Effect of Particle Shape on Dispersion Formation of Harmonic Microstructure of Si<sub>3</sub>N<sub>4</sub>-ZrO<sub>2</sub>

Abstract

Silicon nitride with 50 mass zirconia ceramic matrix composites were processed by mechanical milling (MM) followed by spark plasma sintering (SPS). Two different of Si3N4 particle shapes for create harmonic microstructure were investigated. The microstructure of Si3N4-ZrO2 with initial Si3N4 shape is like coin/flakes after MM for 144 ks was failed to create the harmonic microstructure after SPS. With another sphere shape of Si3N4 after MM for 144 ks, the harmonic microstructure could be formed after SPS. Thus, the initial powders shape of Si3N4 have an effect in the formation of harmonic microstructure could be fully achieved. The highest mechanical properties of Si3N4-ZrO2 are on the powders with mechanical milling time for 144 ks. The Si3N4 ceramic with homogeneous fine grains of ZrO2 dispersed on its surface was obtained, and the mechanical properties were improved. The Vickers hardness obtained on 144 ks is 1031 MPa and the bending strength is 262 MPa. The main factors explaining the improvement in the mechanical properties of Si3N4-ZrO2 are considered to be the porosity decrease caused by the particles shape and appropriate condition of powder processing i.e. MM and SPS.