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Mechanically Robust SiAlON Ceramics with Engineered Porosity via Two-step Sintering for Applications in Extreme Environments

Published online by Cambridge University Press:  10 December 2015

Ike Suchih Chi
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
Sabah K. Bux
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
Marjorie M. Bridgewater
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
Kurt E. Star
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
Samad Firdosy
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
Vilupanur Ravi
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A. Chemical & Materials Engineering Department, California State Polytechnic University, Pomona, 3801 West Temple Avenue Pomona, CA 91768, U.S.A.
Jean-Pierre Fleurial
Affiliation:
Jet Propulsion Laboratory/ California Institute of Technology, 4800 Oak Groove Drive Pasadena, CA 91109, U.S.A.
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Abstract

Porous ceramics have been widely used under extreme environments due to their high strength, good thermal shock resistance, and excellent corrosion resistance. Recently, silicon aluminum oxynitride (SiAlON) ceramic, a solid solution of Si3N4 with AlN, SiO2, and Al2O3, attracted our interest because of its superior mechanical and physical properties for applications under extreme environments (i.e., high temperature, high pressure, excellent mechanical wear, and low PH). However, in spite of its many unique properties, porous SiAlON production has not been scaled up sufficiently to meet industrially relevant quantities due to its high synthesis cost and the difficulty of manufacturing articles. Here, we report on a scalable two-step carbothermal reduction and nitridation (CRN) method to synthesize mechanically robust SiAlON ceramic materials with controlled porosity levels. The morphologies and chemical composition of the synthesized porous SiAlON ceramics were characterized using SEM, XRD, EDAX, and microprobe analysis. In addition, the flexural strength of the engineered porous SiAlON ceramics is also reported in this paper.

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Copyright © Materials Research Society 2015 

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Mechanically Robust SiAlON Ceramics with Engineered Porosity via Two-step Sintering for Applications in Extreme Environments
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