Preparation, Properties and Growth Mechanism of Low-Cost Porous Si3N4 Ceramics with High Levels of β-Si3N4 Powders

Silicon (2021)Cite this article

Abstract

Nowadays, porous Si3N4 ceramics are fabricated by high purity α-Si3N4 powders, resulting in a higher cost of production. To reduce cost and save energy, in this research, high levels of β-Si3N4 powders were effectively utilized to produce excellent and low-cost porous Si3N4 ceramics. The effects of high levels of β-Si3N4 powders on the microstructural evolution and properties were investigated in detail. The results suggested that, with the increase in β-Si3N4 powders from 0 wt.% to 80 wt.%, the aspect ratio of β-Si3N4 grains gradually decreased because of the anisotropic growth of grains significantly impinged by adjacent other β-Si3N4 grains. Additionally, the bending strength and dielectric constant of porous silicon nitride ceramics declined and their values were 685 MPa - 220 MPa, and 7.58–5.57, respectively, while the porosity increased from 5.9% to 28.5%. Similarly, the residual bending strength of Si3N4 ceramics degraded from 615 MPa to 172 MPa at 1000 °C for 20 h owing to the formation of SiO2 on the surface of silicon nitride ceramics after oxidizing.

This is a preview of subscription content, access via your institution.

We’re sorry, something doesn't seem to be working properly.

Please try refreshing the page. If that doesn't work, please contact support so we can address the problem.

Data Availability

The datasets used or analysed during the current study are available from the corresponding author on reasonable request.

References

  1. 1.

    Wang C, Chen M, Wang HJ, Fan XY (2016) Fabrication and thermal shock resistance of multilayer γ-Y2Si2O7 environmental barrier coating on porous Si3N4 ceramic. J Eur Ceram Soc 36:689–695

    CAS  Article  Google Scholar 

  2. 2.

    Liu K, Zhang CR, Li B, Wang SQ, Cao F (2014) Synthesis of porous silicon nitride-boron nitride composites by gel-casting and PIP. J Mater Eng Perform 23:2829–2833

    CAS  Article  Google Scholar 

  3. 3.

    Li D, Li B, Yang XJ, Gao ST, Zheng YY (2018) Fabrication and properties of in situ silicon nitride nanowires reinforced porous silicon nitride (SNNWs/SN) composites. J Eur Ceram Soc 38:2671–2675

    CAS  Article  Google Scholar 

  4. 4.

    Liu W, Tong WX, He RX, Wu HD, Wu SH (2016) Effect of the Y2O3 additive concentration on the properties of a silicon nitride ceramic substrate. Ceram Int 42:18641–18647

    CAS  Article  Google Scholar 

  5. 5.

    Zou CR, Zhang CR, Li B, Wang SQ, Cao F (2013) Microstructure and properties of porous silicon nitride ceramics prepared by gel-casting and gas pressure sintering. Mater Design 44:114–118

    CAS  Article  Google Scholar 

  6. 6.

    Riley FL (2000) Silicon nitride and related materials. J Am Ceram Soc 83:245–265

    CAS  Article  Google Scholar 

  7. 7.

    Ganesh I (2011) Development of β-SiAlON based ceramics for radome applications. Process Appl Ceram 5:113–138

    CAS  Article  Google Scholar 

  8. 8.

    Li XM, Yin XW, Zhang LT, Cheng LF, Qi YC (2019) Mechanical and dielectric properties of porous Si3N4–SiO2 composite ceramics. Mater Sci Eng A 500:63–69

    Article  Google Scholar 

  9. 9.

    Yu JL, Yang JL, Li S, Li HX, Huang Y (2012) Preparation of Si3N4 foam ceramics with nest-like cell structure by particle-stabilized foams. J Am Ceram Soc 95:1229–1233

    CAS  Article  Google Scholar 

  10. 10.

    Chen F, Shen Q, Yan FQ, Zhang LM (2007) Pressureless sintering of α-Si3N4 porous ceramics using a H3PO4 pore-forming agent. J Am Ceram Soc 90:2379–2383

    CAS  Article  Google Scholar 

  11. 11.

    Fukasawa T, Deng ZY, Ando M, Ohji T, Kanzaki S (2002) Synthesis of porous silicon nitride with Unidirectionally aligned channels using freeze-drying process. J Am Ceram Soc 85:2151–2155

    CAS  Article  Google Scholar 

  12. 12.

