Si3N4-Al2O3-ZrO3 hot pressed composites

Si3N4-Al2O3-ZrO3 hot pressed composites

Materials Chemistry, and Physics, qqA12~3-“r02 A. HOT (1987) 205-729 PRESSED P. VINCENZTNT RELLOSI, CNR, 18 Research TRTEC, 205 COMPOSIT...

1MB Sizes 0 Downloads 111 Views

Materials

Chemistry, and Physics,

qqA12~3-“r02

A.

HOT

(1987) 205-729

PRESSED

P. VINCENZTNT

RELLOSI,

CNR,

18

Research

TRTEC,

205

COMPOSITES

and

G.N.

BABTNT

for

Ceramics

Institute

Technology,

Faenza

(Ttaly) Received

March

23,

1987,

accepted

May

13,

1987

ABSTRACT Development

of

microstructure, Vickers

room

temperature

MOR,

been

studied

83wt%Si

for

pressed

at

terious

presence

34.4MPa

Microcracking thermal

has

to

PI-phase

with

zirconia. Si3N4-A1

The 0

to

phases

the

substantial

in

of

the

of

a-j3

the

toughness

MOR

mismatch

microcrack

~370

for

a grain

is of

No

from

from MPa

to

between

model

conversion.

the

dele-

materials.

parameters

results

increase,

properly

ZrO2-induced

cell

hot

The

these

and

have

composites

temperatures.

avoided

because

materialto-

more

specific

is

hehaviour

toughness

A phenomenological

of and

reference

and

and

variation

progress

hardness

heen2azcrihed

than

times

observed

for

the in

Zr-O-N

heen

expansion

N -5wt%A1203-12wt%Zr02 vzr4ous

coefficients.

account

improvement

has

of

expansion

gested

for

thermal microhardness

sug-

the

detectable

the

presence

MPa

for

ZrO

boundary

of

a

composite ghase

effect,

grain

boundary

strengthening.

INTRODnCTION The phase

required

material and

an

size is

have amount

additive

to

limits

strength

nitride in

metastable,

of been

sinter

its

shown

related

difficult

0254-0584/87/$3.50

because

Tn

its

impurity

a fully

at

silicon to

to

metal

Si 7 N 4 to

performance

sintered

distribution.

and

high

nitride

improve

with

content,

of

the

high

dense

and

high

temperatures. and the

particle

Zr02-strengthened

rich

hot

Toughness

pressed

addition size

strength

silicon

of and

m-ZrO

2

[II

particle

N , retention of t-ZrO 3 4 2 mismatch, and the increa-

Si

thermal

0 Elsevier Sequoia/Printed

in The Netherlands

206

sed toughness has been

is mostly

shown

strengthening

associated

in binary

to lower

the hot pressing

reduction

of the amount

so 19,101.

tion

Also

to offer

cutting

Evolution

good high-temperature phase

performances made

have

formed

[Z-B]

during

inconsequent

hot

for the

phases,

properties,

was not detected

been

oxidation

but Al 0 did 2 3 as sintering aid has been

reported

from hot pressed

of microstructure,

temperature

Vickers

of zyttrite

(up to -

[2] or MgOtY 2 0 3 t3*41

proved

of such deleterious

it

and the forma[11,12].

in cast

iron machining

Si N -Al 0 -31'0 compo34 23 2

b 3 ) 141 .

sitions

room

such as MgO

temperature

the addition

tools

boundary

are readily

However

that microcrack

temperatures

grain

which

aids

of the easy-to-oxidize

Excellent using

to moderate

phases,

Use of sintering

pressing.

microcracking.

compositions,

of the catastrophic

of ZrN and or Zr-O-N

proven

Si3N4-ZrO2

is restricted

1073 K) because

with

flexural

microhardness

linear

strength

thermal

expansion

( (I), toughness

(HV) have been

studied,

( A),

(Krc) and

in comparison

with

a Si N -Al 0 reference material, for a Si3N4-A1203-Zr02 composite 34 25 hot pressed at 34.4 MPa for different times and temperatures.

EXPERIMENTAL Two batches and 95wtX

of composition:

Si3N4-SwtX

Si3N4-Swt%

Al 0 - 12wtX Zr02 2 3 by wet mixing commercial

Al 0 were prepared 2 3 and ZrO 2 powders (Table I) and homogeneizing

Si N Al 0 34' 23 plastic jar with

Table

83wt%

I. Main

alumina

balls

characteristics

in isobutyl

alcohol

of the starting

in

a

far 72 hours.

powders.

2 -1 : grain size surface area BET=lB,O m g pm: particle shape: irregular; from -_o,o~i to-4.0 a/pratio 13.4; chemical analysis: NI 38%, CW -1%: O-1.496, Fe-0.04%, Al-0.06%, Ca-0.03%.

Si N (SZ a$ck LC 10)

: Specific

Al 0 (A? c:a A-16)

: S.s.a.

BET

ZrO,,(Harshaw)

: S.s.a.

2 -1 ;mean grain BET 28 m g

2 -1 ; grain 17.7 m g

size from--.5

to-lpm

size --.4 urn.

207 Hot

pressing

was

performed

uniaxially,

in

induction

heated

-3 graphoil-lined Bulk

dies

MOR

microhardness,

pressed

and

plungers,

in

thermal

microstructure,

density,

rature

Bulk

graphite

and

toughness

torr

10

expansion were

and

vacuum. room

determined

tempe-

on

the

hoi

materials:

density

was

measured

by

geometrical

analyses

were

performed

was

investigated

and/or

liquid

displacement

techniques. + Microstructural

by

XRD

, SEM

++

+++ , WDS

and

++++ EDS

.

