Effect of Si3N4 on the in-situ synthetized non-oxide reinforcements in Al-Al2O3 composites under N2 atmosphere

Al-Al2O3 composite is widely used in high-temperature industry due to its excellent properties obtained through in-situ synthesis of non-oxide reinforcing phases. The effect of nitrogen source on the non-oxide reinforcing phases synthesized in-situ in the Al-Al2O3 composites at 1500 degrees C was investigated. The results show that when N2-gas is the sole nitrogen source, Al4O4C is the major reinforcing phase formed in the composite due to insufficient nitrogen amount provided. Through the construction of an Al@AlN core-shell structure and spontaneous nitrogen introduction by solid Si3N4 and N2-gas, higher amount of AlN mesophase is generated, and the complete transformation of Al to (Al2OC)1-x(AlN)x solid solution is successfully achieved. However, when Si3N4 content is excessive (i.e. Si/C mole ratio >= 1, where Si comes from solid nitrogen source Si3N4, C comes from phenolic resin binder), the stability of (Al2OC)1-x(AlN)x solid solution decreases, and more stable AlN-SiC solid solutions and SiAl4O2N4 are generated as reinforcing phases in the composite. This work provides meaningful information for the phase control of Al-Al2O3 composite at high temperature application.