    Wan T, Yao DX, Hu HL, Xia YF, Zuo KH, Zeng YP (2014) Fabrication of porous Si3N4 ceramics through a novel gelcasting method. Mater Lett 133:190–192

    CAS  Article  Google Scholar 

  13. 13.

    Arnaldo JM, Nieto MI, Moreno R (2001) Aqueous gel-forming of silicon nitride using Carrageenans. J Am Ceram Soc 84:62–64

    Article  Google Scholar 

  14. 14.

    Zhang Y, Yao DX, Yin JW, Zuo KH (2019) Fabrication and mechanical properties of porous Si3N4 ceramics prepared via SHS. Ceram Int 45:14867–14872

    CAS  Article  Google Scholar 

  15. 15.

    Yao, X.D., Zeng Y.P (2011) High flexural strength porous silicon nitride prepared via Nitridation of silicon powder. J Inorg Mater 26:422–426

  16. 16.

    Golla BR, Ko JW, Kim HD (2017) Processing and characterization of sintered reaction bonded Si3N4 ceramics. Int J of Refract Met H 68:75–83

    CAS  Article  Google Scholar 

  17. 17.

    Liu CC (2003) Microstructure characterization of gas-pressure-sintered α-silicon nitride containing β-phase seeds. Ceram Int 29:841–846

    CAS  Article  Google Scholar 

  18. 18.

    Wang B, Yang J, Guo R, Gao JQ (2009) Microstructure characterization of hot-pressed β-silicon nitride containing β-Si3N4 seeds. Mater Charact 60:894–899

    CAS  Article  Google Scholar 

  19. 19.

    Yu JJ, Guo WM, Wei WX, Lin HT, Wang CY (2018) Fabrication and wear behaviors of graded Si3N4 ceramics by the combination of two-step sintering and β-Si3N4 seeds. J Eur Ceram Soc 38:3457–3462

    CAS  Article  Google Scholar 

  20. 20.

    Lee HM, Tatami J, Kim DK (2016) Mirostructural evolution of Si3N4 ceramics from starting powders with different α-to-β ratios. J Ceram Soc Jpn 124:800–807

    CAS  Article  Google Scholar 

  21. 21.

    Belmonte M, González-Julián J, Miranzo P, Osendi MI (2010) Spark plasma sintering: a powerful tool to develop new silicon nitride-based materials. J Eur Ceram Soc 30:2937–2946

    CAS  Article  Google Scholar 

  22. 22.

    Jones AH, Dobedoe RS, Lewis MH (2001) Mechanical properties and tribology of Si3N4–TiB2 ceramic composites produced by hot pressing and hot isostatic pressing. J Eur Ceram Soc 21:969–980

    CAS  Article  Google Scholar 

  23. 23.

    Awais Q, Zsolt F, Zsolt EH, Katalin B, Gsaba B (2018) Effect of the oxidation of Si3N4 powder on the microstructural and mechanical properties of hot isostatic pressed silicon nitrdie. Ceram Int 44:14601–14609

    Article  Google Scholar 

  24. 24.

    Kovalčíkováa A, Cs B, Dusza J, Tapasztób O (2012) Mechanical properties and electrical conductivity in a carbon nanotube reinforced silicon nitride composite. Ceram Int 38:527–533

    Article  Google Scholar 

  25. 25.

    Pasupuleti S, Peddetti R, Santhanam S, Jen KP, Wing ZN, Hecht M, Halloran JP (2008) Toughening behavior in a carbon nanotube reinforced silicon nitride composite. Mater Sci Eng A 491:224–229

    Article  Google Scholar 

  26. 26.

    Ryshkewitch E (1993) Compression strength of porous sintered alumina and zirconia. J A Ceram Soc 36:65–68

    Article  Google Scholar 

  27. 27.

    Chao LY, Shetty KD (1992) Extreme-value statistics analysis of fracture strengths of a sintered silicon nitride failing from pores. J Am Ceram Soc 75:2116–2124

    CAS  Article  Google Scholar 

  28. 28.