Thermal

expansion

1573

at

K,

sawed

a heating

from

the

Microhardness

has

pm)

surfaces

and

on-line

pression of

10

by

of

pressed been

and

g

on

toughness

K

was

a Vickers value

Three

point

30

cut

crosshead

Table

mm

up

samples

a

loading

load.

rate

Each

H

polished

to

diamond

(down

* equipped

microdurometer

measured

diamond

represents

room from speed

6 tests.

the

4x4~40

diamond

by

of

0.3

value

with

to

a detector 10

mm/set,

represents

0.1

set

the

im-

average

V

Hot

indentation

an

pyramidal the

average

IC

of

temperature

determinations.

utilizing

mm

on

SK/min,

measured

at

500

room

billets.

a Vickers

computer,

time

Fracture

Each

hot

rate

from

temperature

MOR

was

indenter

pressed

billets,

of

0.5

mm/min.

Each

microstructure

of

the

a load

of

10

5 determinations. ** measured on specimens

hot

conditions

at

test kg.

of

the

pressing

fracture

with

value and

26

mm

represents relevant

hot

pressed

materials

, Ni

filter,

F.R.G.

span

and

the

a

average

parameters are

3x3x

collected

of in

II.

+

Siemens

++

500,

CuK

Autoscan,

Etec

Corp.

+++

Autospec,

Etec

Corp.,

U.S.A.

++++

Edax

Philips,

NL.

0

Netzsch

* XI

Zwick 3212 microdurometer, Instrom,universal testing

PV

D

9100,

Geratebau

U.S.A.

- apparatus,

F.R.G.

F.R.G. machine,mod.l195,Canton,

MS,

U.S.A.

pressing

1853

1923

1923

1923

1973

1923

1923

1923

AZ2

AZ3

AZ4

AZ5

AZ6

Al

A2

A3

(K)

1813

T

Hot

AZ1

Sample

Table II. Composition, pressed from Si3N4-Swt%

pressing

60

30

30

(min)

220

120

60

120

220

120

t

conditions

A1203-12wt%

hot

0.87

0.60

0.31

0.94

0.92

0.74

0.72

0.32

0.13

conditions ZrO 2 and

and

some

a-Si

2 3

0

13.5

40.0

68.0

6.5

8.0

26.0

28.0

68.0

87.0

%

Al

N 34

systems.

microstructural

Residual

Si3N4-6wt%

Relative

99

98

95

98

97

97

97

95

93

%

of pressure

density

parameters (Applied

0.90

0.85

0.72

0.93

0.86

0.56

1.0

hot

(pm)

grain

MPa).

0.48

size

Mean

34.4

materials

209

RESULTS Microstructure Phase

composition a-si

Unconverted amounts

of

tative

N 3 4'

X-SiAlON

estimation

of

Table

III.

Approximate

tive

crystal

phase

Si3N4-Al

0

b5]

were

the

relative

XRD

Si2N20,

detected

by

amounts

m-Zr02 XRD. (Table

semiquantitative

content

in

the

hot

a-Si

N 3 4

P-SiAlON

III)

evaluation

pressed

Si2N20

and

A gross

Si

materials.

2 3

Sample

$'-SiAlON,

ZrO2Cm)

minor semiquantiwas

derived

of

the

N -A1203-ZrO 3 4

relaand

2

X-SiAlON

zr02w

AZ1

56

9

22

7

3

AZ2

41

20

22

7

3

AZ3

20

48

13

a

3

AZ4

17

51

13

a

3

AZ5

6

63

15

5

3

AZ6

5

69

16

3

2

63

28

Al A2

34

54

9

A3

from of

the each

racteristic

with

the

(height)

to

the

sum

reflections

Important

features

progress

(m+t)-ZrO

__

traces

40

_-

2

7

_-

2

82

intensity phase

9

of

content

in

ratio

of of

are:

the all i)

thea--_ the

of

a characteristic

intensities crystal

(heights)

of

the

cha-

phases.

a variations

of

conversion

and,

ii)

pressed

at

materials

reflection

hot

p'-SiAlON

spacings

a decreased higher

tempera-

2 tures

(1923-1973

K),

in

grain

zirconia

the

a-SiJN4--+P'-SiAlON The

which

boundary

(heights)

liquid

a partial

solubilization

of

phase.

transformation

a-Si3N4-p'-SiAlON

intensities

indicates

transformation of

characteristic

was XRD

assessed reflections:

from

the

210

I a

(210)

I

+

(102)

(1)

p'=

/

I

(210)

Residual samples

+ 1

a-Si

hot

(102)

N vs 3 4 --

pressed

hot

at

different

a

1

-

I

Residual

Although fine as N

the

MgO[20

, 211 stand

da =

where

k

of

I

I

250

200

150 (min.) pressing

time

for

the

S i3N4-Al

the On

is

the

a-phase this

co1 lected

data

Y203-

1 81

p7

for

a

appear

previous

order

1st

studies

, Ce02

order

cient

insuffi

[19]

similar

on

and

HPSN

kinetics,

to

precisely systems

sintered

desuch

Si-Al-O-

i.e.:

(2)

transformation in

the

rate

constant

and

a the

concentration

sample.

assumption,

transformation,

0 2 3

studied.

- ka

dt

for

2

reaction [16],

time

vs hot N zoipositions

a-Si

the

1,

temperatures.

100

Si3N4-A1203-ZrO

Fig.

