Micro-sized polycrystalline cubic boron nitride with properties comparable to nanocrystalline counterparts

High-performance polycrystalline cubic boron nitride (PcBN) was sintered without binders at 1500 °C in a pressure range from 11 to 15 GPa using commercial micrometre cubic boron nitride (cBN) with a diameter of approximately 2–4 μm. The results demonstrated that the sample sintered at 12 GPa and 1500 °C had the best mechanical properties and thermal stability. Its average Vickers hardness, fracture toughness, and thermal stability was 63 GPa, 15 MPa m^1/2, and 1315 °C, respectively. The considerable improvement in the mechanical properties was mostly attributed to the high compactness, close bonding between grains, and the sample's internal defect structures. The relatively small specific surface area of the micron grains provides an advantage due to its high thermal stability. The amorphous regions observed in the sample's local areas may provide a new strengthening mechanism under high pressure and temperature.     

Tribological behaviors of polycrystalline cubic boron nitride sliding against silicon nitride in air and vacuum conditions

In order to evaluate the friction and wear properties of polycrystalline cubic boron nitride (PCBN) based on the drilling tools cutting, the ball-on-disk tribological experiments of PCBN sliding against silicon nitride (Si₃N₄) were carried out in air and vacuum conditions. The tribological behaviors were investigated by Scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDS) and Nanomap-D three-dimensional White Light Interferometer. The results demonstrate that the coefficient of friction (CoF) is closely interrelated with the changing tendency of loads, where the CoFs gradually decrease with the growth of the load whether in air or in vacuum on account of a transfer film in air and a change from sliding friction to rolling friction in vacuum. Moreover, the CoF in vacuum condition is invariably greater than that in air under the similar load owing to friction heat. Furthermore, no observable abrasion appears on Si₃N₄ in air while severe abrasive wear is dominant on Si₃N₄ in vacuum. In addition, there is more intense adhesion on PCBN in vacuum than that in air. The reason is that the friction heat is gathered in vacuum condition with a confined environment.     

The effect of boron nitride nanosheets on the mechanical and thermal properties of aluminum nitride ceramics

The boron nitride nanosheets (BNNSs)/aluminum nitride (AlN) composites were prepared by hot press sintering at 1600°C. The microstructure, mechanical properties, and thermal conductivity of the samples were measured, and the effect of adding BNNSs to AlN ceramics on the properties was studied. It is found that the addition of BNNSs can effectively improve the mechanical properties of AlN. When the additional amount is 1 wt%, the bending strength of the sample reaches the maximum value of 456.6 MPa, which is 23.1% higher than that of the AlN sample without BNNSs. The fracture toughness of the sample is 4.47 MPa m^1/2, a 68.7% improvement over the sample without BNNSs. The composites obtained in the experiment have brilliant mechanical properties.     

Spark plasma sintering of boron nitride micron tubes reinforced boron carbide ceramics with excellent mechanical property

In this paper, the novel boron nitride micron tubes (BNMTs) were used to reinforce commercial boron carbide (B₄C) ceramics prepared via spark plasma sintering technology. The effects of the sintering parameters, sintering temperature, the holding time, and the BNMTs content on the microstructure and mechanical properties of B₄C/BNMTs composite ceramics were studied. The results indicated that adding a proper amount of BNMTs could inhibit the grain growth of B₄C and improve the fracture toughness of the B₄C/BNMTs composite ceramics. The prepared composite ceramic sample with 5 wt% BNMTs at 1850°C, 8 min and 30 MPa displayed the best mechanical properties. The relative density, hardness, fracture toughness, and bending strength of the samples were 99.7% ± .1%, 35.62 ± .43 GPa, 6.23 ± .2 MPa m^1/2, and 517 ± 7.8 MPa, respectively. Therein, the corresponding value of hardness, fracture toughness, and bending strength was increased by 10.3%, 43.59%, and 61.5%, respectively, than that of the B₄C/BNMTs composite ceramic without BNMTs. It was proved that the high interface binding energy and bridging effect between boron carbide and BNMTs were the toughening principle of BNMTs.     

