Oxidation Behavior of Liquid-Phase Sintered Silicon Carbide with Aluminum Nitride and Rare-Earth Oxides (Re2O3, where Re = Y, Er, Yb)

Silicon carbide (SiC) ceramics have been fabricated by hot-pressing and subsequent annealing under pressure with aluminum nitride (AlN) and rare-earth oxides (Y₂O₃, Er₂O₃, and Yb₂O₃) as sintering additives. The oxidation behavior of the SiC ceramics in air was characterized and compared with that of the SiC ceramics with yttrium–aluminum–garnet (YAG) and Al₂O₃–Y₂O₃–CaO (AYC). All SiC ceramics investigated herein showed a parabolic weight gain with oxidation time at 1400°C. The SiC ceramics sintered with AlN and rare-earth oxides showed superior oxidation resistance to those with YAG and Al₂O₃–Y₂O₃–CaO. SiC ceramics with AlN and Yb₂O₃ showed the best oxidation resistance of 0.4748 mg/cm² after oxidation at 1400°C for 192 h. The minimization of aluminum in the sintering additives was postulated as the prime factor contributing to the superior oxidation resistance of the resulting ceramics. A small cationic radius of rare-earth oxides, dissolution of nitrogen to the intergranular glassy film, and formation of disilicate crystalline phase as an oxidation product could also contribute to the superior oxidation resistance.     

High-Temperature Fatigue Strength of Crack-Healed Al2O3 Toughened by SiC Whiskers

Al₂O₃ reinforced by SiC whiskers (Al₂O₃/SiC-W) was hot-pressed to investigate the fatigue strength of crack-healed specimens at high temperature. Semielliptical surface cracks of 100 μm surface length were introduced on each specimen surface. These specimens were crack-healed at 1300°C for 1 h in air, and static and cyclic fatigue strengths were systematically investigated at room temperature, 900° and 1100°C by three-point bending. The static and cyclic fatigue limits of the crack-healed specimens were more than 70% of the average bending strength at each testing temperature. Crack-healed specimens of Al₂O₃/SiC-W were not sensitive to static and cyclic fatigue at room temperature and high temperatures. Therefore, the combination of crack-healing and whisker reinforcement can play an important role in increasing static and cyclic fatigue strengths at high temperature.     

Strength Retention in Hot-Pressed Si3N4 Ceramics with Lu2O3 Additives after Oxidation Exposure in Air at 1500°C

The effect of oxidation exposure on room-temperature flexural strength was examined in 3.33- and 12.51-wt%-Lu₂O₃-containing hot-pressed Si₃N₄ ceramics exposed to air at 1500°C for up to 1000 h. After oxidation exposure, the room-temperature strength of the ceramics was degraded, and strength retention decreased with time at temperature, dependent on the amount of additive. The retention in room-temperature strength displayed by the two compositions after 1000 h of oxidation exposure was 75%–80%. The degradation in strength was attributed to the formation of new defects at and/or near the interface between the oxide layer and the Si₃N₄ bulk during oxidation exposure.     

Superplasticity of Liquid-Phase-Sintered β-SiC with Al2O3–Y2O3–AlN Additions in an N2 Atmosphere

Compression and tension tests were performed on liquid-phase-sintered β-SiC fabricated by hot-pressing, using ultrafine powders, at 1973–2048 K in an N₂ atmosphere. Amorphous phases were observed at the grain boundaries and at multigrain junctions in the as-sintered material. Strain hardening was observed under all experimental conditions. Stress exponents in the compression test were 1.7–2.1 in the temperature range 1973–2023 K. A maximum tensile elongation of 170% was achieved at the initial strain rate of 2 × 10⁻⁵ s⁻¹ at 2048 K.     

Elastic Properties of Al2O3 and Si3N4 Matrix Composites with SiC Whisker Reinforcement

A study of the elastic moduli of Al₂O₃ and Si₃N₄ ceramics reinforced with 0 to 25 wt% SiC whiskers has been performed. The Young's moduli, shear moduli, and longitudinal modulus are compared with calculated predictions for aligned fiber composites by Hill and Hashin and Rosen, and for fibers randomly oriented in three dimensions by Christensen and Waal. The measured values are in excellent quantitative agreement with those derived for the random orientation of the SiC whiskers.     

