Dielectric properties in GHz range of porous Si3N4–BN–SiO2 ceramics with considerable flexural strength prepared by low temperature sintering in air

Abstract

Porous Si₃N₄–BN–SiO₂ ceramics with ultimate apparent porosities between 0·140 and 0·799 were fabricated in air at 1100°C by partial sintering using core starch as both consolidator and pore former in the green bodies. The pores were derived from burning off the starch, the partial oxidation of silicon nitride and the stack of particles of the start materials. Effect of retaining time on the microstructure of sintering bodies was analysed by SEM analysis. Reference intensity ratio (RIR) technique based on the X-ray diffractometry results demonstrated the phase components content of sintered bodies. Influence of porosity on the flexural strength of porous Si₃N₄–BN–SiO₂ ceramics was investigated. The ceramic with a porosity of 0·140 attained a maximal flexural strength of 60±4·11 MPa. In addition, the dielectric constants and loss tangents were presented for porous Si₃N₄–BN–SiO₂ triphase ceramics in the frequency range of 18–40 GHz, and the real part of dielectric constant of the materials reached as low as 2·67 at the porosity of 0·732 at a frequency of 20 GHz.     

Preparation and properties of pressureless-sintered porous Si3N4

Wave-transparent materials used at high temperature environment generated by high supersonic and hypersonic speeds must possess excellent mechanical property. In this paper, porous Si₃N₄ ceramics with high strength were fabricated by low molding pressure (10 MPa) and pressureless sintering process, without any other pore forming agents. The sintering behavior and the effect of porosity on the mechanical strength and dielectric properties were investigated. The flexural strength of porous Si₃N₄ ceramics was up to 57–176 MPa with porosity of 45–60%, dielectric constant of 2.35–3.39, and dielectric loss of 1.6–3.5 × 10⁻³ in the frequency range of 8–18 GHz, at room temperature. With the increase of porosity, the flexural strength, dielectric constant, and dielectric loss all decreased.     

Oxidation bonding of porous silicon nitride ceramics with high strength and low dielectric constant

Silica (SiO₂) bonded porous silicon nitride (Si₃N₄) ceramics were fabricated from α-Si₃N₄ powder in air at 1200–1500 °C by the oxidation bonding process. Si₃N₄ particles are bonded by the oxidation-derive SiO₂ and the pores derived from the stack of Si₃N₄ particles and the release of N₂ and SiO gas during sintering. The influence of the sintering temperature and holding time on the Si₃N₄ oxidation degree, porosity, flexural strength and dielectric properties of porous Si₃N₄ ceramics was investigated. A high flexural strength of 136.9 MPa was obtained by avoiding the crystallization of silica and forming the well-developed necks between Si₃N₄ particles. Due to the high porosity and Si₃N₄ oxidation degree, the dielectric constant (at 1 GHz) reaches as low as 3.1.     

Effects of talc and clay addition on pressureless sintering of porous Si<Subscript>3</Subscript>N<Subscript>4</Subscript> ceramics

Porous Si₃N₄ ceramics were successfully synthesized using cheaper talc and clay as sintering additives by pressureless sintering technology and the microstructure and mechanical properties of the ceramics were also investigated. The results indicated that the ceramics consisted of elongated β-Si₃N₄ and small Si₂N₂O grains. Fibrous β-Si₃N₄ grains developed in the porous microstructure, and the grain morphology and size were affected by different sintering conditions. Adding 20% talc and clay sintered at 1700°C for 2 h, the porous Si₃N₄ ceramics were obtained with excellent properties. The final mechanical properties of the Si₃N₄ ceramics were as follows: porosity, P ₀ = 45·39%; density, ρ = 1·663·g·cm⁻³; flexural strength, σ _b (average) = 131·59 MPa; Weibull modulus, m = 16·20.     