ZrOz

hot pressing 1.

in

F

50

0

and

plotted

5wt%A1203

l! Fig.

is

b c

5wt%AI,03+12wt%

____

time

K

-1813

z

pressing

Ea= -450

apparent kJ/mol,

activation derived

energy from

the

for

the

Arrhenius

a-+ plot

p’ of

211

\ \\S1~N4+5wt%MgO \ kTmol-'

\<520 \

\

\

\

\

\

1F4/T Fig.

2.

sion

reaction.

Arrhenius

plot Data

of

for

(K-‘)

the

MgO-

rate and

constant

CeO 2

comparison.

Fig.

2,

compares

C-470

kJ/mol)

Si 3 N 4

(-480

with [19]

parameters

Previous

studies

sions

of

the of

Al

constant

0 is 2 3

P'-SiAlON near SiA'ON

Si

XRD

decrease phase

c-500

[17]

similar

and

at

of

N in

sites

by

(Fig.

the

hot

pressed

and

conver-

reported

CeO

b6,17,22]

stress

show

cell

3). Thus,

Al

and

which

and

for

-Si N 3 4 2 Y203-

temperature.

increase the

Al

amount

0 resp. a shift

results

parameters the

an to

materials,

reflections, of

also

kJ/mol'

proportional

our

for

a-p’

the

are

B'-SiAlON

[15,23-261

PLSiAlON

cupation

obtained

MgO-Si3N4

kJ/mol)

Lattice

results

for

-HPSN

with and

of

an

solid

cell

dimen-

fractional the

recorded

oc-

overall in

the

approximately

increasing

0 in

the

Although was

in

of

amount solution

liof

the

within

212

UNIT

CELL I 1

AA

DIMENSIONS

5Wt%

Al203

o l 5Wt%

Al203

‘-4s

--__

J

c (A, +12wt% ZrOz

2.96 2.94

I

---a

--so_ -_0

aA 7.66

,

-&OS_

2.92

0

2.90

)

7.64 7.62 7.60 (

I

3.

Fig.

Variation

function and

zro

p'content

Si

N

perztures

the

- Al

conversion,

the

cell

dimensions

( PI/( Cl++‘))

compositions 0 2 3

appear

[ZO] . On

lattice

lid

solution from

to

with

i.e.

the

range

.a

1I I

of

the

for

samples

of

hot

pressed

for

P'-SiAlON

as

Si

0 -

N -Al

dlf 3t

a

erezt3tem-

azd4times.

P'-SiAlON

ported

in

of

-I

I

0.6

0.4

the

the

- 0.3

to

with

increasing

basis

parameters in

decrease

of

of hot

the

progress

pressing

the

known

p'-SiAlON

pressed

time,

as

and

Al

has

mol%,

according

to

fracture

surfaces

re-

53between

been the

a-p'

III

the

0 2 3'

the

previously

relationships

materials

-0.1

of

alumina

in

evaluated

hot

soto

pressing

schedule.

Morphology -Polished, tion

and

etched

morphology

morphology

of

Fig.

clustering

of

ZrO

step, the

which dense

and of 4 on

2

occurred,

resulted

in

The

SEM

body.

shown 2' the sample

ZrO

grain

by

sizes

micrograph

the

AZ2,

possibly

were

polished

indicates

during from of

examined.

a polished

surface that

the

-0.2

DistribuSEM

noticeable

homogenization

urn to

-10

surface

pm of

in A3

213

Fig.

4.

showing

SEM

micrograph

clustering

SEM

Fig.

5.

Dark

areas

of

of

micrograph are

a polished

starting

associated

of

ZrO

surface

the

AZ2

sample

of

the

A3

sample.

2

a polished with

of

particles.

Si_N_O.

surface

214 (Fig.

Fi), shows

an homogeneous to silicon re path

very minor distribution

oxynitride.

is evident

from

amounts

of isolated

of darker

A mixed

areas

residual

which

might

pores

correspond

intergranularltransgranular

SEM micrographs

of fracture

and

fractu-

surfaces

for

both

Si N -A1203-ZrO 2 (Figs. 6a, c) and Si3N4-Al 2 0 3 (Figs. 7a, b). 3 4 Similar to other HPSN [19, 27-321 a preferred orientation was

detected, peaks,

On the basis

the growing

of the intensities

$-SiAlON

grains

show

of X-ray a trend

diffraction

to align

their

a)

of fracture surfaces Fig. 6. SEM micrographs pressed at: a) AZ3, 1923 K, 60 min.: b) AZ5, AZ6, 1973 K, 120 min.

of AZ materials, hot 1923 K, 220 min.: c)

b)

a) Fig.

7. SEM micrograph

basal

of fracture

and b) A3 sample

60 min),

plane

aligning

(002) parallel

effect

surface

of Al sample

a)

(1923 K,

(1923 K, 220 min).

with

increases

the hot pressing

at increased

direction.

hot pressing

This

time.

Properties Thermal Repeated ple.

expansion thermal

Dilatometric

expansion

curves

Al 0 -ZrO materials 2 3 2 Fig. 9 shows thermal

runs were

of the first

(AZ3 and AZ5!

three

runs

are reported

on each AZ samfor some SiSN4in Figs.

8a, h.

for Si N -Al 0 samples (Al 34 23 which begins and A3). The martensitic t-+m transformation of ZrO 2 at temperatures as high as 1328 K is incomplete, the finer ZrO 2 symmetry down to room tempeparticles remaining in the tetragonal rature. relevant

Microcracking thermal

and ZrO 2 grains, the thermal The

curves

in the bulk

expansion originates

expansion

linear

expansion

performed

mismatch

of the AZ samples, between

the irreversible

the nitride

matrix

elongation

shown

by

curves.

thermal

expansion

coefficients

samples

for different

materials

and temperature

heating,

i.e. before ----

sformation,

due to the

and after

are collected

the beginning

in Table

IV.

f h 1 of AZ and A intervals

of the m--+t

on tran-

216

DILATOMETRIC

m

TESTS

It I I

1

I

,’

/ /

1

,

I

. //’

1 /

I/(

,/

/I

/’

,

/ /(/



, .

