Effect of in-situ formed Y2O3 by metal hydride reduction reaction on thermal conductivity of β-Si3N4 ceramics

The effect of YH₂ on densification, microstructure, and thermal conductivity of Si₃N₄ ceramics were investigated by adjusting the amount of YH₂ in the range of 0–4 wt% using a two-step sintering method. Native SiO₂ was eliminated, and Y₂O₃ was in situ formed by a metal hydride reduction reaction, resulting in various Y₂O₃/SiO₂ ratios. Full densification of YH₂-doped samples could be achieved after sintering at 1900 °C for 4 h. The Y₂O₃/SiO₂ ratio had a significant influence on the composition of crystalline secondary phases. Besides, the increased Y₂O₃/SiO₂ ratio is conducive not only to the grain growth but also to the reduction of activity of SiO₂ in the liquid phase, resulting in enlarged purified grains, reduced volume fraction of intergranular phases and increased Si₃N₄-Si₃N₄ contiguity. Ultimately, the thermal conductivity increased by 29 % from 95.3 to 123.0 W m⁻¹ K⁻¹ after sintering at 1900 ℃ for 12 h by the substitution of Y₂O₃ with YH₂.     

Effect of large β-Si3N4 particles on the thermal conductivity of β-Si3N4 ceramics

Mean-field micromechanics model, the rule of mixture is applied to the prediction of the thermal conductivity of sintered β-Si₃N₄, considering that the microstructure of β-Si₃N₄ is composed of a uniform matrix phase (which contains grain boundaries and small grains of Si₃N₄) and the purified large grains (⩾2 μm in diameter) of Si₃N₄. Experimental results and theoretical calculations showed that the thermal conductivity of Si₃N₄ is controlled by the amount of the purified large grains of Si₃N₄. The present study demonstrates that the high thermal conductivity of β-Si₃N₄ can be explained by the precipitation of high purity grains of β-Si₃N₄ from liquid phase.     

Effect of the addition of β-Si3N4 nuclei on the thermal conductivity of β-Si3N4 ceramics

Various microstructures of β-Si₃N₄ were fabricated, with or without the addition of β-Si₃N₄ seed particles to high-purity β-Si₃N₄ powder, using Yb₂O₃ and ZrO₂ as sintering additives, by gas-pressure sintering at 1950 °C for 16 h. The thermal conductivity of the specimen without seeds was 140 W·(m·K)⁻¹, and the specimen exhibited a bimodal microstructure with abnormally grown grains. The thermal conductivity of the specimen with 24 vol.% seed addition was 143 W·(m·K)⁻¹, and this specimen had the bimodal microstructure with finer grain size than that without the seeded material, but maintained the same amount of large grains (⩾2 μm in diameter) as in the specimen without the seeds. This finding indicates that the thermal conductivity of β-Si₃N₄ is controlled by the amount of reprecipitated large grains, rather than by the grain size of the β-Si₃N₄.     

ZrSi2–MgO as novel additives for high thermal conductivity of β-Si3N4 ceramics

A novel ZrSi₂–MgO system was used as sintering additive for fabricating high thermal conductivity silicon nitride ceramics by gas pressure sintering at 1900°C for 12 hours. By keeping the total amount of additives at 7 mol% and adjusting the amount of ZrSi₂ in the range of 0-7 mol%, the effect of ZrSi₂ addition on sintering behaviors and thermal conductivity of silicon nitride were investigated. It was found that binary additives ZrSi₂–MgO were effective for the densification of Si₃N₄ ceramics. XRD observations demonstrated that ZrSi₂ reacted with native silica on the Si₃N₄ surface to generate ZrO₂ and β-Si₃N₄ grains. TEM and in situ dilatometry confirmed that the as formed ZrO₂ collaborated with MgO and Si₃N₄ to form Si–Zr–Mg–O–N liquid phase promoting the densification of Si₃N₄. Abnormal grain growth was promoted by in situ generated β-Si₃N₄ grains. Consequently, compared to ZrO₂-doped materials, the addition of ZrSi₂ led to enlarged grains, extremely thin grain boundary film and high contiguity of Si₃N₄–Si₃N₄ grains. Ultimately, the thermal conductivity increased by 34.6% from 84.58 to 113.91 W·(m·K)⁻¹ when ZrO₂ was substituted by ZrSi₂.     

