Effect of Al addition on SiC–B4C cermet prepared by pressureless sintering and spark plasma sintering methods

SiC–B₄C–Al cermets containing 5, 10 and 20 wt.% of Al were fabricated by high-energy planetary milling followed by conventional sintering and spark plasma sintering (SPS) techniques separately. The average particle size reduced to ~ 3 μm from an initial size of 45 μm after 10 h of milling. The as-milled powders were conventionally sintered at 1950 °C for 30 min under argon atmosphere and SPS was carried out at 1300 °C for 5 min under 50 MPa applied pressure. The formation of Al₈B₄C₇ and AlB₁₂ phases during conventional sintering and SPS were confirmed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses. The formation of Al₈B₄C₇ at 700 °C and AlB₁₂ at 1000 °C was well supported by XRD and differential scanning calorimetry (DSC). The maximum relative density, microhardness and indentation fracture resistance of SiC–B₄C–10Al consolidated by SPS are 97%, 23.80 GPa and 3.28 MPa·m^1/2, respectively.