0 ~~

/

,

H

l’

/ I’

’ 6’

I’

a

,,e

/’

_--A/

/’

w ‘)r

500

1000 T

_--

500

1500

(Kb

1000

T(K)

1500

*

Fig. 8. Thermal expansion curves for AZ materials hysteresis loop and irreversible elongation. zro III'indicate order of the repeated tests. a) AZ3, b) AZ5, 1973 K, 220 min.

showing m-tSuffix I, II and 1973K, 60 min.;

217

500

1500

Id00

T(K) Fig.

9.

Al:

1923

Table

Thermal K,

IV.

expansion

60

Average

Sample

curves 1923

linear

K,

for 220

thermal

Si3N4-A1

0

2 3

A materials

hot

pressed

at:

min.

expansion

coefficients

materials,

within

( A)

selected

for tem-

ranges.

Thermal exp.

test

IO AZ1

A3:

2 and

Si3N4-A1203-ZrO perature

min;

A(293-91;

K)

h(293-111;

x10

X10

K)

3.09

3.14

4.!io

110

3.19

3.17

4.65

1110

3.16

3.27

4.75

3.35

3.38

4.40

AZ3

IO IO

3.43

3.48

4.!io

AZ5

110

3.29

3.32

1110

3.23

3.32

4.75 5.25

10

3.69

3.86

5.15

110

3.82 3.52

3.96 3.71

4.50 5.55

AZ6

1110

A(zgz-993

K)

A(293-1173

K)

A(293-1473

Al

IO

3.00

3.18

3.39

A3

10

2.89

3.06

3.30

K)

218 Microhardness values for both A and AZ samples (Table V) locat e at the V upper limit among other hot pressed Si N -based materials [33,34] 3 4 and exceed those for both single crystal (H = 19.6 GPa) and poV5OO lycrystalline Si3N4 p5,361 . No appreciable effect on microhardThe H

ness

results

Table xural

from

the presence

of ZrO

2'

V. Fracture toughness (K ), microhardness strength (CJ) of Si3N4- A?;03 and Si3N4-Al

Sample

H

K Ic (MPa1'2)

(H 0

2 3

) and fleXl?&rials.

U(MPa)

(CPa) V500

(' 30%) AZ1 AZ2 AZ3 AZ4 AZ5 AZ6

4.0 5.7 6.3 5.6 5.7 5.8

23.5 29.8 24.5 20.9 20.5 19.1

f f 4 f f 4

1.4 1.6 2.5 1.5 1.4 1.7

360 f: 33 n.d. n.d. 599 A 30 630 * 25 n.d.

Al A2 A3

6.0 6.0 4.9

29.5 f 23.6 * 21.2 f

3.5 2.5 2.2

314 * 20 n.d. 36% * 54

Fracture

toughness

and strength

Fracture

toughness

(KIcf has been

level

accuracy,

malized

from

the Evans

for hot pressed

K&H

alI2

where

H is the hardness

median

= 0.203

crack

length.

for SiAlON-based [1,39,40 ]-

(c/a

ZrO2

Si3N4

and Charles

(Table

V), at a 30%

L371 relationship

nor-

[38] :

-3/2 (3) a the impression

Measured

materials seems

obtained

radius

and C the radial/

K

values agree with Ic and silicon nitride-based

practically

not to affect

those

reported

composites

fracture

toughness

of our materials. MOR has been in Table -dense similar

determined

V, which

ZrO

2

show

containing

to those

on selected

a relevant material

previously

samples;

aincrease (AZ4 and AZ9)

reported

data

are reported

in the nearly-fullywhose

for SOwt%SiAlON

strengths

are

- SOwt%ZrO

2

Cutting

tool

Cutting

performance -

tools

were

tested

in

were

obtained

prepared

from

grey

cast

iron

(Az2,

AZ4,

A3)

Al,

A3,

Azl,

machining as

AZ2

and

AZ4

samples results

[z3 ( 141 . Excellent

reported

in

l1

Fig.

10,

which

show?

+IORKlNG CONDITIONS

,:utting speed

45Om mm-'

depth of cut

1.5m-n

feed rate

0.35mm rev-l

1.0 BREAKAGE

FREIXIENCE

high(100%) :A1

very

hlgh(507.1: S,AZl,AZ2. tow (50%) : YS very LOW (5%)

K,G,AZ4,A3

J

0.0 0

Fig.

10.

rials

in

ratory

pieces

Flank the

wear

vs --

number

machining

(S;

flank

number

of

wear

K;

Q)

vs. ---

laboratory

the

and

; YS:

number

some

pieces

iron,

Si

worked

for

compared

N -7wt%Y

cu?t!ng

of

pressed

worked

cast

Si3N4zbased

hot

Y,03-14wt%Si02)

of

grey

Si3N4-lOwt%CeO

(Ce:

commercial

other

200

100 Worked

the

: a,

AZ

and

to

other

A mate-

03-14wt%SiOz)

laboand

tools.

pieces

in

comparison

(Ce:

Si3N4-lOwt%CeO

; YS:

commercial

Si3N4-based

2 cutting

with

Si3N4-7wt% tools

(s,K,Q).