Physical and mechanical properties of hexagonal boron nitride ceramic fabricated by pressureless sintering without additive

Hexagonal boron nitride hBN ceramic was successfully fabricated by pressureless sintering at 2100C using submicrometre hBN powders without any sintering additive. The as-prepared hBN ceramic showed a room temperature flexural strength of 30.7MPa. Its flexural strength increased with the increment of temperature in N₂ atmosphere, and it retained a strength of 57.2MPa nearly two times of the room temperature strength at 1600C due to clean grain boundaries with no glassy phase. Additionally, the as-prepared hBN ceramic showed a high thermal conductivity of 31.76Wm¹k¹ and a good thermal shock resistance, which retained a relatively high residual flexural strength of 22.6MPa 73.5 of the original flexural strength at T800C. The as-prepared hBN ceramic presents a good application prospect at high temperature.     

Synthesis of ultrafine nano-polycrystalline cubic boron nitride by direct transformation under ultrahigh pressure

Using a turbostratic pyrolytic boron nitride as a starting material, we synthesized a variety of ultrahard polycrystalline cubic boron nitride (PcBN) as a function of the heating duration changing from 1 to 60?min under a constant temperature and pressure conditions (1950?°C and 25?GPa) using a multi-anvil apparatus. When the heating duration was less than 13?min, ultrafine nano-polycrystalline cBN (U-NPcBN) with the mean grain size of <50?nm was produced. Among these U-NPcBNs those synthesized with 11–13?min were found to have a uniform texture composed purely of cBN (i.e. with no wurzite BN residue) and a Knoop hardness of >53?GPa, which is 20% higher than that of the hardest conventional binderless PcBN in practical use. Furthermore, the PcBNs synthesized with 18–20?min showed a unique nanocrystalline texture composed of relatively coarse grains dispersed in a fine grained matrix and even higher Knoop hardness (54.5–55.2?GPa).     

Recrystallization behaviour of cubic boron nitride under high pressure

The recrystallization behaviour of micron-sized cubic boron nitride (cBN) was studied by analysing the grain size and morphology of samples treated at 8−16 GPa/1500–2200 °C. The results show that the recrystallization temperature of cBN under a pressure of 8 GPa is approximately 1650 °C and increases by approximately 100 °C with every 2 GPa increase in pressure. Once grain recrystallization starts, the grains grow abnormally quickly as the temperature rises, and the strengthening effects of grain refinement and defect structure are greatly weakened. The recrystallization behaviour of cBN at high pressure is helpful to understand the sintering mechanism and control the microstructure and mechanical properties of sintered polycrystalline cBN compacts. In addition, the melting curve for cBN under high pressure is inferred according to the empirical relationship between recrystallization temperature and melting temperature, and the phase diagram for boron nitride is revised based on this new melting curve.     

Thermal properties of polymer-derived ceramic reinforced with boron nitride nanotubes

We report the thermal properties of boron nitride nanotube (BNNT) reinforced ceramic composites using the polymer derived ceramic (PDC) processing route. The nano-composites had a BNNT loading of up to 35.4 vol.%. TGA results showed that nano-composites have good thermal stability up to 900°C in air. BNNTs in nano-composites survived in an oxidizing environment up to 900°C, revealing that nano-composites can be used for high temperature applications. Thermal conductivity of PDC reinforced with 35.4 vol.% BNNT was measured as 4.123 W/(m·K) at room temperature, which is a 2100 % increase compared to that of pristine PDC. The thermal conductivity value increases with the increase of BNNT content. A thermal conductivity percolation phenomenon appeared when the BNNT content increased to 36 ± 5 vol.%. The results of this study showed that BNNTs could effectively improve the thermal conductivity of PDC materials. BNNT reinforced PDC could be used as thermal structural materials in a harsh environment at temperatures up to 900°C.     