The microstructure and thermal conductivity of porous β-SiAlON ceramics fabricated by pressureless sintering with Y-α-SiAlON as the sintering additive

Porous β-SiAlON ceramics are fabricated by pressureless sintering with Y-α-SiAlON ceramic powders obtained by the combustion synthesis method as the main additives. The microstructure and composition of porous β-SiAlON ceramics are tailored by changing the addition of the synthesized Y-α-SiAlON ceramic powders. The formation mechanism of porous β-SiAlON ceramics illustrates that their bimodal grain size distributions are determined by the β-SiAlON seed crystals which are derived from the starting synthesized powders and the first precipitates in the liquid phase, respectively. A small addition of Y-α-SiAlON is conducive to the reduction of the thermal conductivity of porous β-SiAlON ceramics. Furthermore, the higher the addition of Y-α-SiAlON ceramics powders, the lower the open porosity, columnar grain size, and dielectric loss, but the larger the density, flexural strength, dielectric constant, and thermal conductivity.     

Effect of lattice defects on the thermal conductivity of β-Si3N4

Two types of β-Si₃N₄ were sintered at 1900 °C one for 8 h and the other for 36 h by using Yb₂O₃ and ZrO₂ as sintering additives. The latter specimen was further annealed at 1700 °C for 100 h to promote grain growth. The microstructures of the sintered materials were investigated by SEM, TEM, and EDS. The thermal conductivities of the specimens were 110 and 150 Wm⁻¹K⁻¹, respectively. The sintered material which possessed 110 Wm⁻¹K⁻¹ had numerous small precipitates that consisted of Yb, O and N elements and internal dislocations in the β-Si₃N₄ grains. In the sintered material with 150 Wm⁻¹K⁻¹ neither precipitates nor dislocations were observed in the grains. The microscopic evidence indicates that the improvement in the thermal conductivity of the β-Si₃N₄ was attributable to the reduction of internal defects of the β-Si₃N₄ grains with sintering and annealing time as the grains grew.     

Effect of lattice impurities on the thermal conductivity of β-Si3N4

Effect of impurities in the crystal lattice and microstructure on the thermal conductivity of sintered Si₃N₄ was investigated by the use of high-purity β-Si₃N₄ powder. The sintered materials were fabricated by gas pressure sintering at 1900 °C for 8 and 48 h with addition of 8 wt.% Y₂O₃ and 1 wt.% HFO₂. A chemical analysis was performed on the loose Si₃N₄ grains taken from sintered materials after the chemical treatment. Aluminum was not removed from Si₃N₄ grains, which originated from the raw powder of Si₃N₄. The coarse grains had fewer impurities than the fine grains. Oxygen was the major impurity in the grains, and gradually decreased during grain growth. The thermal conductivity increased from 88 Wm⁻¹ K⁻¹ (8 h) to 120 Wm⁻¹ K⁻¹ (48 h) as the impurities in the crystal lattice decreased. Purification by grain growth thus improved the thermal conductivity, but changing grain boundary phases might also influence the thermal conductivity.     

Gelcasting and pressureless sintering of silicon carbide ceramics using Al2O3–Y2O3 as the sintering additives

In this paper, silicon carbide ceramics were prepared by aqueous gelcasting and pressureless sintering using Al₂O₃ and Y₂O₃ as the sintering additives. In order to develop well dispersed SiC slurries in the presence of sintering additives, the Al₂O₃ and Y₂O₃ powder was treated in the citric acid solution in advance. Zeta potential measurement showed that the isoelectric point (IEP) of Al₂O₃ and Y₂O₃ powder moved toward low pH region after treatment. Rheological measurement confirmed that the addition of as-treated powder showed very limited influence on the slurry properties as compared to that of untreated powder. SiC slurries with solid content of 54 vol% and enough fluidity can be developed. After gelcasting and pressureless sintering, SiC ceramics with nearly full density, fine grained and homogeneous microstructure can be obtained. Results showed that the surface treatment of Al₂O₃ and Y₂O₃ with citric acid is effective for the gelcasting process of SiC.     