    Kalemtas A, Topates G, Özcoban H, Mandal H, Kara F, Janssen R (2013) Mechanical characterization of highly porous β-Si3N4 ceramics fabricated via partial sintering & starch addition. J Eur Ceram Soc 33:1507–1515

    CAS  Article  Google Scholar 

  29. 29.

    Xu X, Huang LP, Liu XJ, Fu XR (2002) Effects of α/β ratio in starting powder on microstructure and mechanical properties of silicon nitride ceramics. Ceram Int 28:279–281

    CAS  Article  Google Scholar 

  30. 30.

    Lin SJ, Ye F, Ma J, Ding JJ, Liu Q, Dong SL (2015) Fabrication and properties of porous boron nitride/silicon oxynitride ceramic composites via gas pressure sintering. Mater Design 87:272–277

    CAS  Article  Google Scholar 

  31. 31.

    Zhao YJ, Zhang YJ, Gong HY, Wang XL, Sun HB (2015) Effects of Y2O3–MgO nanopowders content on mechanical and dielectric properties of porous BN/Si3N4 composites. Ceram Int 41:3618–3623

    CAS  Article  Google Scholar 

  32. 32.

    Logesh G, Mohammed R, Mangesh L, Ummen S (2018) Mechanical and dielectric properties of carbon fiber reinforced reaction bonded silicon nitride composites. J Alloy Compd 767:1083–1093

    CAS  Article  Google Scholar 

  33. 33.

    Yang WL, Shi ZQ, Wang HL, Qiao GJ, Li YF, Yang JF, Jin ZH (2014) Effects of ZrO2 on the Nitridation behavior and mechanical properties of reaction-bonded Si3N4/h-BN composite. J Mater Eng Perform 23:3436–3443

    CAS  Article  Google Scholar 

  34. 34.

    Xia YF, Zeng YP, Jiang DL (2011) Mechanical and dielectric properties of porous Si3N4 ceramics using PMMA as pore former. Ceram Int 37:3775–3779

    CAS  Article  Google Scholar 

  35. 35.

    Lee SJ, Baek S (2016) Effect of SiO2 content on the microstructure, mechanical and dielectric properties of Si3N4 ceramics. Ceram Int 42:9921–9925

    CAS  Article  Google Scholar 

  36. 36.

    Penn SJ, Alford NM, Templeton A, Wang XR (2005) Effect of porosity and grain size on the microwave dielectric properties of sintered alumina. J Am Ceram Soc 80:1885–1888

    Article  Google Scholar 

  37. 37.

    Liang HQ, Yao XM, Huang ZR, Zeng YP, Su BZ (2016) The relationship between microstructure and flexural strength of pressureless liquid phase sintered SiC ceramics oxidized at elevated temperatures. Ceram Int 42:13256–13261

    CAS  Article  Google Scholar 

  38. 38.

    Liang HQ, Zeng YP, Zuo KH, Xia YF, Yao DX, Yin JW (2017) The effect of oxidation on the mechanical properties and dielectric properties of porous Si3N4 ceramics. Ceram Int 43:5517–55233

    CAS  Article  Google Scholar 

Download references

Acknowledgments

The work is supported by National Natural Science Foundation of China (project number: 50872108).

Author information

Affiliations

  1. State Key Laboratory for Mechanical of Materials, Xi’an Jiaotong University, Xi’an, 710049, Shaanxi, China

    Haiqiang Ma & Chonggao Bao

Authors
  1. Haiqiang Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chonggao Bao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Dr. Haiqiang Ma: Investigation and Validation, Writing-original draft preparation. Prof. Chonggao Bao: Supervision, Methodology, Validation and Writing-review.

Corresponding authors

Correspondence to Haiqiang Ma or Chonggao Bao.

Ethics declarations

Conflicts of Interest

The authors declared that they have no conflicts of interest to this work.

Consent to Participate

Participants provide their written or verbal informed consent to participate in this study.

Consent for Publication

Written informed consent for publication was obtained from all participants.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Ma, H., Bao, C. Preparation, Properties and Growth Mechanism of Low-Cost Porous Si3N4 Ceramics with High Levels of β-Si3N4 Powders. Silicon (2021). https://doi.org/10.1007/s12633-021-00941-8

Download citation

Keywords

  • Silicon nitride
  • Low-cost
  • Oxidation resistance
  • Steric hindrance