponent between 3 and 4. Nanoindentation measurements of nanolaminates with 5-nm thick zirconia lavers give a hardness of similar to 8 GPa for the upper strata where the morphology of the tetragonal zirconia layers contains an intrinsic roughness. The hardness increases to similar to 10 GPa closer to the substrate where the laminar morphology is more pronounced, Young's modulus is between 156 and 195 GPa for these same nanolaminates. (C) 1998 Elsevier Science S.A. All rights reserved.