Numerical simulation analysis and experimental validation on wear/fracture mechanisms of polycrystalline cubic boron nitride superabrasives in high-speed grinding

In this study, a two-dimensional finite element model is proposed to investigate the wear/fracture mechanisms of polycrystalline cubic boron nitride (PCBN) superabrasives in high-speed grinding process. The special geometric microstructures of PCBN grains are constructed by using the classic Voronoi tessellation technique, and cohesive elements are embedded into the geometric model of PCBN grains as the potential crack propagation paths for simulating the wear/fracture behaviours of PCBN grains under grinding loads. The effects of uncut chip thickness per grain (a_gmax) on the stress distribution characteristics and wear/fracture behaviours of PCBN grains during grinding are discussed in detail. Results show that the wear behaviour of PCBN grains during grinding mainly occurs around the grain vertex region; however, the fracture behaviour, leading to the quick failure of PCBN grains, is prone to appear around the grain–filler bonding interface, which is usually on the opposite side of the in-feed direction. Moreover, to separate the PCBN grains from the macro-fracture during grinding, the uncut chip thickness per grain should be kept smaller than 1.0?µm to prevent the unfavourable fracture behaviour from appearing around the grain–filler bonding interface. Furthermore, the corresponding single-grain grinding trials are performed to validate the numerical simulation results by evaluating the wear/fracture morphologies of the PCBN superabrasives in the actual grinding operation.     

Effects of SiC whiskers on the mechanical properties and microstructure of SiC ceramics by reactive sintering

As-received and pre-coated SiC whiskers (SiC_w)/SiC ceramics were prepared by phenolic resin molding and reaction sintering at 1650 °C. The influence of SiC_w on the mechanical behaviors and morphology of the toughened reaction-bonded silicon carbide (RBSC) ceramics was evaluated. The fracture toughness of the composites reinforced with pre-coated SiC_w reached a peak value of 5.6 MPa m^1/2 at 15 wt% whiskers, which is higher than that of the RBSC with as-received SiC_w (fracture toughness of 3.4 MPa m^1/2). The surface of the whiskers was pre-coated with phenolic resin, which could form a SiC coating in situ after carbonization and reactive infiltration sintering. The coating not only protected the SiC whiskers from degradation but also provided moderate interfacial bonding, which is beneficial for whisker pull-out, whisker bridging and crack deflection.     

Deposition of cubic boron nitride films on diamond-coated WC:Co inserts

Cubic boron nitride (cBN) thin films were deposited on diamond-coated tungsten carbide (WC) cutting inserts using electron cyclotron resonance (ECR) microwave plasma chemical vapor deposition (MPCVD). The effects of gas flow rate and substrate bias on the phase composition and structure of the BN films deposited on diamond surfaces were studied. It was revealed that both the cubic phase formation and the selective etching of hexagonal phase were controlled by modulating the hydrogen and boron trifluoride flow rate ratio. By the trial and error method the gas flow rate ratio and substrate bias voltage were optimized. Moreover the phase composition of the BN film was found to be affected by the thickness of diamond buffer layer and interrelated to the effective substrate bias. The hardness of the resulting cBN films reached the value of 70 GPa. In the synthesized coatings, the diamond beneath renders the best mechanical supporting capacity while the top cBN provides the superior chemical resistance and extreme hardness. The cBN/diamond bilayers deposited on WC inserts may serve as universal tool coatings for machining steels and other ferrous metals.     

Dielectric properties of polymer-derived ceramic reinforced with boron nitride nanotubes

The electrical and dielectric properties of boron nitride nanotubes (BNNTs) reinforced ceramic composites using the polymer-derived ceramic (PDC) processing route were investigated in this work. The electrical resistivity of the pristine PDC increases from 10⁶ to 10⁸ Ω m after the addition of BNNTs. When the BNNT loading was increased to 5 wt%, the average real relative permittivity of the PDC decreased from 2.94 to 2.80, while the quality factor (Q) of the PDC increased from 134.40 to 176.77. The BNNTs can increase the Q factor of the PDC due to the reduction in the porosity cause by the introduction of the BNNTs. Further increasing the BNNT content decreases the real relative permittivity of the nanocomposites and increases the Q factor at high frequency. The average real relative permittivity decreases to 2.29, while the average Q factor increases to 208.60 when the BNNT content is increased to 30 wt%. The dielectric loss after the addition of high fraction of BNNTs can be explained by the Lorentz resonance relaxation process. Results of this work showed that PDC-BNNT nanocomposites are satisfactory electromagnetic transparent materials when the BNNT fraction is less than 10 wt%.     