Si3N4/SiC-Whisker Composites without Sintering Aids: III, High-Temperature Behavior

The fracture behavior at high temperature of a Si₃N₄-based SiC-whisker composite fabricated by hot isostatic pressing without sintering aids is compared with that of other highly refractory materials. Particular attention is directed toward evaluating the slow-crack-growth resistance of the composite up to 1440°C and relating this resistance to the microfracture behavior of Si₃N₄ grains, SiC whiskers, and the intergranular, glassy SiO₂ phase. Only thick whiskers operate to bridge the wake of the crack; these whiskers may make a positive contribution to the slow-crack-growth resistance. Impurities detected by EDX microanalysis at the grain boundary, however, apparently degrade the high-temperature properties, a finding supported by internal-friction measurements. Nevertheless, the high potential of the system without sintering aids for high-temperature structural applications has been demonstrated by the time to failure estimated from the measured slow-crack-growth resistance for a fixed flaw size.     

Evidence for Bulk Residual Stress Strengthening in Al2O3/SiC Nanocomposites

The fracture behavior of Al₂O₃/SiC nanocomposites has been studied as a function of the SiC volume fraction and compared to that of the pure Al₂O₃ matrix. A pronounced strengthening effect was only observed for materials with low SiC content (i.e., ≤10 vol%) although no evidence of concurrent toughening was found. Assessment of near-tip crack opening displacement (COD) could not experimentally substantiate significant occurrence of an elastic crack-bridging mechanism, in contrast with a recently proposed literature model. Quantitative fractography analysis indicated that transgranular crack propagation in Al₂O₃/SiC nanocomposites depends on the location of the SiC dispersoids within the matrix texture; the higher the fraction of transgranularly located dispersoids, the more transgranular the fracture mode. Experimental evidence of remarkably high residual stresses arising from thermal dilatation mismatch (upon cooling) between Al₂O₃ and SiC phases were obtained by fluorescence and Raman spectroscopy. A strengthening mechanism is invoked which merely arises from residual stress through strengthening of Al₂O₃ grain boundaries.     

Effect of Dynamic Microstructural Change on Deformation Behavior in Liquid-Phase-Sintered Silicon Carbide with Al2O3–Y2O3–CaO Additions

Nanocrystalline β-SiC with additions of 7 wt% Al₂O₃, 2 wt% Y₂O₃, and 1 wt% CaO was subjected to tensile deformation to study its microstructural behavior under the dynamic process. The liquid-phase-sintered body had a relative density of >97% and an average grain size of 170 nm. Tension tests were conducted at initial strain rates ranging from 2 × 10⁻⁵ to 5 × 10⁻⁴ s⁻¹, in the temperature range 1973–2023 K, in both argon and N₂ atmospheres. Although grain-boundary liquids formed by the additions vaporized concurrently with the decomposition of SiC and extensive grain growth, the maximum tensile elongation of 48% was achieved in argon. Annealing experiments under the same conditions revealed that vaporization and grain growth were both dependent on experimental time. Therefore, high strain rates suffered less from the hardening effect when cavitation damage was more severe. Testing in an N₂ atmosphere brought about crystallization of the grain-boundary phase and prevented severe vaporization; however, fracture occurred at only 8% elongation. Grain-boundary sliding was still the dominant mechanism for deformation.     

