Carbothermally prepared nanophase SiC/Si3N4 composite powders and densified parts

Nanophase SiC/Si3N4 composite powders were synthesized by the carbothermal nitridation of SiO2. These powders have desirable characteristics of high quality with oxygen contents on the order of 2.5 to 2 wt. %, surface area of similar to 10 m(2)/g, submicron alpha-Si3N4, low metallic impurity levels, and a homogeneous distribution of the nanophase SiC phase. High-resolution TEM analysis has shown that the content and size of the nanophase SiC can be varied from 0.5 to 50 wt. % and 25 to 500 nm, respectively, through proper control of raw materials and reactor conditions. To determine how the nanophase SiC reinforcement affects the mechanical properties of Si3N4, densified components were fabricated using both pressureless and pressure-assisted densification methods. TEM analysis revealed that the nanophase SiC particles are distributed both intergranularly and intragranularly throughout the Si3N4 matrix. By controlling the sintering additive package and the sintering conditions, the ratio of inter-to intragranular SiC can be adjusted. Mechanical property measurements at elevated temperatures showed a dramatic improvement in high-temperature strength and creep resistance over components made with commercially available powders.