Influence of β-Si3N4 whiskers on sintering and crystallization of fused silica ceramics

Fused silica ceramics are widely applied for radome materials, crucibles, and vanes, but the mechanical properties were deteriorated due to the cristobalite crystallization. The fused silica ceramics added with by β-Si₃N₄ whiskers were prepared by a slip-casting method to retard the cristobalite crystallization. The influences of the sintering environments and the β-Si₃N₄ whiskers on the microstructure and phase structure were investigated. The silanol (Si-(OH)_n) and oxygen vacancies (V_O) in the fused silica in formed in different conditions were studied by Fourier Transform Infra-Red (FT-IR) and X-ray photoelectron spectroscopy (XPS), and the results indicated that the ball-milled produced a large amount of the silanol groups onto the surface of the fused silica particles. The fused silica heated in the vacuum created the maximum oxygen vacancies (24.2%) on the surfaces. Silanol groups reacted with the β-Si₃N₄ whiskers, and the O atoms in the silanol groups were fixed into the bulk materials. And the crystallization kinetics and the activation energy of Si₃N_4w/SiO₂ ceramics at the temperature ranging from 1200 to 1400°C were calculated based on the JMA(Johnson-Mehl-Avrami) model. The activation energy of the fused silica ceramics with the addition of the β-Si₃N₄ is 506.2 kJ/mol, increased by 23.6% than that of the pure fused silica ceramic.     

Fabrication of Si3N4 ceramics by post-reaction sintering using Si–Y2O3–Al2O3 nanocomposite particles prepared by mechanical treatment

Post-reaction sintering of a powder compact of Si and sintering aids is a useful technique for fabricating silicon nitride (Si₃N₄) ceramics at low costs. In order to inhibit the inhomogeneous and uncontrollable exothermic nitridation of Si in the powder compact, Si–Y₂O₃–Al₂O₃ nanocomposite particles are designed as an aid for post-reaction sintering. These Si–Y₂O₃–Al₂O₃ nanocomposite particles are prepared via mechanical treatment applying high shear stress. Scanning electron microscopy (SEM) observations show that Y₂O₃ and Al₂O₃ particles are homogenously dispersed, and fixed to the Si particles. A green compact prepared using the Si–Y₂O₃–Al₂O₃ nanocomposite particles results in lower electrical resistivity than that prepared using a powder mixed by wet ball-milling, which suggests that Si particles in the green compact prepared using the nanocomposite particles are isolated by Y₂O₃ and Al₂O₃ particles. The isolation of Si particles by the sintering aids successfully prevents the Si particles from melting and agglomerating during the nitridation process, resulting in a higher nitridation ratio and higher α-Si₃N₄ phase content due to the inhibition of rapid heat transfer caused by the exothermic reaction. The nitridation ratio also increases with the applied power during mechanical treatment. As a result of firing the homogeneously nitrided powder compacts at high temperatures, Si₃N₄ ceramics with homogeneous microstructure and improved density are successfully fabricated in this manner.     

Mechanical properties and thermal conductivity of dense β-SiAlON ceramics fabricated by two-stage spark plasma sintering with Al2O3-AlN-Y2O3 additives

Fully dense β-SiAlON ceramics with excellent mechanical properties and good thermal conductivity were fabricated by two-stage spark plasma sintering (SPS) processes without and with applying pressure respectively, using α-Si₃N₄ powder and 6 Al₂O₃-3 AlN-6 Y₂O₃ (in wt.%, label with 636), 424 and 422 additives. In the first stage SPS process without pressure, the relative dense β-SiAlON ceramics with interlock microstructures of elongated grains and density of 3.14˜3.18 g cm⁻³, hardness of 14.00˜14.82 GPa and fracture toughness of 6.00˜6.63 MPa m^1/2 were obtained by sintering at about 1600 °C for 20 min. In the second stage SPS process at about 1425 °C for 5 min under pressure of 24 MPa, the fully dese β-SiAlON ceramics with density of 3.22˜3.24 g cm⁻³, high hardness of 15.68˜15.95 GPa, high fracture toughness of 6.38˜7.03 MPa m^1/2 and thermal conductivity of 13.5˜19.6 Wm^-1K^-1 were obtained. The reaction between the samples and the graphite mold can be avoided in this fabrication method.     