Preparation of zirconium pyrophosphate bonded silicon nitride porous ceramics

Abstract

A new method for preparing high bending strength porous silicon nitride ceramics with controlled porosity was developed using a pressureless sintering technique, using zirconium pyrophosphate as a binder. The fabrication process was described in detail and the sintering mechanism of porous ceramics was analysed by an X-ray diffraction method. The microstructure and mechanical properties of the porous Si₃N₄ ceramics were investigated, as a function of the content of ZrP₂O₇. The resultant porous silicon nitride ceramics sintered at low temperature (1000 and 1100°C) showed fine micropore structure and a high bending strength. Porous silicon nitride ceramics with porosity of 34–47%, a bending strength of 40–114 MPa and a Young's modulus of 20–50 GPa were obtained.     

Mechanical and microstructural properties of cordierite-bonded porous SiC ceramics processed by infiltration technique using various pore formers

Cordierite-bonded porous SiC ceramics were prepared by air sintering of cordierite sol infiltrated porous powder compacts of SiC with graphite and polymer microbeads as pore-forming agents. The effect of sintering temperature, type of pore former and its morphology on microstructure, mechanical strength, phase composition, porosity and pore size distribution pattern of porous SiC ceramics were investigated. Depending on type and size of pore former, the average pore diameter, porosities and flexural strength of the final ceramics sintered at 1400 °C varied in the range of ~ 7.6 to 10.1 µm, 34–49 vol% and 34–15 MPa, respectively. The strength–porosity relationship was explained by the minimum solid area (MSA) model. After mechanical stress was applied to the porous SiC ceramics, microstructures of fracture surface appeared without affecting dense struts of thickness ~ 2 to 10 µm showing restriction in crack propagation through interfacial zone of SiC particles. The effect of corrosion on oxide bond phases was investigated in strong acid and basic salt medium at 90 °C. The residual mechanical strength, SEM micrographs and EDX analyses were conducted on the corroded samples and explained the corrosion mechanisms.     

Effect of starting PMMA content on microstructure and properties of gel casting BN/Si3N4 ceramics with spherical-shaped pore structures

By gel casting with polymethylmethacrylate microbeads (PMMA) as pore-forming agent, porous boron nitride/silicon nitride (BN/Si₃N₄) composite ceramics were successfully prepared. The obtained ceramic shows bimodal hierarchical structures that composed of spherical-shaped micro pores depending on PMMA content and irregular sub-micro pores formed by the stacking of ceramic particles. Porosity of the porous BN/Si₃N₄ ceramics can be well controlled from 53.0 to 60.6 % by the PMMA content from 10 to 40 wt%, as well as the mechanical and dielectric properties. Effect of PMMA content on phase composition and the relationship between microstructure and the basic properties of the porous BN/Si₃N₄ ceramics was discussed in detail. Microstructure analysis reveals that the sub-micro pores acted as channels between micro pores. BN particles have a relatively denser distribution on the wall of spherical-shaped micro pores with a window between micro and sub-micro pores, and resulting in a half-closed micro pore structure, which is meaningful for material design with concentration of BN particles on the wall of pore structure.     

Preparation and characterization of porous Si<Subscript>3</Subscript>N<Subscript>4</Subscript> ceramics prepared by compression molding and slip casting methods

Porous silicon nitride (Si₃N₄) ceramics were fabricated by compression molding and slip casting methods using petroleum coke as pore forming agent, and Y₂O₃-Al₂O₃ as sintering additives. Microstructure, mechanical properties and gas permeability of porous Si₃N₄ ceramics were investigated. The mechanical properties and microstructure of porous Si₃N₄ ceramics prepared by compression molding were better than those which were prepared by slip casting method, whereas slip casting method is suitable for the preparation of porous Si₃N₄ ceramics with higher porosity and excellent gas permeability.     