DISCUSSION Development

of

microstructure

Densification,

hot

pressed

phenomena tions the

or liquid

diffusing

and where

by

the phase,

species

a-P’

transformation

sintered

silicon

nitride

processes

are

transport

capability

according and

some

to

and

either

the

processing

are

grain

liquid-phase

governed of

the

inherent

growth

by

interface

for

aided reac-

diffusing

species

chemical

reactions,

parameters

such

as

both

in

atmosphe-

220

re,

applied

above

processes

silicon also

stress

has been

nitride

should

of liquid

and temperature. reported

materials.

follow

Detailed

[16,17, 26,42-443

The densification

the same pattern,

is formed

information

at high

for several

mechanisms

provided

temperature

on the

of SiAlON

a sufficient

where

dissolution

amount of

Q-

Si N and its reprecipitation as PI-phase [20] is realized, this 3 4 process offering the main contribution to densification and to the overall

development

Densification

of microstructure.

in our materials

tes at T > 1723 K at a value retical

density

and with

the material

during

grain

version,

growth)

material

transport

which

of available

densificatjon,

thus

most

complete than

fraction

in a few minu-

the expected

in the microstructure ( a-+$

of hot pressing

without

such lead

further

as surface

to structural

vacuum

may play

spaces

a role

rel.iable for covalent

bonded

diffusion

condensiother

and evapo-

modifications

without

with

an increase

in the evolution

compounds

of

remarkable

, evaporation/condensation

[20,21,45,46]

theo-

a-Si3N4conver-

of

to solution/diffusion/reprecipitation

redistribution

structure

stage

take place

processes

ration/condensation,

a small

lower

modifications

the final

In addition

fication.

a little

only

p' . So the gross

ted to

is nearly

in

of the microappearing

the

[Zl] .

The reaction:

Si3N4

(s)--+

which

takes

K, would sfer

JSi(g) place

provide

through

+ 2N2

with

(g)

a vapour

a mechanism

the gas

phase

the developing

p' . This

contact

and reduces

points

diffusion. vely

the interfering cation

of liquid

favours

filling

the stress

atm at 1963 by ion tran-

a-Si 3N 4 grains

gradients

further

-3

of the regions

in compositions

phase,

10

conversion

the residual

evaporation/condensation,

is reached.

of about

for the a--+p from

As a consequence,

low amount

pressure

sintering before

at crystal

for grain

containing

to

boundary

a relati-

is stopped complete

by

densifi-

221 when

Nevertheless, tical

as

P'-SiAlON,

cient

amount

lower

densification

lions

and

Higher

of

liquid

at

ascribed

ii)

and,

the

and

of

The

rates

to:

the

the

the

the

amount

of

aconverted

for

30

metal

beneath

hours,

the

impurities

scale.

In

perties minium sing

in

the the

Figure

higher

A1203/Si

in

the

liquid

phase,

which

surface

of

that

being

phase

in

the

N ratio 3 4 especially

increases

boundary

the

amount

characteri-

observed

SiAlON

depleted

in

zone

influence

region

lower may

is

by

XRD

the

hulk

nearer the

amount

of

play

at

to

of

diffc-

oxidized

on

also

a criti-

variation

samples

higher

the

phase

Remarkable

been

being

obvious

conversion

1 shows

grain

has

near-surface

the

phase.

the

phase,

liquid

for

this

refractory/viscosity

top'

the

boundary

a-_,p

the

to

0 , 2 3

Si3N4-Al

1)

the

boundary

aluminium

renc-

2

and

p content

and

addition

of

the

(Fig.

of

temperature,

a+p

which

chemical

of

lransformation.

of

K

ZrO

insuffi-

to

amount

of

aspect

depths

to

throrc_

[zo].

observed

composition

cal

rent

of

grain

temperature,

place

been

because

composition

liquid

actual

have

the an

although

take

a larger

processing

at

associated,

compared

i)

approaches

compositions,

formed

rearrangement

dissolution

higher

pressed

is

are

materials

some

modifies

stics

rates

composition

hot

phase

materials,

containing

2

SiAlON

our

reaction

Zr02-containing

ZrO

for

structural

a-p

possibly

the

at

1773

than

in

the

oxide

transport

ihc

pro-

disposable

a role

in

alu-

depres-

rate.

ZrO

increases

the

phase-conversion

rate

2 whereas

the

largely in

the

at

the

unaffected

stages

is

solubilized

findings

change

in

of

phase

del

from

early

These

the

lla),

grains

and

3).

the

of

in

in

growth

a-3 the

on

fresh

by cell

p’ grain

of

P'takes

p' nuclei

evaluating

boundary

At

the

places from

the

the

Al

it

most

the

with

of

the

continuous

the

progress

phenomenological

beginning on

content 0 2 3 appears that

the

of

p'-phase to

is

phase.

explanation the

PI-phase

the

parameters,

according h.

of

transformation

a reliable

lla,

of

parameters

Also,

parameters

Figs.

cell

actual

the

offer

cell

the

transformation

proposed

(Fig.

of

(Fig.

$-phase

alumina

the

variation

of

preexisting

AI-O-N-S1

the

mo-

process p-Si

liquid.

N 3 4 In this

lJlnuclei dA++

a Si4+ N3-

Fig.

11.

Phenomenological

reaction a)

in

hot

initial,

b)

model

pressed final

Si

for

a solid

solution

quasi-equilibrium

high

in

conditions

liquid.

outer

the

to

pained

by

Some

inner

and

Al

region

of

a counterdiffusion

equilibrium.

