Carbon Additions to Molybdenum Disilicide: Improved High-Temperature Mechanical Properties

C addition (2 wt%) to MoSi₂ acted as a deoxidant, removing the otherwise ubiquitous siliceous grain boundary phase in hot-pressed samples, and causing formation of SiC and Mo₅Si₃C₁ (a variable-composition Nowotny phase). Both hardness and fracture toughness of the C-containing alloy were higher than those of the C-free (and oxygen-rich) material; more significantly, the fracture toughness of the MoSi₂+ 2% C alloy increased from 5.5 MPa·m^1/2 at 800°C to ∼11.5 MPa·m^1/2 at 1400°C.     

Mechanical Properties of La1-xSrxCo0.2Fe0.8O3 Mixed-Conducting Perovskites Made by the Combustion Synthesis Technique

This paper examined the room-temperature mechanical properties of a mixed-conducting perovskite La_{1– x} Sr _x Co_0.2Fe_0.8O₃ ( x = 0.2–0.8). Powders were made by the combustion synthesis technique and sintered at 1250°C in air. Sintered density, crystal phase, and grain size were characterized. Young's and shear moduli, microhardness, indentation fracture toughness, and biaxial flexure strength were determined. The Young's and shear moduli slightly increased with increasing strontium content. Young's modulus of 151–188 GPa and shear modulus of 57–75 GPa were measured. Biaxial flexure strength of ∼160 MPa was measured for lower strontium content batches. Strength greatly decreased to ∼40 MPa at higher strontium concentrations ( x = 0.6–0.8) because of the formation of extensive cracking. Indentation toughness showed a higher value (∼1.5 MPa·m^1/2) for low strontium ( x = 0.2) content and a lower value (∼1.1 MPa·m^1/2) for the other batches ( x = 0.4–0.8). Materials with fine and coarse grain size were also tested at various indent loads and showed no dependence of toughness on crack size. In addition, fractography was used to characterize the critical flaw and fracture mode.     

Heat-Resistant Silicon Carbide with Aluminum Nitride and Erbium Oxide

Fully dense SiC ceramics with high strength at high temperature were obtained by hot-pressing and subsequent annealing under pressure, with AlN and Er₂O₃ as sintering additives. The ceramics had a self-reinforced microstructure consisting of elongated SiC grains and a grain-boundary glassy phase. The strength of these ceramics was ∼550 MPa at 1600°C, and the fracture toughness was ∼6 MPa·m^1/2 at room temperature. The beneficial effect of the new additive composition on high-temperature strength might be attributable to the introduction of aluminum from the liquid composition into the SiC lattice, resulting in a refractive grain-boundary glassy phase.     

Fabrication of New Cemented Carbide Containing Diamond Coated with Nanometer-Sized SiC Particles

A simple process for depositing a coating of silicon carbide (SiC) crystallites ∼10 nm in size onto diamond particles has been developed. SiO powders react with diamond in a vacuum at 1350°C to form a uniform β-SiC polycrystalline layer ∼60 nm thick. The SiC coating improves the oxidation resistance of the diamond. A cemented carbide material containing 20-vol%-SiC-coated diamond particles was sintered to a relative density of 99.5% by pulsed-electric-current sintering. A Vickers hardness and indentation fracture toughness of 15 GPa and 16.3 MPa·m^1/2, respectively, were obtained. This toughness is two times higher than that of cemented carbide containing no particles. The higher toughness is attributed to deflection and blockage of crack propagation by the diamond particles.     

Reactive Hot Pressing and Properties of Nb2AlC

Dense Nb₂AlC ceramic was synthesized from NbC, Nb, and Al powder mixture at 1650°C and a pressure of 30 MPa for 90 min using an in situ reaction/hot-pressing method. The reaction kinetics, microstructure, physical, and mechanical properties of the fabricated material were investigated. A thermal expansion coefficient of ∼8.1 × 10⁻⁶ K⁻¹ was measured in the temperature range of 30°–1050°C. At room temperature a thermal conductivity of ∼20 W·(m·K)⁻¹ and a Vickers hardness of ∼4.5 GPa were determined. The material attained Young's modulus, four-point bending strength and fracture toughness of ∼294 GPa, ∼443 MPa, and ∼5.9 MPa·m^1/2, respectively. The nanolayered grains with a mean grain size of 17 μm contributed to the damage tolerance of this ceramic. Quenching from 600°, 800°, and 1000°C into water at room temperature resulted in decrease in bending strength from 443 MPa for the as-synthesized Nb₂AlC to 391, 156, and 149 MPa, respectively.     