Mechanical and dielectric properties of porous Si3N4–SiO2 composite ceramics

In order to prepare a structural/functional material with not only higher mechanical properties but also lower dielectric constant and dielectric loss, a novel process combining oxidation-bonding with sol–gel infiltration-sintering was developed to fabricate a porous Si₃N₄–SiO₂ composite ceramic. By choosing 1250 °C as the oxidation-bonding temperature, the crystallization of oxidation-derived silica was prevented. Sol–gel infiltration and sintering process resulted in an increase of density and the formation of well-distributed micro-pores with both uniform pore size and smooth pore wall, which made the porous Si₃N₄–SiO₂ composite ceramic show both good mechanical and dielectric properties. The ceramic with a porosity of 23.9% attained a flexural strength of 120 MPa, a Vickers hardness of 4.1 GPa, a fracture toughness of 1.4 MPa m^1/2, and a dielectric constant of 3.80 with a dielectric loss of 3.11 × 10⁻³ at a resonant frequency of 14 GHz.     

Effect of grain size distribution on the strength of porous Si3N4 ceramics composed of elongated β-Si3N4 grains

The grain size distributions (diameter and aspect ratio) of porous Si₃N₄ ceramics composed of elongated -Si₃N₄ grains were evaluated statistically, and their effect on the pore size distribution and the flexural strength of the porous Si₃N₄ was investigated. Porous Si₃N₄ ceramics having porosities of 27 to 43% and median pore diameters of 0.56 to 0.96 m were used as specimens. The grain diameter distribution was well correlated to the pore size distribution of the porous Si₃N₄ ceramics. We concluded that the strength of the porous Si₃N₄ ceramics increased with increasing grain length of -Si₃N₄ as well as with decreasing porosity.     

Effect of sintering parameters on the microstructure and properties of strontium modified PZT ceramics prepared using spray-dried powders

PZT powders of the composition Pb_0.94Sr_0.06 (Zr_0.53Ti_0.47)O₃, prepared by spray drying and calcining techniques, were processed to sintered ceramics by conventional cold pressing and sintering at various temperatures and periods between 1000 to 1250°C for 0.5 to 12h. Sintered ceramics were evaluated for their microstructure and electromechanical properties. Highly dense ceramics having bulk density of the order of 97% of the theoretical value could be obtained after sintering at a considerably lower temperature of 1000°C in comparison to the 1300°C generally required for powders prepared by conventional ceramic processing. However, the increase in sintering temperature of reactive spray-dried powders causes the entrapment of closed pores as a result of exaggerated grain growth and subsequent pore coarsening thereby leading to a decrease in the bulk density of the ceramics. It has been observed that minor variations in the sintering parameters influence the porosity, grain size and electromechanical properties. Values of the dielectric constant, piezoelectric strain coefficient and electromechanic coupling factor increase with the increase in grain size and decrease with the increase in porosity of the sintered ceramic whereas the dielectric dissipation factor decreases with the increase in sintering temperature.     

Pore structure control of starch processed silicon nitride porous ceramics with near-zero shrinkage

Zirconium phosphate (ZrP₂O₇) bonded silicon nitride (Si₃N₄) porous ceramics were prepared using starch powder as the pore forming agent and pressureless sintering technique. The obtained results show that the porosity of the sintered starch processed 25 wt.% ZrP₂O₇ bonded Si₃N₄ porous ceramics is 36-62.3%. All the samples exhibit surprisingly low linear shrinkage. The pores are formed by the continuous reaction of ZrP₂O₇ at ~ 250 °C and burnout of starch at ~ 550 °C, during which a large amount of pores with pore sizes of less than 0.5 μm and ~ 10 μm are formed.     

Microstructure and properties of porous silicon nitride ceramics prepared by gel-casting and gas pressure sintering

Wave-transparent porous Si₃N₄ ceramics were prepared by gel-casting and gas pressure sintering, and the effects of solid loading on microstructure, mechanical and dielectric properties were investigated. Microstructures with interlocked elongated β-Si₃N₄ grains and uniformly distributed pores were observed, while both the β-Si₃N₄ phase content and grain aspect ratio reduced as the solid loading increased due to the restrained anisotropic growth of β-Si₃N₄ grains. As the solid loading increased from 30 to 45 vol.%, the porosity of ceramics declined from 57.6% to 36.4%. The flexural strength increased linearly from 108.3 to 235.1 MPa, and the dielectric constant and loss tangent of ceramics increased from 2.63 and 2.85 × 10⁻³ to 3.68 and 3.56 × 10⁻³ (10 GHz), respectively.     