With

and

nitrogen

continuously

and

the

of

liquid

grain

The

alumina.

tion

of

this

constituent.

now

the

p'-nuclei, species phase

and

termining

the

the

is

0 materials; 2 3

formed

growing

diffusion

is

progress

of

the

supplied phase

by

to

a-Si

the

composition

preexisting

p grains

Balance

of

with

state

activities

aluminium

and

of

vacant

diffusion

composition

of

sites. are

the

which

the

of

thermochemi-

Transport

therefore

silicon

is

both

composi-

poorer

atomic the

in

source,

a depletion

the

nitrogen

the accom-

3 N 4 grain

from

oxygen

a counterdiffusion the

N grain 3 4

suffers

P'on

sur-

from

a-+p'reaction,

growing

of

the

assure

for

the

meet

required p-Si

preexisting 4+ 3and N Si

to

p'and

established

accommodate

the

2-

o 2-

each

boundary

exolution

solid

and

are

together to

conversion

Si3N4-Al

conditions

fresh

requires

0

of

cal

are

Al

between

3+ rounding

a-+p~SiAlON 2 and

stage. 3+

stage

the

N -Al203-ZrO 3 4

in

species core and

the

of

the

silicon

liquid

important

in

de-

$-phase.

Properties The

thermal

expectedly

lower

expansion than

coefficients for

Si3N4-A1203-Zr02

for

Si

N -Al

0

c~m~osi~e~.

materials The

higher

are

223

A value

for

cts

higher

the

Al

bl

at

3 4

AZ6

of

reported

N

x

content

coefficient

Si

(3.00

for

4

is

-6

in

P'-SiAlON

K-J)

ttIan

p' of being

p'-SiAlON

comparable

series

10

in

latter,

lower

than

(z=3)

an

12.

(2.89 the

that

hvalue

A plot

Fig.

A3

the

temperature.

reported

for

of

This

x

of the

-6K-1

thermal for

shows

10

A

expansion

a-Si3N4.

2.?

x


10-6K-1

within

an

refle-

1

AZl-

the

increase

for

of

the

Si3Nq-A12%-Zr02

Fig.

12.

Average

function

of

thermal

expansion

of

what

would

on

thermal

crystal the

thermal

with

be

P'-SiAlON

and

of

the

it

should

be

taken

unt

and

crease

glass

is

evolution

A

(293-1173

expected

to

a -Si

different

the

the

for

of

hardly

continuous that

the

the

additive

constituting

boundary can

KJ,

as

phase

to

the

ZrO

change

in

of

no in

most

Forp',

both

both

of

its hot

the

Si-Al-0-N-(Zr,

complexity

pressing

and

its

conditions.

2

of

thermal

performed.

a redistribution

@-phase

based

contribution

a-P'conversion, the

rule

a,p'and

the

be

inverse

amothe

large

de-

converted

N 3 4'

expansion

for

a simole

grain

during

be

i.e. ---

calculation

considering

thermal

the

of

material

place

unpredictable under

glassy

account

but

should

hand,

the

into

compared

other

applying

A precise

composite

0 takes 2 3 A

materials, In

of

composition,

in

by

coefficients

alone.

expansion

Al

coefficient

-Lncreasing$/atp'content,

predicted

expansion

species

overall

expansion

flj(atP')

impurity) continuous

224 Processing rosity,

grain

hardness.

and microstructural

techniques

composition

size and phase

the most

Fnr our materials,

ratio are the j3/l/atp'

and grain

such

are all affecting

relevant

Figure

size.

parameters

variance

13 is a plot

as po-

micro-

parameters of HV

“S

500 --

I

,

,

0

1

,

1

.

I

25 residual

.

I

I

.

*

I

I

I

75 50 cc-phase (“/d)

8

and Si 3N 4-Al 0 Fig. 13. Vickers microhardness of Si N -Al 0 -ZrO 2 3 2 a-gi3N hot pressed materials as a function zf4 3 4'

30-

2

a

2

25-

0 0

>” I

20-

1

1

0.4

,

I

0.8 0.6 mean grain size

I

1.0 (Brn)

Fig. 14. Vickers microhardness of Si N -Al 0 -ZrO a 4 2 3 2.and hot pressed material as a function c mean grain size.

Si3N4-A1203

225 a-si

residual data

by

N 3 4'

Parr

and

The

behaviour

Mastin

the

basal

p -Si3N4

single

crystal

14

a plot

and

[47]

a-Si

reported

is

fairly

good

Chakraborty

N planes 3 4 under

in

to

be

identical

and

about

agreement

Mukerij

28%

[3S]

harder

microhardness

with

, who

than

test

condi-

tions.

Figure bodies. size

The

shows

is

linearly

parameters in

in

determining

sed.

As

within

thermal

cycling.

ing

from

eking

ZrO the

hot

bly

associated

a sufficiently

larger

than

for

low

phase

rupture

of

are

chining ge,

etc).

phase. our

by

hot

Coe

pressed

fracture key

damage, Among

of

criteria impact other

in

grain

et

al.

has AZ

dense

bodies.AZl

to

between

a microcraloading.

observed.

can

hot be

pres-

presuma-

which

is of

exhibits hot

of

both

hardness

temamount

grain

hardness

inverse and

a

a ve-

pressing

amount

the

to

cool-

a substantial

favour with

complies [48]

of

de-

speci-

formation

low

scarce

seems

asses-

during

phase

the

them

is

materials

AZS)

et -

sub,jected

that

been

promotes

relatively

be

subsequent

which

formation

which

or

the

Coe

of

pressed

occur

and

promote

materials

hot

boundary

with

The

hardly

also

(AZ4,

associated to

a behaviour

Hardness, tures

strength

in

suggested

temperature

each

ceramic

for

by

population

fresh

effect

grain

independent

of

can

during

strength

amount

being

temperature,

generated

flexural

the

in

pressed

increasing

influence

might

toughening

texture

boundary

brittleness, ships

easily

insufficient

boundary

room

A composition,

flexural

grain

to

high

interconnected

perature, of

in

not

composite

2

that

hot

results

a microcrack

micr,ocracking

evident

with

separate

suspected

be

previous ratio

8a,b,

the

with

characteristics

pressing

improvement

at

the

N -A1203-ZrO 3 4

is

would

with

ci/(Cl+#)

