Mechanical and thermal properties of light weight boron-mullite Al5BO9

Al₅BO₉ is a promising thermal sealing material for hypersonic vehicles due to its low density, theoretically predicted low shear modulus, and low thermal conductivity. However, experimental investigations on the mechanical and thermal properties of bulk Al₅BO₉ have not been carried out. Herein, we report the mechanical and thermal properties of bulk Al₅BO₉ prepared by spark plasma sintering of solid-state reaction synthesized Al₅BO₉ powders. The bulk (B), shear (G), and Young's (E) moduli are 148 GPa, 85 GPa, and 214 GPa, respectively, which are close to the theoretical values. The Pugh's ratio G/B is 0.574, indicating its intrinsic damage tolerance, which is also revealed by Hertzian contact test. The Vickers hardness (H_v) is 10.8 GPa, being lower than mullite. The flexural strength, compressive strength, and fracture toughness are, respectively, 277 ± 35 MPa, 814 ± 75 MPa, and 2.4 ± 0.3 MPa·m^1/2, which are close to those of mullite. Al₅BO₉ has anisotropic coefficient of thermal expansion (CTE) in three crystallographic directions, ie α_a = (4.40 ± 0.21) × 10^?6 K^?1, α_b = (7.11 ± 0.18) × 10^?6 K^?1, α_c = (6.70 ± 0.29) × 10^?6 K^?1 from Debye temperature to 1473 K, which are underpinned by its structural feature, ie lower α_a is resulted from the edge-shared AlO₆ octahedron chains along the 100] direction. The average CTE is (6.05 ± 0.06) × 10^?6 K^?1. The thermal conductivity declines with temperature as κ = 1336.39/T + 1.97, consisting with predicted trend from Slack's model. The low thermal conductivity and low density guarantee Al₅BO₉ a promising candidate as ceramic wafer in the seal structure for hypersonic vehicles.