Effects of talc and clay addition on pressureless sintering of porous Si3N4 ceramics

Porous Si3N4 ceramics were successfully synthesized using cheaper talc and clay as sintering additives by pressureless sintering technology and the microstructure and mechanical properties of the ceramics were also investigated. The results indicated that the ceramics consisted of elongated β-Si3N4 and small Si2N2O grains. Fibrous β-Si3N4 grains developed in the porous microstructure, and the grain morphology and size were affected by different sintering conditions. Adding 20% talc and clay sintered at 1700°C for 2 h, the porous Si3N4 ceramics were obtained with excellent properties. The final mechanical properties of the Si3N4 ceramics were as follows: porosity, P0 = 45·39%; density, ρ = 1·663·g·cm−3; flexural strength, σb (average) = 131·59 MPa; Weibull modulus, m = 16·20.