Fabrication of Functionally Graded SiAlON Ceramics by Tape Casting

Functionally graded SiAlON ceramics (FG-SiAlONs) were successfully prepared by the tape casting and lamination approach. Non-aqueous SiAlON slurries with five different α to β-SiAlON ratios (85α:15β, 70α:30β, 55α:45β, 40α:60β, and 25α:75β) were prepared by a 66 methyl ethyl ketone/34 ethanol (vol%) mixture. Phase and microstructure analyses incorporation with hardness measurements clearly show that the FG-SiAlONs, prepared by tape casting, exhibit a continuous and gradual change in composition and hardness. Thus, the tape casting approach is a viable method to produce FG-SiAlONs with a precisely controlled composition, and subsequently properties, as a function of position.