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Research Article | Open Access | Just Accepted

Sintering-free fabrication of dense SiBCN monolith at a lower temperature and its high-temperature performance

Zi-Bo Niua,bDaxin Lia,b( )Dechang Jiaa,b,c( )Zhihua Yanga,b,cKunpeng Lina,bYan Wanga,bPaolo Colombod,eRalf RiedelfYu Zhoua,b,c,g

a Institute for Advanced Ceramics, School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150080, China

b Key Laboratory of Advanced Structural-Function Integrated Materials and Green Manufacturing Technology, Ministry of Industry and Information Technology, Harbin 150080, China

c State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150080, China

d Department of Industrial Engineering, University of Padova, Italy, Via Marzolo, 9, Padova, Italy

e Department of Materials Science and Engineering, The Pennsylvania State University, University Park, PA 16802, USA

f Institute of Materials Science, Darmstadt University of Technology, Otto-Berndt-Str. 3, 64287, Darmstadt, Germany

g School of Materials Science and Engineering, Harbin Institute of Technology (Shenzhen), Shenzhen 518055, China

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Abstract

In this study, a crack-free pyrolysis process of partially cured precursor powder compacts was developed to prepare dense SiBCN monoliths at much lower temperatures (1300℃), thereby circumventing the challenges of sintering densification (>1800℃). Unlike the elastic fracture in over-cured precursors or the viscoelastic deformation in under-cured ones, the partially cured precursor, exhibiting elastic-plastic deformation behavior, facilitates limited nanoscale pore formation in a dense structure, achieving a balance between crack-free pyrolysis and densification. Compared to SiBCN derived from the over-cured precursor (σ=~159 MPa, KIC=1.9 MPa·m1/2, HV=7.8 GPa, E=122 GPa), the resulting SiBCN monolith exhibits significantly improved mechanical properties (σ=~304 MPa, KIC=3.7 MPa·m1/2, HV=10.6 GPa, E=161 GPa) and oxidation resistance. Besides, this study delves into the high-temperature performance of the SiBCN monolith including crystallization and oxidation and determines the oxidation kinetics law transition induced by the pore structure healing and the different oxidation mechanisms of Si-C-N and B-C-N clusters in the amorphous structure. Due to its unique composition and structure, the oxide layer of SiBCN ceramic exhibits exceptional self-healing effects repairing the nanoporous system in the initial stage and shows outstanding high-temperature stability during prolonged oxidation, mitigating adverse effects from bubble formation and crystallization. Due to the nanoporous structure, the oxidation rate is initially controlled by gas diffusion following a linear law before transitioning to oxide layer diffusion characterized by a parabolic law. Finally, due to different valence bond configurations, Si-C-N transforms into an amorphous SiCNO structure after phase separation, unlike the nucleation and growth of residual B-N-C.

Journal of Advanced Ceramics
Cite this article:
Niu Z-B, Li D, Jia D, et al. Sintering-free fabrication of dense SiBCN monolith at a lower temperature and its high-temperature performance. Journal of Advanced Ceramics, 2024, https://doi.org/10.26599/JAC.2024.9220929

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Received: 01 April 2024
Revised: 28 May 2024
Accepted: 11 June 2024
Available online: 12 June 2024

© The author(s) 2024

The articles published in this open access journal are distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/).

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