Correlations between microstructure and dielectric properties of hexagonal boron nitride

Hexagonal boron nitride is a material with a unique combination of mechanical, chemical, and electrical properties and therefore of considerable technical and commercial interest. Nevertheless, there exists only very limited knowledge concerning the correlation of microstructure and electrical and dielectrical properties of such materials. In this work, the microstructure, dielectric breakdown resistance (dielectric strength), and low permittivity of different BN ceramics and composites were investigated. Besides exhibiting a very high specific electrical resistivity of 10¹³–10¹⁵ Ω cm, the materials had excellent dielectric strengths (up to 53 kV/mm) and low electrical permeability (4.1). The dielectric strength depended strongly on the porosity and to a lesser extent on the content of secondary phases, whereas the permittivity was influenced by the secondary phases. The aging of the materials in humid air did not significantly alter these values. The permittivity was found to be independent of frequency between 0.1 MHz and 10 MHz and temperature up to 300 °C.     

Mechanical and tribological properties of SiC whisker-reinforced SiC composites via oscillatory pressure sintering

SiC whisker (SiCw)-reinforced SiC composites were prepared by an oscillatory pressure sintering (OPS) process, and the effects of SiCw content on the microstructure and mechanical and tribological properties of such composites were investigated. The addition of SiCw could promote the formation of long columnar α-SiC, and the aspect ratio of α-SiC grains first increased and then decreased with the increase of SiCw content. When the SiCw content was 5.42 wt%, the relative density of the SiC–SiCw composite reached up to 99.45%. The SiC–5.42 wt% SiCw composite possessed the highest Vickers hardness, fracture toughness, and flexural strength of 30.68 GPa, 6.66 MPa·m^1/2, and 733 MPa, respectively. In addition, the SiC–5.42 wt% SiCw composite exhibited the excellent wear resistance when rubbed with GCr15 steel balls, with a friction coefficient of .76 and a wear rate of 4.12 × 10⁻⁷ mm³·N⁻¹·m⁻¹. This could be ascribed to the improved mechanical properties of SiC–SiCw composites, which enhanced the ability to resist peeling and micro-cutting, thereby enhancing the tribological properties of the composites.     

Polyamide 6 composites reinforced with silicon nitride whiskers: Synthesis,interface interaction,and mechanical properties

In this study, polyamide 6 (PA6)/silicon nitride whisker (SNW) composites were fabricated via in situ hydrolytic ring‐opening polymerization of ε‐caprolactam. By this novel method, SNWs can be dispersed uniformly in PA6 matrix. The interface interaction between SNW and PA6 was investigated, and the reinforcing efficiency of SNW on PA6 was evaluated. It was revealed by Fourier transform infrared spectroscopy that a large amount of polar groups, such as ? SiOH, ? NH, and ? NH₂, were present on the SNWs, by which hydrogen bonding and covalent bonding can be formed at interface. Mechanical test showed that at a loading of 5.0 wt % SNW, the tensile strength, tensile modulus, flexural strength, flexural modulus, and impact strength of PA6/SNW composite were 37.9, 80.5, 60.3, 73.9, and 64% higher than those of neat PA6, respectively. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Structure,morphology and dielectric properties of hexagonal boron nitride nanoparticles reinforced biopolymer nanocomposites

Hexagonal boron nitride nanoparticles (h-BNNPs)/Chitosan (CS)/Hydroxypropyl methylcellulose (HPMC) based ternary nanocomposites were prepared using solution casting method and characterized using Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), thermogravimetric analyses (TGA), Scanning electron microscopy (SEM) and Atomic force microscopy (AFM). The dielectric properties of CS/HPMC/h-BNNP nanocomposite films were also investigated as a function of frequency and temperature and a maximum dielectric constant of ~1200 was achieved at 5 wt % of h-BNNP loading in CS/HPMC blend matrix. The results from the structural, morphological and thermal studies revealed good interactions between h-BNNPs, CS and HPMC.     