Effect of Heating Schedule on the Microstructure and Fracture Toughness of α-SiAlON—Cause and Solution

The effect of heating schedule on microstructure and fracture resistance has been investigated in single-phase Nd-, Y-, and Yb-α-SiAlON. Such effect is strongly system dependent, reflecting the strong influence of phase stability on α-SiAON nucleation and the amount of transient/residual liquid during processing. The addition of 1% of α-SiAlON seeds to the starting powders nearly completely obliterates such effect, while it simultaneously improves microstructure homogeneity and fracture resistance. SENB toughness of 7 MPa·m^1/2 and peak R -curve toughness of ∼11 MPa·m^1/2 have been obtained for seeded Y-α-SiAlON ceramics using heating rates from 1°C/min to 25°C/min.     

Mechanical Properties and Failure Analysis of Alumina-Glass Dental Composites

Strength measurements and fractography were used to investigate the failure of alumina-glass dental composites containing 75 vol% alumina and 25 vol% glass. Alumina compacts were prepared by slip casting and sintering at 1100°C for 2 h. Dense composites were made by infiltrating partially sintered alumina with glass at 1150°C for 8 h. Young's modulus and the hardness of the composites were 270 GPa and 12 GPa, respectively. The mean strength (460 MPa) and fracture toughness (4.0 MPa·m^1/2) of the composites were insensitive to the glass thermal expansion coefficient (α_glass= 5.9 × 10⁻⁶ to 7.8 × 10⁻⁶°C⁻¹). Typical flaws were pores and cracklike voids formed by poor particle packing and differential sintering near agglomerates of alumina in the composite. Crack deflection and crack bridging were observed in indentation cracks. Fracture toughness was single-valued because the alumina particle size was small (∼3 μm). Alumina-glass composites are promising new ceramics for dental crown and bridge applications, because their strength and fracture toughness are ∼2 times greater than those of current dental ceramics.     

Tetragonal Zirconia Polycrystals Reinforced with SiC Whiskers

The microstructure and the mechanical properties of hot-pressed tetragonal ZrO₂ polycrystals (TZP) reinforced with up to 30 vol% SiC whiskers were studied. The SiC whisker-TZP composites were stable under the hot-pressing conditions at 1450°C. Annealing in an oxidizing atmosphere at ∼1000°C resulted in glass formation and microcracking caused by whisker oxidation and transformation of the ZrO₂ grains near the whiskers to monoclinic symmetry. The fracture toughness was markedly improved by the dispersed whiskers (∼12 Mpa·m^1/2 at 30 vol% SiC) compared to the values measured for the matrix (∼6 Mpa·m^1/2). The flexural strength of the hot-pressed TZP-30 vol% SiC whisker composite at 1000°C (∼400 MPa) was twice that of the TZP matrix.     

Hot Isostatic Pressing of Chromium Nitrides (Cr2N and CrN) Prepared by Self-Propagating High-Temperature Synthesis

Cr₂N, CrN, and their mixtures (with desired fractions) have been prepared via self-propagating high-temperature synthesis (SHS) under a controlled nitrogen pressure, followed by hot isostatic pressing at 1300°C and 196 MPa under an atmosphere of argon gas. The combustion temperature increased as the nitrogen pressure increased. Single-phase Cr₂N was formed at 1040°C under a pressure of 0.18 MPa, and single-phase CrN was formed at 1730°C under a pressure of 2 MPa. The mechanical properties of the dense nitride ceramics (99.2% of the theoretical density) have been examined; the Vickers hardness (11.2 GPa for CrN and 14.5 GPa for Cr₂N) increased linearly as the fraction of Cr₂N increased, whereas the fracture toughness (∼4.7 MPa·m^1/2) and bending strength (∼355 MPa) are constant, regardless of the fraction of Cr₂N/CrN.     

