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<p>Nanoscale Si<sub>3</sub>N<sub>4</sub> powder facilitates densification at lower sintering temperatures, allowing sintered bodies to more readily approach theoretical density and achieve nanoscale microstructures. In this study, amorphous nanoscale Si<sub>3</sub>N<sub>4</sub> powder was used as the starting material and consolidated via spark plasma sintering (SPS) at a heating rate of 100°C/min to investigate the effects of rapid sintering on phase ratio, microstructure, and mechanical properties. A fully densified 62% Si<sub>3</sub>N<sub>4</sub>/38% O'-SiAlON composite ceramic can be achieved in 16 min. These characteristics were also compared with those of samples prepared by hot pressing at a heating rate of 10°C/min. At a sintering temperature of 1800°C, the β-Si<sub>3</sub>N<sub>4</sub> phase dominated in both methods. SPS promoted the formation of elongated rod-like grains while preserving a submicron matrix, thereby increasing the aspect ratio. Consequently, the SPS method not only improved the toughness of the Si<sub>3</sub>N<sub>4</sub>-based composites but also maintained high hardness due to the strong matrix.</p>

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Densification Behavior and Microstructures of β-Si3N4/O'-SiAlON Composites Prepared by Spark Plasma Sintering

  • 期刊论文

  • 发表日期：

    2026年7月20日

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  • Yi-Chi Huang,
  • Alex C. H. Lee,
  • Horng-Hwa Lu,
  • Jow-Lay Huang

摘要

Nanoscale Si3N4 powder facilitates densification at lower sintering temperatures, allowing sintered bodies to more readily approach theoretical density and achieve nanoscale microstructures. In this study, amorphous nanoscale Si3N4 powder was used as the starting material and consolidated via spark plasma sintering (SPS) at a heating rate of 100°C/min to investigate the effects of rapid sintering on phase ratio, microstructure, and mechanical properties. A fully densified 62% Si3N4/38% O'-SiAlON composite ceramic can be achieved in 16 min. These characteristics were also compared with those of samples prepared by hot pressing at a heating rate of 10°C/min. At a sintering temperature of 1800°C, the β-Si3N4 phase dominated in both methods. SPS promoted the formation of elongated rod-like grains while preserving a submicron matrix, thereby increasing the aspect ratio. Consequently, the SPS method not only improved the toughness of the Si3N4-based composites but also maintained high hardness due to the strong matrix.