Effect of temperature on the growth of boron nitride interfacial coatings on SiC fibers by chemical vapor infiltration

In order to improve bonding property between SiC fibers and matrix of SiC_f/SiC composites, boron nitride (BN) interfacial coatings were synthesized by chemical vapor infiltration. BN coatings were fabricated from BCl₃–NH₃ gaseous mixtures at four different temperatures (843 °C, 900 °C, 950 °C and 1050 °C) with different deposition times. Growth kinetics, nucleation and growth processes, microstructure and chemical composition of boron nitride coatings were investigated by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and Raman spectrometry. Results showed that deposition rate increased as the temperature increased from 843 °C to 950 °C. However, deposition rate decreased slightly from 23.10 ± 0.85 nm/min (950 °C) to 21.39 ± 0.67 nm/min when the temperature was increased further to 1050 °C. It could be due to the nucleation occurring in the gas and the consumption of a large amount of BCl₃ and NH₃. When deposition temperature was 843 °C, BN grains deposited on top layer of the coating could not completely cross Ehrlich-Schwoebel barrier and grew in island growth mode. On the other hand, the deposition pattern followed a layer-by-layer growth mode when deposition temperature was 1050 °C. Deposition temperature significantly affected the microstructure of as-deposited BN coatings. At 843 °C, 950 °C and 1050 °C, the coatings presented amorphous, polycrystalline and hexagonal structures, respectively.     

Degradation of boron nitride interfacial coatings fabricated by chemical vapor infiltration on SiC fibers under ambient air/room temperature conditions

Hexagonal boron nitride (h-BN) interfacial coatings were deposited on SiC fibers by chemical vapor infiltration (CVI) and their degradation behavior under ambient air/room temperature conditions was studied with time. Degradation of the interfacial coatings with time was investigated by characterizing the morphology and microstructure of these materials with scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and transmission electron microscopy (TEM). Thermogravimetry coupled with differential thermal analysis (TG-DTA) and X-ray photoelectron spectroscopy (XPS) was used to analyze the chemical reactions and phase transitions taking place in the BN coatings. The results showed that the as-deposited BN interfacial coatings fabricated by CVI were compact and well bonded to the SiC fibers. BN coatings remained relatively stable under ambient air/room temperature conditions for 50?h, while severe degradation was observed after 500?h of exposure. The degradation of BN interfacial coatings was mainly caused by two factors, namely, reaction with atmospheric air to produce boric oxide and amorphization of the hexagonal structure. The degradation observed under ambient air/room temperature might be due to incomplete crystallinity of BN interfacial coatings. Presence of water vapor may accelerate degradation of the coatings. The results of this degradation test can be used as a reference for the storage of BN coatings fabricated by CVI.     

Fabrication and mechanical properties of boron nitride nanotube reinforced silicon nitride ceramics

In this study, silicon nitride (Si₃N₄) ceramics added with and without boron nitride nanotubes (BNNTs) were fabricated by hot-pressing method. The influence of sintering temperature and BNNTs content on the microstructures and mechanical properties of Si₃N₄ ceramics were investigated. It was found that both flexural strength and fracture toughness of Si₃N₄ were improved when sintering temperature increases. Moreover, α-Si₃N₄ phase could transform into β-Si₃N₄ phase completely when sintering temperature rises to 1800 °C and above. BNNTs can enhance the fracture toughness of Si₃N₄ dramatically, which increases from 7.2 MPa m^1/2 (no BNNTs) to 10.4 MPa m^1/2 (0.8 wt% BNNTs). However, excessive addition of BNNTs would reduce the fracture toughness of Si₃N₄. Meanwhile, the flexural strength and relative density of Si₃N₄ decreased slightly when BNNTs were added. The related toughening mechanism was also discussed.     

Development of matrix microstructure in polycrystalline cubic boron nitride ceramics

The development of matrix microstructure in polycrystalline cubic boron nitride cutting tool materials has been investigated by X-ray diffraction and scanning and transmission electron microscopy combined with energy dispersive X-ray spectrometry. The materials had a matrix based on Ti(C,O,N) and Al and were fabricated from powder mixtures milled with either WC-Co cemented carbide or (Ti,W)(C,N)-Co cermet milling media. The introduction of WC-Co debris resulted in the formation of an Al- and W-rich liquid phase during high pressure high temperature sintering. Crystalline intergranular phases rich in W partitioned from this liquid. Debris from the cermet milling media resulted in the formation of intergranular Co₂B; the W was retained in the (Ti,W)(C,N) structure during sintering. Al-rich reaction zones on cBN grain surfaces developed locally during high pressure high temperature sintering.