Hot-pressed ZrB2–SiC composite ceramics: Effect of various Ta-containing additives on the microstructure and mechanical properties

Abstract

The ZrB2–SiC composites have been commercially used at ultrahigh temperatures, but it often failed due to their poor toughness. In order to solve this problem, four types of Ta-containing additives (Ta, TaC, TaB2 and TaSi2) were used as the “third phase” to regulate the microstructure, so as to enhance the mechanical properties of hot-pressed ZrB2–20SiC-based ceramics (in vol. %). The incorporation of the additives generated a core–shell structure, which comprised of a ZrB2 core and a (Zr, Ta)B2 solid solution shell. The additives helped refine the ZrB2 grains in addition to the metallic Ta and release the internal stress field generated by the thermal misfit. The interfacial structure was modified by the formation of the coherent core/shell interface and the semi-coherent interface of adjacent ZrB2 grains and the semi-coherent ZrB2/(Zr, Ta)C interface in the TaC-additive composite. The addition of TaB2 or TaC hardened the ZrB2–20SiC ceramics, whereas the addition of Ta or TaSi2 reduced the hardness. The fracture toughness was enhanced by the formation of the Ta-containing phases. These phases reduced the stress intensity factor of the crack tip, which was proportional to the intrinsic residual stress. However, the crack-propagation mechanism would be changed by the incorporation of various Ta-containing additives. The decrease in the crack deflection, which was induced by the stronger interfacial bonding force and the significant consumption of SiC, resulted in relatively low toughness in the Ta- and TaC-included samples. The weaker interfacial bonding force in the TaB2- and TaSi2-included samples caused an increase in deflection and generated branching, which enhanced the toughness of the TaSi2-included composites to ∼4.72 MPa⸱m1/2.