High-Temperature Neutron Diffraction of the AlN–Al2O3–Y2O3 System

The importance of aluminum nitride (AlN) stems from its application in microelectronics as a substrate material due to high thermal conductivity, high electrical resistance, mechanical strength and hardness, thermal durability, and chemical stability. Yttria (Y₂O₃) is the best additive for AlN sintering. AlN densifies by a liquid-phase mechanism, where the surface oxide, Al₂O₃, reacts with Y₂O₃ to form an Y-Al-O-N liquid that promotes particle rearrangement and densification. Construction of the phase relations in this multicomponent system is essential for optimizing the properties of AlN. The ternary phase diagram of the AlN–Al₂O₃–Y₂O₃ was developed by Gibbs energy minimization using interpolation procedures based on modeling the binary subsystems. This paper aims at testing the resultant understanding experimentally at selected compositions using in situ high-temperature neutron diffractometry. These experimental results agree with the thermodynamic calculations of AlN–Al₂O₃–Y₂O₃. The ternary phase diagram has been constructed for the first time in this work. High-temperature neutron diffractometry has permitted real time measurement of the reactions involved in this ternary system, especially to determine the temperature range for each reaction, which would have been difficult to establish by other means.     

Compressive Creep of SiC-Whisker-Reinforced Al2O3

Compressive creep of SiC-whisker-reinforced Al₂O₃ composites (0, 5, 15, and 25 wt% SiC) was measured in the temperature range of 1300° to 1500°C in air and argon. The creep resistance increased with increasing whisker concentration. The results indicated that the whiskers degraded in air, increasing strain rates compared to those in argon. Stress exponents between 1.0 and 2.0 and an activation energy of 620 ± 100 kJ/mol were measured. Transmission electron microscopy observations indicated that cavitation was minimal and that the deformed composites had the same dislocation structure as did the as-received samples.     

Mechanical Property and Oxidation Behavior of Self-Reinforced Si3N4 Doped with Re2O3 (Re=Yb, Lu)

In this work, self-reinforced silicon nitrides with β-Si₃N₄ seeds doped with Re₂O₃ (Re=Yb, Lu) were investigated. Firstly, the two kinds of seeds were obtained by heating α-Si₃N₄ powder with Yb₂O₃ or Lu₂O₃, respectively. Then the self-reinforced silicon nitride ceramics were prepared by HP-sintering of α-Si₃N₄ powder, Re₂O₃ as additive, and the as-prepared seeds. Oxidation test was carried out at 1400°C in air for 100 h with thermogravimetry analysis (TGA) measurement. Mechanical properties, scanning electronic microscopy microstructures, and X-ray diffraction patterns were measured before and after oxidation. The results indicated that the introduction of the seeds doped with Re₂O₃ (Re=Yb, Lu) could obviously increase the toughness and keep the room temperature and high-temperature strength of the ceramics at high values. After oxidation, the crystalline phase in grain boundary changed and the mechanical properties decreased. TGA showed a parabolic weight gain and the oxidation mechanism was discussed.     

Micromechanical Stresses in SiC-Reinforced Al2O3 Composites

Applying an Eshelby approach, the internal micromechanical stresses within an SiC-inclusion-reinforced (platelet to whisker geometries) polycrystalline alumina matrix composite were calculated. The results are compared to the experimental residual stress measurements of a SiC-whisker-reinforced Al₂O₃ by Predecki, Abuhasan, and Barrett and found to be in excellent agreement. The calculations are then extended to SiC-reinforced composites with polycrystalline mullite, silicon nitride, and cordierite matrices. It is concluded that the internal stresses are significantly influenced by the inclusion geometry as well as the thermoelastic differences between the inclusion and the matrix and also the volume fraction.     

High-Temperature Mechanical Properties of SiC–Mo5(Si,Al)3C Composites

SiC–Mo₅(Si,Al)₃C composites were fabricated by the melt infiltration process, and the infiltration characteristics were studied in detail. Fracture strength and toughness were measured up to 1600°C using a three-point bending test and indentation strength method, respectively. Both fracture strength and toughness significantly increased at 1400°C with respect to the values at room temperature. These increases were mainly attributed to plastic deformation of the infiltrated Mo₅(Si,Al)₃C phases at elevated temperatures, which acted as ductile toughening inclusions. Compressive creep tests were used to study the creep behavior of the composite in the range of 1550°–1650°C and 150–200 MPa. The stress exponent and activation energy were 1.3 and 277 kJ/mol, respectively. Preliminary oxidation tests showed that the composites exhibited good oxidation resistance at 1500°C because of the formation of a dense oxide scale.     

