Abstract
The “reaction bonding of aluminum oxide” (RBAO) technology is a novel process that has been well developed for manufacturing low-cost alumina or ZTA components. The principle of this technology is using metallic Al as one of the starting components so that the green strength of such Al/ceramic compact is much higher than that of conventional ceramic green bodies. This allows easy machining on green bodies to give a desired shape and dimension instead of the hard work on fired product. In the present study, this technology was used to prepare β-sialon (β′) from starting powders of Si 3N 4, AlN and Al. Precursor powder mixture after attrition milling possessed a much higher green strength than that without Al additive. Al in the mixture was converted to Al 2O 3 via an oxidation firing at 900 °C for 1 h in air. Dense β′ can be achieved by pressureless sintering (PLS) in 0.1 MPa nitrogen at 1700 °C for 2 h. Even lower temperature sintering at 1650 °C yielded the product with same density but a small amount of O-sialon (O′) phase remained in the composition. Results from this research show a great potential of fabrication low-cost sialon ceramics through reaction-sintering process.
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