Figs.

induced

no

sed

ry

Si

It

2

Nevertheless,

more

from the

pattern

The

materials

concluded

some

the

and

in

size

microhardness

agreement

microhardness

veloped

mens

good

size our

VA grain

decreasing

a fairly

[48] . Grain

al,

H v500

of

and

relationmodulus

of

Si3N4+lwt%MgO.

toughness, for

strength

materials

damage,

wear

specifications,

and

microstructural

resistance resistance, the

overall

to

damage

thermal

fea(i.e.

shock

performance

madamaof

226 Si3N4-based

cutting

i)

(with

hardness

tools

optimal

ii) the degree

GPa);

to type

mance

in grey cast

tions

appears

boundary

and the excellent

of

secondary

on

[13,14]

in the range

between

cutting

:

20-25

the work

tools,

phases.

pie-

is specifical-

The good

perfor-

of some of the A and AZ oomposi-

to the low amount compromise

stability

found

interaction

iron machining

the good

phase,

to depend

being

in Si3N4-based

and amount

related

reported

H V5GOvalue

of chemical

ce and the tool which, ly related

has been

of a reactive

between

in oxidizing

hardness

glassy

grain

and toughness,

environment

[49] .

CONCLUSIONS

Hot pressed characterized. re occur

Si N -Al 0 -ZrO 2 composites have been prepared and 34 23 Densification and development of the microstructu-

through

liquid

additive-densified reached.

phase

nitrides.

This may

sintering Complete

be as an effect

mechanisms

common

densification

to most

has not been

of evaporation/condensation

pro-

cesses. A phenomenological nuous

variation

occurs

during

No evident

interpretation

of the cell parameters

improvement

crease

temperature

in the room

interconnected

from

compared

an higher with

Because

of reactive ce

content

material

good

grain

strength

P)-SiAlON,

which

in liquid

phase

at high

of Zr-O-N

composites 0 -2rG 2 2 3 iron machining.

Si3N4-Al

and excellent

phase,

phases

proved

resul-

ZrO

.

2 and toughness, low amount

oxidation

in the hot pressed

excellent

with

body

but without

of hardness

in-

temperature,

of strength , the relatively

boundary

from

associated

in the dense

composition

combination

results

and the relevant

has been

developed

of similar

value

due to the absence

cast

for the conti-

toughness

in the matrix,

texture

of the suitable

the reasonably

of the

of the fracture

dispersed

ting

given

hot pressing.

the Zr02 particles

the more

has been

cutting

tools

resistanbodies, in grey

ACKNOWI,~DGEMKNTS We wish samples

to thank

Mr. D. Dalle

and for his helpful

Fabbriche

technical

for fabrication

activity.

of the

227 REFERENCES N.

Claussen

J. Am. Ceram.

A. Bellosi,

P. Vincenzini,

Rahini,

G.N.

R. Visani, -ZrO

and J. Jahn,

composites,

2

Faenza, G.N.

in P. Vincenzini

(rd.),

in Science

A. Bellosi

Babini,

Effect

Dufour

(eds.),

bility

of materials

P. Vincenzini, (1986)

Report

G.N.

of the secondary

hot pressed

Babini

No 831209,

F.F.

Lange,

7

J.D.

Desmaison,

J. Am. Ceram. M. Billy

Sot.,

of zirconium

nitride

Plenum

Press,

J. Weiss, (1979)

New York,

L.J.

Si3N4-MgG-Y2G3-

Science

Publishers

Ceramics

Int.,

B.V.,

12

CNR-Irtec,

Internal

68.

Smeltzer,

Vannenberg in oxygen,

1977,

Gauckler

63 (1980)

in f. Wood,

(eds.1,

Oxidation

0. 1,indq beha-

in Reactivit ,y of Solids,

p. 107.

and T.Y.

Tien,

J. Am. Ceram. ___...

Sac., --

62

632,

Bahini,

Report

A.

Bellosi

No 84/232,

10 G.N. Bahini, Report

and P. Vincenzini,

CNR-Irtec,

Internal

and P. Vincenzini,

CNR-Irtec,

Internal

1984.

A. Bellosi

No 84/243.

11 S. Dutta

and B.J.

Sanders

13 G.N. Babini,

Babini,

Special

Ceram.

Adv.

Sot.,

67 (1984)

Ceram.

Mat.,

89.

2 (l986)

R. Chiara

and M. Bruno,

Adv.

R. Chiara

and M. Bruno,

Proceedings

166.

Ceram.

146.

A. Bellosi,

8, London,

R.J. wimmer,

Sot.,

J. Am.

Miekowski,

A. Bellosi,

Ceramics

Land,

Buzek,

and D.M.

2 (1987)

Ceram.

Elsevier

W.W.

and

viour

15 P.L.

the system

sta-

1983.

and N.C.

14 G.N.

from

and L.C.

on the thermal

phase

and P. Vincenzini,

C. Helgesson

Mat.,

behaviour

in P. Barret

and G.N. Babini,

vist,

12 W.A.

and

of Si N 3 4 12, Ceramurgica s.r.l.,

and P. Vincenzini,

A. Hellosi

6

G.N.