Improvements in Mechanical Properties in SiC by the Addition of TiC Particles

Silicon carbide ceramics containing up to 24.6 vol% dispersed TiC particles yielded fully dense composites by hot-pressing at 2000°C with 1 wt% Al and 1 wt% C added. The micro-structure consists of fine TiC particles in a fine-grained SiC matrix. Addition of TiC particles increases the critical fracture toughness of SiC (to ∼6 MPa·m^1/2 at 24.6 vol% TiC) and yields high flexure strength (≥680 MPa), with both properties increasing with increasing volume fraction of TiC. The strengths at high temperatures are also improved by the TiC additions. Observations of the fracture path indicate that the improved toughness and strength are a result of crack deflection by the TiC particles.     

Mode I Fracture Toughness of a Small-Grained Silicon Nitride: Orientation, Temperature, and Crack Length Effects

The Mode I fracture toughness ( K _{I C} ) of a small-grained Si₃N₄ was determined as a function of hot-pressing orientation, temperature, testing atmosphere, and crack length using the single-edge precracked beam method. The diameter of the Si₃N₄ grains was <0.4 µm, with aspect ratios of 2–8. K _{I C} at 25°C was 6.6 ± 0.2 and 5.9 ± 0.1 MPa·m^1/2 for the T–S and T–L orientations, respectively. This difference was attributed to the amount of elongated grains in the plane of crack growth. For both orientations, a continual decrease in K _IC was observed through 1200°C, to ∼4.1 MPa·m^1/2, before increasing rapidly to 7.5–8 MPa·m^1/2 at 1300°C. The decrease in K _IC through 1200°C was a result of grain-boundary glassy phase softening. At 1300°C, reorientation of elongated grains in the direction of the applied load was suggested to explain the large increase in K _IC. Crack healing was observed in specimens annealed in air. No R -curve behavior was observed for crack lengths as short as 300 µm at either 25° or 1000°C.     

Toughening Behavior in Sic-Whisker-Reinforced Alumina

The development of hot-pressed Sic-whisker-reinforced alumina has resulted in composites with fracture toughness values ∼;8.7 MPa·m¹¹² at 20 vol% SiC. Whisker orientation during processing leads to anisotropy in both fracture toughness and fracture strength. Fracture strengths are also limited by the ability to disperse the Sic whiskers; however, use of both fine alumina powders and ultrasonic dispersion techniques yields strengths ∼;800 MPa.     

Microstructure-Property Relations of Hot-Pressed Silicon Carbide-Aluminum Nitride Compositions at Room and Elevated Temperatures

A series of SiC-AlN compositions of 0, 10, 25, 50, 75, 90, and 100 mol% AlN were hot pressed at 2100°C for a 1 h soak at a pressure of 35 MPa under vacuum. 2H-wurtzite SiC-AlN solid-solution structures were formed for compositions with 25-100 mol% AlN. The associated lattice parameters for these solid solutions followed Vegard's law. The microstructures varied with composition; the number of needlelike grains decreased for compositions up to 25 mol% AlN and the amount of equiaxed grains increased for compositions with 25–100 mol% AlN. Densities for all the specimens were >99% of the theoretical density. Coefficients of thermal expansion varied from 4.80 × 10^-6/°C to 6.25 × 10^-6/°C in the 20°-1400°C range. Young's moduli varied from 451 GPa to 320 GPa at room temperature (RT) and retained 98%, 96%, and 94% of their RT values at 500°, 1000°, and 1250°C, respectively. These three properties correlated linearly with composition. RT microhardness varied from 21.6 GPa to 11.2 GPa and correlated linearly with composition within the solid-solution range. Flexural strengths increased from 487 MPa to 604 MPa from 0 mol% AlN to 25 mol% AlN and then decreased to 284 MPa for 100 mol% AlN. At 1250°C, flexural strengths decreased from 90% to 65% of the RT values. Fracture toughness increased from 3.6 MPa·m^1/2 to 4.2 MPa·m^1/2 from 0 mol% AlN to 10 mol% AlN and then decreased to 2.5 MPa·m^1/2 for 100 mol% AlN.     

Fabrication, Mechanical Properties, and Electrical Conductivity of Co3O4 Ceramics

Well-densified Co₃O₄ ceramics (98.3% of theoretical) have been fabricated by the combined use of hot pressing (800°C/I h/30 MPa) and hot isostatic pressing (880°C/2 h/196 MPa). Their Vickers hardness and fracture toughness are 10.3 GPa and 4.2 MPa·m^1/2, respectively. They exhibit a high electrical conductivity of 3.35 × 10' S·cm⁻¹ at 800°C.     

