Abstract
This paper reports a dense textured single Ca-α-sialon fabricated by strong magnetic field alignment (SMFA) during non-aqueous slip casting of α-Si3N4, CaCO3, Al2O3 and AlN starting powders, followed by reaction pressureless sintering at 1800°C. XRD analysis reveals that the orientation of the α-Si3N4 crystals occurs with the c-axis perpendicular to the magnetic field during slip casting. It is shown that the formation of the single Ca-α-sialon is complete within 5 min and nearly complete densification is achieved within 60 min. SEM observation reveals that the textured Ca-α-sialon is featured by the long-axis (c-axis) of large elongated grains perpendicular to the magnetic field. The texturing mechanism is attributed to the heterogeneous nucleation and epitaxially elongated growth on the initially oriented α-Si3N4 seeds. The prolonged sintering leads to a higher orientation as a result of the promoted grain growth.
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