Enhancement of thermal shock resistance in β-Si3N4 coating with in situ synthesized β-Si3N4 nanowires/nanobelts on porous Si3N4 ceramics

A dense β-Si₃N₄ coating toughened by β-Si₃N₄ nanowires/nanobelts was prepared by a combined technique involving chemical vapor deposition and reactive melt infiltration to protect porous Si₃N₄ ceramics in this work. A porous β-Si₃N₄ nanowires/nanobelts layer was synthesized in situ on porous Si₃N₄ ceramics by chemical vapor deposition, and then Y–Si–Al–O–N silicate liquid was infiltrated into the porous layer by reactive melt infiltration to form a dense composite coating. The coating consisted of well-dispersion β-Si₃N₄ nanowires/nanobelts, fine β-Si₃N₄ particles and small amount of silicate glass. The testing results revealed that as-prepared coating displayed a relatively high fracture toughness, which was up to 7.9 ± 0.05 MPa m^1/2, and it is of great significance to improve thermal shock resistance of the coating. After thermal cycling for 15 times at ΔT = 1200 °C, the coated porous Si₃N₄ ceramics still had a high residual strength ratio of 82.2%, and its water absorption increased only to 6.21% from 3.47%. The results will be a solid foundation for the application of the coating in long-period extreme high temperature environment.     

Effect of β-Si3N4 starting powder size on elongated grain growth in β-Si3N4 ceramics

The microstructural evolution of pressureless sintered silicon nitride ceramics prepared from different particle sizes of β-Si₃N₄ as starting powders, has been investigated. When the specimen prepared from as-received β-powder of 0.66 μm in average size, was sintered at 1850°C, equiaxed β-Si₃N₄ grains were observed. As the size of the initial β-powder went down to 0.26 μm, however, the growth of elongated grains was enhanced, which resulted in a whisker-like microstructure similar to that made from α-starting powder. When the sintering temperature was increased to 2000°C, the elongated grains were also developed even in the specimen made from 0.66 μm β-powder. The observed results were discussed with relation to the two dimensional nucleation and growth theory for faceted crystals. In addition, fracture toughness of the specimen consisting of elongated grains, which was prepared from finer powders, increased.     

Improved oxidation resistance properties of Si3N4/O′–SiAlON composite ceramics by a repeated sintering method

Si₃N₄/O′–SiAlON composite ceramics with superior oxidation resistance properties were fabricated by a repeated sintering method. The effects of sintering time on the phase evolution, microstructure, and oxidation resistance properties of the Si₃N₄/O′–SiAlON composite ceramics were investigated. The results indicated that the content of the O′–SiAlON phase and the densification of Si₃N₄/O′–SiAlON composite ceramics increased after two-time sintering. Furthermore, the thickness of the oxide layer of the Si₃N₄/O′–SiAlON composite ceramics after oxidation at 1100–1500°C for 30 h was not significant. Compared to the oxidation weight gain after the one-time sintering process, the oxidation weight gain of Si₃N₄/O′–SiAlON composite ceramics was 0.432 mg/cm² after two-time sintering when oxidized at 1500 C for 30 h, which was reduced by 43.3%. The mechanism of the improved oxidation resistance properties was ascribed to the formation of more O′–SiAlON and the enhancement of the densification.     

Microstructure–permeability relation of porous β-Si3N4 ceramics

Porous β-Si₃N₄ ceramics with two distinct structures were produced by using two different Si₃N₄ sources to investigate the relationship between microstructure and permeability. Results showed that regardless of pore amount, size of pore channels, shape-distribution of β-Si₃N₄ grains are more effective on permeability of porous Si₃N₄ ceramics. Higher permeability and lower contribution of inertial forces was obtained by microstructure consists of coarse and equiaxed grains even at lower porosity amount. Calculated Forchheimer number (F_o) and measured the local breadth of a pore also supported the effect of microstructure on permeability.     

Microwave sintering of IR-transparent Y2O3–MgO composite ceramics

A method for preparation of dense Y₂O₃–MgO composite ceramics by the microwave sintering was developed. The initial powders were obtained by glycine-nitrate self-propagating high-temperature synthesis (SHS) with different oxidant-to-fuel ratio. Density and IR-transmission of microwave sintered Y₂O₃–MgO ceramics increase with respect to dispersity of the SHS-powders and reach its maximum values for the powder prepared in a 20% fuel excess. The sintering behavior of Y₂O₃–MgO compacts was investigated by optical dilatometry and measuring an electric conductivity upon heating. Significant microwave radiation power surges at temperatures of 900–1000 °C, caused by the decomposition of magnesium carbonate, have been found. As a result of matching the conditions for the synthesis of powders and sintering modes, a transmission of composite ceramics of 78% at a wavelength of 6 μm was achieved at a maximum processing temperature of 1500 °C.     