Effect of sintering temperature and time on microwave dielectric properties of CaNb2O6 ceramics

The microwave dielectric properties of CaNb₂O₆ ceramics were investigated with a view to their application in mobile communication. The CaNb₂O₆ ceramics were prepared by the conventional solid-state method with various sintering temperatures and sintering times. A maximum density of 4.67 g/cm³ was obtained for CaNb₂O₆ ceramic, sintered at 1,400 °C for 4 h. Dielectric constants (ε _r ) of 13.3–18.1 and quality factor (Q × f) of 12,200–50,000 GHz were obtained at sintering temperatures in the range 1,300–1,500 °C for 4 h. Dielectric constants (ε _r ) of 18.0–18.1 and quality factor (Q × f) of 44,300–50,000 GHz were obtained for sintering times in the range 2–6 h at a sintering temperature of 1,400 °C. A dielectric constant (ε _r ) of 18.1, a quality factor (Q × f) of 50,000 GHz, and a temperature coefficient of resonant frequency (τ _f ) of ?54 ppm/°C were obtained when CaNb₂O₆ ceramics were sintered at 1,400 °C for 4 h.     

Improvement microwave dielectric properties of Zn2SnO4 ceramics by substituting Sn4+ with Si4+

The microwave dielectric properties of Zn₂(Sn_(1?x)Si_x)O₄ ceramics were examined with a view to their exploitation for mobile communication. The Zn₂(Sn_(1?x)Si_x)O₄ ceramics were prepared by the conventional solid-state method with various sintering temperatures. The X-ray diffraction patterns of the Zn₂(Sn_(1?x)Si_x)O₄ ceramics revealed no significant variation of phase with sintering temperatures. A maximum density of 6.24 g/cm³ was obtained for Zn₂(Sn_0.93Si_0.07)O₄ ceramic, sintered at 1,175 °C for 4 h. Dielectric constant (? _r ) of 8.12, quality factor (Q × f) of 55,500 GHz, and temperature coefficient of resonant frequency (τ _f ) of ?119.3 ppm/°C were obtained for Zn₂(Sn_0.93Si_0.07)O₄ ceramics that were sintered at 1,175 °C for 4 h.     

Study on particle-stabilized Si3N4 ceramic foams

The stability of bubbles and the microstructures of sintered Si₃N₄ ceramic foams produced by direct foaming method were investigated. The bubbles produced by short-chain amphiphiles (propyl gallate) have higher stability as compared with that produced by long-chain surfactants (TritonX-114). Si₃N₄ ceramic foams using short-chain amphiphile are particle-stabilized one, the pore cells are spherical and closed, and cell surfaces are smooth and dense. The pore cells of sintered Si₃N₄ ceramic foams using TritonX-114 foaming are coarse and large, and pore cells are polyhedral. High gas-pressure sintering is conducive to the development of the whisker-like microstructures in Si₃N₄ ceramic foams. The sintered Si₃N₄ ceramic foams with the whisker-like microstructure are quite promising for improving the mechanical strength of the ceramics by a simple and safe way.     

Effects of LiF addition on the sintering behavior and microwave dielectric properties of Li<Subscript>2</Subscript>Mg<Subscript>3</Subscript>SnO<Subscript>6</Subscript> ceramics

