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Fabrication of Dense -SiAlON Ceramics with ZrO2 Additions Via a Rapid Reaction-Bonding and Postsintering Route

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Rapid nitridation was used to fabricate reaction-bonded and postsintered -Si6−ZAlZOZN8−Z (Z=1) ceramics with monoclinic ZrO2 added to the starting powder. Thermo-gravimetric analysis revealed that the addition of ZrO2 reduced the starting temperature of the main nitridation reaction. Using a reaction-bonding route with heating rates of 5°, 10°, and 20°C/min, to fabricate -SiAlON ceramics without ZrO2 resulted in unreacted silicon that bled out of the specimens and the Z=1 composition samples did not maintain the original green compact morphology. On the other hand, no such bleeding of melted silicon was observed for samples with ZrO2 additions and the samples following nitridation maintained the original green morphology. The microstructure and mechanical properties of samples produced by rapid reaction bonding and postsintering were comparable to those of samples produced by a conventional reaction-bonding and postsintering route.
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Document Type: Research Article

Affiliations: National Institute of Advanced Industrial Science and Technology (AIST), 2266-98 Shimo-shidami, Moriyama-ku, Nagoya, Aichi 463-8560, Japan

Publication date: 2011-04-01

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