DEVELOPMENT OF α/β-SIALON NANO CERAMIC FOR WEAR RESISTANCE APPLICATIONS
Moath Mohammed Al Malki, Taher Laoui
كلية الهندسة-جامعة الملك فهد للبترول والمعادن · السعودية
Si3N4 ceramics are known for their outstanding performance in challenging environments. However, due to the covalent binding present between Si and N, fully-dense Si3N4 ceramics are difficult to achieve via solid state sintering. Thus, SiAlON ceramics have been introduced into the field, in which part of Si and N are replaced by Al and O, respectively.The use of nano-size starting powder materials in the present work proved its positive impact in accelerating the reaction kinetics, yielding lower sintering temperature and shorter holding (dwell) time. Spark plasma sintering technique was utilized for consolidation to benefit from its novelty in limiting phase transformation and undesirable grain growth, along with being an economical processing route when compared to conventional sintering techniques. Furthermore, calcium (Ca) additive was shown to enhance the densification and wetting through the production of a liquid phase, with the least crystal distortion in α- SiAlON unit cell, which was reflected in a higher stability of the latter phase.Aluminum (Al) metal precursor was also explored in the context of improving sinterability at lower temperature, by partial substitution of aluminum nitride (AlN), up to 30% mol. It was observed that by such replacement, Ca- α- SiAlON could be sintered at lower peak temperature (1450oC) with either retained or enhanced mechanical properties. Additionally, Al metal precursor was shown to be a novel tool in preserving α-SiAlON at high sintering temperature (1600oC) by hindering alpha to beta phase transformation. Si metal precursor was examined as well in a similar context, however, it did not show the same behavior due to the limited chemical reactivity and its relative high melting point when compared to Al metal.Barium (Ba) additive was also investigated in this study to establish a basis for comparison with Ca additive. The formation of S-SiAlON was shown to be typical with Ba additive. Moreover, an increase in the amount of β-phase occurred when β-Si3N4 was introduced into the starting mixtures in place of amorphous Si3N4. The mechanical properties of the sintered Ba-SiAlON were far below than those of Ca- α- SiAlON due to the ionic radius of Ba, which lowered the stability of α- SiAlON, and the presence of low- hardness phases, such as SiO2 and S-SiAlON.In an attempt to improve the fracture toughness of sintered Ca- α- SiAlON ceramics, post- sintering heat treatment of selected samples was carried out at 1500oC for 12 hours in Ar environment. The fracture toughness was measured using crack indentation technique. An enhancement in the fracture toughness was observed after heat treatment, due to several contributing phenomena, such as crack deflection and crack bridging mechanisms as well as alpha to beta phase transformation. As a result of the devitrification process after heat treatment, Ca amount and N:O ratio increased in the grain boundary, as revealed by energy dispersive spectroscopy analysis, leading to harder grain boundary and, consequently, intergranular crack propagation.