Improved dielectric properties of Ba0.5Sr0.5TiO3–ZnAl2O4 composite ceramics using double sintering

Ba_0.5Sr_0.5TiO₃–ZnAl₂O₄ composite ceramics were prepared by double sintering and conventional sintering. The results show that the double sintering can effectively reduce the ion diffusion between Ba_0.5Sr_0.5TiO₃ and ZnAl₂O₄ phases. The double sintered samples exhibit higher density and more uniform grain size distribution than the conventional sintered samples. The dielectric permittivity of double sintered samples is lower than that of conventional sintered samples. Impedance spectrum analysis shows that the oxygen vacancy content and grain boundary resistance of the double sintered samples is lower than that of the conventional sintered samples, which indicates that the Q value of the double sintered samples is higher than that of the conventional sintered samples. The optimum dielectric tunability and Q value of double sintered 60 wt%Ba_0.5Sr_0.5TiO₃-40 wt%ZnAl₂O₄ sample are 23.4% at 30 kV/cm and 276 at 2.257 GHz, respectively. Therefore, double sintering is a strategy that can effectively adjust the dielectric tunability and Q value of BST-ZA composite ceramics.     

Low thermal conductivity in porous SiC–SiO2–Al2O3–TiO2 ceramics induced by multiphase thermal resistance

The introduction of multiple heterogeneous interfaces in a ceramic is an efficient way to increase its thermal resistance. Novel porous SiC–SiO₂–Al₂O₃–TiO₂ (SSAT) ceramics were fabricated to achieve multiple heterogeneous interfaces by sintering equal volumes of SiC, SiO₂, Al₂O₃, and TiO₂ compacted powders with polysiloxane as a bonding phase and carbon as a template at 600 °C in air. The porosity could be controlled between 66% and 74% by adjusting the amounts of polysiloxane and the carbon template. The lowest thermal conductivity (0.059 W/(m·K) at 74% porosity) obtained in this study is an order of magnitude lower than those (0.2–1.3 W/(m·K)) of porous monolithic SiC, SiO₂, Al₂O₃, and TiO₂ ceramics at an equivalent porosity. The typical specific compressive strength value of the porous SSAT ceramics at 74% porosity was 3.2 MPa cm³/g.     

Enhanced thermal conductivity of low-temperature sintered borosilicate glass–AlN composites with β-Si3N4 whiskers

The effects of β-Si₃N₄ whiskers on the thermal conductivity of low-temperature sintered borosilicate glass–AlN composites were systematically investigated. The thermal conductivity of borosilicate glass–AlN ceramic composite was increased from 11.9 to 18.8 W/m K by incorporating 14 vol% β-Si₃N₄ whiskers, and high flexural strength up to 226 MPa were achieved along with low relative dielectric constant of 6.5 and dielectric loss of 0.16% at 1 MHz. Microstructure characterization and percolation model analysis indicated that thermal percolation network formation in the ceramic composites led to the high thermal conductivity. The crystallization of the borosilicate microcrystal glass also contributed to the enhancement of thermal conductivity. Such ceramic composites with low sintering temperature and high thermal conductivity might be a promising material for electronic packaging applications.     

Synthesis of β-Si3N4 particles from α-Si3N4 particles

This report describes an investigation of the synthesis of β-Si₃N₄ particles from α-Si₃N₄ particles. The β fraction of Si₃N₄ particles was found to depend on temperature, heating time, and the type of crucibles in which the Si₃N₄ particles were heated. When Si₃N₄ particles were heated in a crucible made of carbon, most α-Si₃N₄ particles converted to β-Si₃N₄ after heating at 2000°C for 90 min in an atmosphere of N₂ of 9 kgf/cm². The morphology of the resulting β-Si₃N₄ particles appeared as a whisker shape. When Si₃N₄ particles were heated in a crucible made of boron nitride, most α-Si₃N₄ particles converted to β-Si₃N₄ after heating at 2000°C for 480min in an atmosphere of N₂ of 9kgf/cm². The resulting morphology was equiaxed. It is suspected that the transformation occurs via the gas phase and is affected by the partial pressure of oxygen in the atmosphere.