In-situ synthesis of 15R-Sialon from Al-Si3N4-Al2O3 composite at 1500°C via liquid-phase sintering

In this study, alumina-based composite with 12 wt% Al and 16 wt% Si3N4 was designed to achieve the synthesis of 15R-Sialon reinforced alumina composite. To investigate the reaction mechanism, two-step sintered Al-Si3N4-Al2O3 samples at different temperatures ranging from 600 degrees C to 1500 degrees C were prepared and characterized via X-ray diffraction and scanning electron microscope (SEM). The results revealed that 15R-Sialon was synthesized at 1500 degrees C through a novel liquid Si phase sintering and Si3N4 played as a precursor and a reactant. First, Si3N4 precursor reacted with Al to form intermediate phases AlN and Si, which were not further transformed below 1400 degrees C. When the sintering temperature was 1500 degrees C, the formed Si presented as a liquid phase, under the influence of which plate-like15R-Sialon was generated from Al2O3, residual Si3N4, and derived AlN. The obtained Si was also involved in the synthesis of 15R-Sialon and completely transformed. In addition to the AlN from Si3N4, the AlN deriving from the nitridation of Al may not react with liquid Si. Compared to 15R-Sialon from liquid Si, plate-like 15R-Sialon with smaller size was generated from AlN, SiO, and O-2.