Densification of Si3N4 with LiYO2 Additive

This paper deals with the densification and phase transformation during pressureless sintering of Si₃N₄ with LiYO₂ as the sintering additive. The dilatometric shrinkage data show that the first Li₂O- rich liquid forms as low as 1250°C, resulting in a significant reduction of sintering temperature. On sintering at 1500°C the bulk density increases to more than 90% of the theoretical density with only minor phase transformation from α-Si₃N₄ to β-Si₃N₄ taking place. At 1600°C the secondary phase has been completely converted into a glassy phase and total conversion of α-Si₃N₄ to β-Si₃N₄ takes place. The grain growth is anisotropic, leading to a microstructure which has potential for enhanced fracture toughness. Li₂O evaporates during sintering. Thus, the liquid phase is transient and the final material might have promising mechanical properties as well as promising high-temperature properties despite the low sintering temperature. The results show that the Li₂O−Y₂O₃ system can provide very effective low-temperature sintering additives for silicon nitride.     

Analysis of Residual Stress in 6H-SiC Particles within Al2O3/SiC Composites through Raman Spectroscopy

We measured the Raman spectrum associated with the E₂-TO_quasi and LO_quasi modes of 6H-SiC particles as a function of hydrostatic pressure using a diamond anvil cell. The results of this calibration experiment were used to analyze the residual stress in 6H-SiC particles within Al₂O₃/SiC composites with 12%, 20%, and 30% SiC by volume. The Raman spectra show that residual stress in the SiC near the surface of the composites is −2040 ± 120, −1841 ± 110, and −1615 ± 100 MPa for the 12%, 20%, and 30% SiC composites, respectively. The measured decrease in stress with increasing packing fraction is consistent with theoretical predictions based on micromechanics.     

Effects of Temperature and Whisker Volume Fraction on Average Residual Thermal Strains in a SiC/Al2O3 Composite

Residual thermal strains in a SiC-whisker-reinforced/Al₂O₃-matrix composite were measured as functions of temperature and volume fraction of whiskers by means of a neutron diffraction technique. The residual strains in both phases decrease with increasing temperature. At room temperature, the residual strains in the whiskers decrease with increasing whisker volume fraction, but the tensile residual strains in the matrix increase. The results agree well with those predicted by an analytical method.     

Effects of (B2O3, P2O5) Additives on Microstructural Development and Phase-Transformation Kinetics of Stoichiometric Cordierite Glasses

The microstructural development and phase-transformation kinetics of stoichiometric cordierite glasses containing B₂O₃ and/or P₂O₅ additives were highly affected by the microstructural characteristics of the μ-cordierite and the type of additives. The addition of B₂O₃ tended to cause the formation of μ-spherulitic dendrites with thin dendritic arms, which promoted the formation of α-cordierite, either from crystallization of the residual glass or from transformation of μ-cordierite. P₂O₅ had the opposite effect: Increasing the temperature increased the growth rate of α-cordierite more than that of μ-cordierite.     

Grain-Size Distribution in Al2O3─ZrO2 Generated by High-Temperature Annealing

Grain-size distribution in various Al₂O₃─ZrO₂ (2.5 mol% Y₂O₃) ceramics during high-temperature annealing was examined. In alumina-rich alloys, the grain size of major and minor phases was very different, while grain size was almost uniform in zirconia-rich alloys. This difference in grainsize distribution was related to the difference in grain growth rate of the major phase and to the effectiveness of grain-boundary pinning by minor-phase grains.     

Effects of Y2O3 and ZrO2 on the Densification of Si3N4-Zr(Y)O2 Composites

The effects of ZrO₂ and Y₂O₃ on the densification of hotpressed Si₃N₄-Zr(Y)O₂ composites have been studied. High density could not be obtained by the addition of pure or 3-mol%-Y₂O₃-doped ZrO₂ in this composite; however, nearly full density (>97%) could be obtained in Si₃N₄ using 6- and 8-mol%-Y₂O₃-doped ZrO₂. It is concluded that Y₂O₃ diffusing out from the added Zr(Y)O₂ promoted the densification and that ZrO₂ also had some role in the formation of an oxynitride glass.