Li₂Mg₃SnO₆ (abbreviation for LMS) ceramics doped with 1–4 wt% lithium fluoride (LiF) were prepared by the conventional solid-state reaction method. The effects of LiF addition on the phase compositions, sintering behaviors and microwave dielectric properties of LMS ceramics were investigated. A small amount of LiF addition could effectively decrease the sintering temperatures due to the liquid phase in the sintering process and induced no apparent degradation of the microwave dielectric properties. The optimized quality factor values for each composition firstly increased and then decreased with the increase of the LiF content. Whereas, the optimized dielectric permittivity increased with increasing of the LiF content. Distinguished microwave dielectric properties with a dielectric constant (ε _r) of 11.13, a quality factor (Q·f) of 104,750 GHz, and a temperature coefficient of resonant frequency (τ _f ) of ?10.83 ppm/°C were obtained for LMS ceramics sintered at 950?°C doped with 3 wt% LiF, which showed that the materials were suitable for the low temperature co-fired ceramics applications (LTCC).     

Preparation process,microstructure and dielectric properties of Na0.5La0.5Cu3Ti4O12 ceramics by a sol–gel method

Effect of concentration, water content (molar ratio of the water and titanium) and pH value of the sol, and sintering temperatures and holding time on microstructure and dielectric properties of Na_0.5La_0.5Cu₃Ti₄O₁₂ (NLCTO) ceramics by a sol–gel method were investigated in detail, respectively. It is found that the optimum concentration, the molar ratio of the water and titanium, and pH value of the sol were 1.00 mol/L, 11.0, and 0.3, respectively. The NLCTO ceramics sintered at 1,080 °C for 10 h exhibited more homogeneous microstructure, higher dielectric constant (about 1.1–1.8 × 10⁴) and lower dielectric loss (about 0.051–0.064 at 1–10 kHz). The higher dielectric constant of the NLCTO ceramics might be due to the internal barrier layer capacitor effect. The NLCTO ceramics prepared by the sol–gel method showed two kinds of dielectric relaxation at higher temperature by electric modulus analysis, and two relaxation activation energy values were obtained.     

Structure,dielectric property and impedance spectroscopy of La<Subscript>2/3</Subscript>Cu<Subscript>3</Subscript>Ti<Subscript>4</Subscript>O<Subscript>12</Subscript> ceramics by sol–gel method

La_2/3Cu₃Ti₄O₁₂ (LCTO) precursor powders were synthesized by the sol–gel method. Effect of sol conditions and sintering process on microstructure and dielectric properties of LCTO powders or ceramics were investigated systematically. The optimum sol conditions for the synthesis of precursor powders were as follows: the Ti⁴⁺ concentration of 1.00 mol/L, the molar ratio of water and titanium of 5.6:1 and the sol pH of 1.0, respectively. After sintered at 1105 °C for 15 h, the LCTO ceramics exhibited more homogeneous microstructure, much higher dielectric constant (ca 09–1.6 × 10⁴) and lower dielectric loss (ca 0.057). The higher dielectric constant of the LCTO ceramics might be due to the internal barrier layer capacitor effect. The LCTO ceramics showed two kinds of conductivity activation energy for grain boundary conductivity from complex impedance analysis. The transition temperature of two activation energy values occured between 170 and 210 °C. The temperature range of 170–210 °C was critical pseudocritical region of the dielectric constant, dielectric loss and activation energy. Furthermore, it was concluded that the grain boundary play an important role for electrical properties.     

Preparation and characterization of a novel willemite bioceramic

Willemite (Zn₂SiO₄) ceramics were prepared by sintering the willemite green compacts. The effects of sintering temperature on the linear shrinkage, porosity and mechanical strength of the ceramics were examined. With the sintering temperature increased, the linear shrinkage of the ceramics increased and the porosity decreased. When sintered at 1,300°C, willemite ceramics showed mechanical properties of the same order of magnitude as values for human cortical bone, as measured by bending strength (91.2 ± 4.2 MPa) and Young’s modulus (37.5 ± 1.5 GPa). In addition, the adhesion and proliferation of rabbit bone marrow stromal cells (BMSCs) on willemite ceramics was investigated. The results showed that the ceramics supported cell adhesion and stimulated the proliferation. All these findings suggest that willemite ceramics possess suitable mechanical properties and favorable biocompatibility and might be a promising biomaterial for bone implant applications.