Fabbriche

133.

ii A. Bellosi,

9

Oxidation

94,

1984, p. 471.

in Reactivity of Solids, 2' Amsterdam 1985, p. 827.

8

61 (1978)

D. Dallc

of Ceramics

-zro

4

Sot.,

61 (2978)

R.W. 56.

18-20

December

Burns,

of

1985.

and N.S.

Choudhury,

J. Am.

228 16 L.J. Bowen, ter.

R.J.

13 (1978)

Sci.,

17 L.J. Rowen, 61 (1978) la G.N.

T.G.

Carruthers

and R-J.

Brook,

J. Ma-

341.

Carruthers

T.G.

and R.J.

Brook,

J. Am. Ceram.

Sot.,

335. A. Bellosi

Babini,

11 (1984) -

and P. Vincenzini,

Mater.

Chem.

Phys.,

365.

19 G.N. Babini, (1980)

Weston,

A. Bellosi,

and P. Vincenzini,

Ceramics

Int.,

6

91.

20 M. Kuwabara,

M. Benn

and F.L.

Riley,

J. Mater.

Sci.,

15 (1980)

1047. 21 M.N.

Rahaman,

(1981)

Special

on Trent,

24 Y. Oyama

Brook,

J. Mater.

in D. Taylor

1981,

Sci.,

16

Kai Shi,

26 R.J.

Lumby,

J. Mater.

Sci.,

B, North

Ceramic

82 (1974)

Research

(eds.),

Association,

3Sl.

Yogyo-Kyo

Kai Shi, 80 (1972)

11 (1976)

1135.

and A.J.

6, British

Ceramics

and P. Popper

p. 119.

and 0. Kamigaito,

Jack,

1975,

Jack

7, The British

Yogyo-Kyo

25 K.H.

Taylor,

Ceramic

in P. Popper

Research

Ass.,

327.

(ed.) Spe_

Stoke-on-Trent,

p. 283.

27 Kossowsky, 28 F.F.

and H.K.

Ceramics

23 Y. Oyama,

cial

and R.J.

660.

22 S. Hampshire

stoke

Riley

F.L.

J. Matei,. Sci.,

Lange,

29 K. Nuttall

J. Am. Ceram. and D.P.

30 J.E. Weston, (1978)

P.L.

32 A. Bellosi,

Thompson,

Pratt

J. Mater., CNR-Irtec,

33 G.N. Babini,

A. Bellosi

(eds.),

The Institute 34 A, Bellosi, (1987)

Sot.,

1603.

56 (1973)

J. Mater.

and B.C.H.

518.

Sci..

Steele,

9 (1974)

J. Mater.

850.

Sci.,

13

2137.

31 J.E. Weston,

Taylor

8 (1973)

Special

Sci.,

15 (1980)

Internal

Report

N. ?9/117,

and C. Galassi, Ceramics

of Ceramics, G.N. Babini

1568.

in S.P. Howlett

8, British

Stoke-on-Trent,

and C. Galassi,

1979.

Ceramic 1986,

J. Mater.

and D.

Proceedings,

p. 65. Sci.,

22

1687.

35 D. Chakraborty 36 C, Greskovich

and 3. Mukerji, and H.C.

Yeh,

J.

3. Mater. Hater.

Sci.

Sci.,

15 (1980)

Lett.,

3051.

2 (1983)

657.

229

Evans

and

Niihara,

A.

37

A.G.

38

K. C

39

E.A.

Charles,

Nakahira

J.

and

Am.

Ceram.

T.

Hirai,

in

G.S.

Sot.,

Comm.

59

Am.

(1976)

Ceram.

371.

Sac.,

13-14(1984).

S.T.

Buljan

Metal

and

Ceramic

V.K.

Sarin,

Composites,

Elsevier

Upadhyaya Sci.

(ed.1,

Pub.

B.V.,

Sintered Amsterdam,

1984. 40

Seshadri,

S.G. (1983)

41

Advances The 42

G.N.

M.

Rtihle,

Ceramics

in

A.

King,

Heuer

Science

3.

Ceramic

Babini,

G.N.

L.

Ceram.

Eng.

Proc.,

4

Society,

and

L.W.

and

Technology

Columbus

OH,

Hobbs of

1981,

(eds.),

Zirconia, p.

A.

Bellosi

and

P.

Vincenzini,

Annali

A.

Bellosi

and

P.

Vincenzini,

Ceramics

A.

Bellosi

and

P.

Vincenzini,

Mater.

137.

di

Chimica

507.

(1980) 44

in

Babini,

(1980) 43

and

American

G.N.

and

853.

Claussen

N.

Srinivasan

M.

Int.,

3

91. Babini,

11 -

(1984)

45

P.

Drew

46

G.

Greskovich

and

Parr

G.F.

Chem.

Phys.,

365. and

M.H.

Mater.

LeWiS,J.

S.

Sci.,

Prochazka,

J.

9

Am.

(1974)

Ceram.

261. Sot.,

60

(1977)

471. 47

N.L.

Haywood, 48

London,

R.F.

Coe,

cial

Ceramics

on-Trent, 49

and

A.

Rellosi,

cation.

R.J.

Mastin, 1960,

Lumby 5,

1972, G.N.

p. and

British p.

in

P.

Popper

ted.),

Special

Ceramics,

102. M.F.

Pawson,

Ceramic

in

Research

P.

Popper

Association,

(ed.),

Spe-

Stoke-

361.

Babini

and

P.

Vincenzini,

submitted

for

publi-