Controlling the preparation process is essential to ensure the quality of the ceramics. Previous research on the ceramic process concentrated on a certain part of powder synthesis, forming, or sintering. Herein, we propose a novel process, foam precursor–derived Al2O3 ceramics, to realize particle rearrangement, assembly, and sintering and find that this method has a marvelous influence on the microstructure and mechanical properties. Alumina foams prepared by the particle‐stabilized foam method are used as ceramic precursors, and after pre‐sintering, crash, and hot pressing, foam precursor–derived Al2O3 ceramics can be obtained. It has fine grains (1/5 of the traditional process) and uniform grain size without any additional sintering aid, realized by the high grain growth exponent of foams. Ultrahigh dislocation density (∼1010 mm−2) is discovered in (0 0 0 1) plane of foam precursor–derived ceramics, comparable to the dislocation density of high‐entropy ceramics. Besides, transgranular fracture mode is observed in the ceramics prepared by the new method rather than the intergranular fracture in the control group, and the comprehensive mechanical properties are promoted accordingly. The unusual microstructure and fracture mode caused by the foam precursor process reveal the influence of the microstructure such as dislocation and grain boundary on the fracture behavior of ceramics, which is less considered in conventional research. This preparation process may be applied in the preparation of other high‐performance ceramics.

中文翻译：

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泡沫结构衍生的强韧氧化铝陶瓷，具有细晶粒和穿晶断裂特性

控制制备过程对于保证陶瓷的质量至关重要。以往对陶瓷工艺的研究主要集中在粉末合成、成型或烧结的某一环节。在此，我们提出了一种新工艺，泡沫前体衍生的铝2氧3陶瓷，实现颗粒重排、组装和烧结，并发现该方法对微观结构和力学性能有着巨大的影响。采用颗粒稳定泡沫法制备的氧化铝泡沫作为陶瓷前驱体，经过预烧、破碎、热压，得到泡沫前驱体Al2氧3可以获得陶瓷。它具有细晶粒（传统工艺的1/5）和均匀的晶粒尺寸，无需任何额外的烧结助剂，这是通过泡沫的高晶粒生长指数实现的。超高位错密度（∼1010毫米−2）在泡沫前体衍生陶瓷的（0 0 0 1）平面中被发现，与高熵陶瓷的位错密度相当。此外，新方法制备的陶瓷观察到穿晶断裂模式，而不是对照组的沿晶断裂，综合力学性能相应提高。泡沫前驱体过程引起的异常微观结构和断裂模式揭示了位错和晶界等微观结构对陶瓷断裂行为的影响，这在常规研究中较少考虑。该制备工艺可应用于其他高性能陶瓷的制备。