Room and high temperature flexural failure of spark plasma sintered boron carbide

Dense (95–98.6%) bulk boron carbide prepared by Spark Plasma Sintering (SPS) in Ar or N₂ atmospheres were subject to three-point flexural tests at room and at 1600 °C. Eight different consolidation conditions were used via SPS of commercially available B₄C powder. Resulting specimens had similar grain size not exceeding 4 µm and room-temperature bending strength (σ_25 °C) of 300–600 MPa, suggesting that difference in σ_25 °C is due to development of secondary phases in monolithic boron carbide ceramics during SPS processing. To explain such difference the composition of boron carbide and secondary phases observed by XRD and Raman spectroscopy. The variation in intensity of the Raman peak at 490 cm⁻¹ of boron carbide suggests modification of the boron carbide composition and a higher intensity correlates with a higher room-temperature bending strength (σ_25 °C) and Vickers hardness (HV). Secondary phases can modify the level of mechanical characteristics within some general trends that are not dependent on additives (with some exceptions) or technologies. Namely, HV increases, σ_25 °C decreases, and the ratio σ_1600 °C/σ_25 °C (σ_1600 °C – bending strength at 1600 °C) is lower when fracture toughness (K_IC) is higher. The ratio σ_1600 °C/σ_25 °C shows two regions of low and high K_IC delimited by K_IC=4.1 MPa m^0.5: in the low K_IC region, boron carbide specimens are produced in nitrogen.