Microwave-Sintered MgO-Doped Zirconia with Improved Mechanical and Tribological Properties

This paper reports the results of microwave sintering (without post-sintering annealing) on the microstructure, phase assemblage, and properties of 8 mol% (PSZ—partially stabilized zirconia), and 16 mol% (FSZ—fully stabilized zirconia) MgO-alloyed zirconia. For the PSZ samples sintered at 1585°C, a maximum densification of ∼98%ρ_th, along with a hardness of ∼10.6 GPa and a fracture toughness of ∼6.8 MPa·m^1/2, was obtained. The results of tribological experiments on some selected samples revealed that a good combination of a lower coefficient of friction of 0.35 and a wear rate of 10⁻⁷ mm³/N m can be obtained with the optimally sintered Mg-PSZ.     

Strength and Toughness of Tape-Cast Yttria-Stabilized Zirconia

The biaxial flexural strength and fracture toughness of tape-cast yttria-stabilized zirconia, for application as the electrolyte in solid oxide fuel cells, have been measured at room temperature and at a typical operating temperature of 900°C. The flexural strength was measured in ring-on-ring loading and decreased from 416 MPa at room temperature to 265 MPa at 900°C. The fracture toughness was measured using two different techniques: indentation fracture and double-torsion loading. The latter was more reliable and gave a fracture toughness of 1.61 ± 0.12 MPa·m^1/2 at room temperature and 1.02 ± 0.05 MPa·m^1/2 at 900°C. The flexural strength and fracture toughness were quantitatively consistent with fracture being initiated at the observed surface defects. The lower fracture toughness at 900°C is partly due to a reduction in elastic modulus and partly due to a reduction in the work of fracture.     

TiN-TiB2 Composites Prepared by Reactive Hot Pressing and Effects of Ni Addition

Using TiH₂ and BN as raw materials, the reaction process of TiH₂ and BN in the temperature range 1000°-1600°C was studied. Then TiN-TiB₂ composites were prepared by reactive hot pressing. The effects of Ni addition on the sinterability and the mechanical properties of the composites were discussed. A composite containing 1 wt% Ni exhibited a bending strength of 614 MPa, fracture toughness of 6.20 MPa·m^1/2, and Vickers hardness of 20.5 GPa.     

Fabrication and Mechanical Properties of Titanium Boride Ceramics

Dense TiB ceramics (99.6% of theoretical) with a grain size of ∼5 µm have been fabricated by reaction hot pressing of TiB₂ and titanium for 2 h at 1900°C and 28.5 MPa. The TiB ceramics exhibit a fracture toughness ( K_IC ) of 4.5 MPa·m^1/2 and a bending strength (sigma_b) of 360 MPa. Electrical resistivity (rho) is 3.4 × 10^-7 Omega·m at room temperature.     

Slow Growth of Microcracks: Evidence for One Type of ZrO2 Toughening

Alumina containing 15 vol% monoclinic ZrO₂ dispersed at the grain boundaries exhibited very high room-temperature fracture toughness (∼11 MPa·m^1/2) on cooling from 1275°C when microcrack precursors nucleated at Ts. With increasing time (up to ∼12 h) at room temperature, K_Ic and Young's modulus decreased when dilational and thermal-expansion strains subcritically propagated inter granular microcracks. Thus, transformation toughening of ceramics with inter crystalline ZrO₂ dispersions is to a great extent caused by microcrack nucleation and extension.     

Pressureless Sintering of High-Density ZrB2–SiC Ceramic Composites

Ultra-high-temperature ceramic composites of ZrB₂ 20 wt%SiC were pressureless sintered under an argon atmosphere. The starting ZrB₂ powder was synthesized via the sol–gel method with a small crystallite size and a large specific surface area. Dry-pressed compacts using 4 wt% Mo as a sintering aid can be pressureless sintered to ∼97.7% theoretical density at 2250°C for 2 h. Vickers hardness and fracture toughness of the sintered ceramic composites were 14.82±0.25 GPa and 5.39±0.13 MPa·m^1/2, respectively. In addition to the good sinterability of the ZrB₂ powders, X-ray diffraction and scanning electron microscopy results showed that Mo formed a solid solution with ZrB₂, which was believed to be beneficial for the densification process.