A comparative study on nitridation mechanism and microstructural development of porous reaction bonded silicon nitride in the presence of CaO, MgO and Al2O3

During the in-situ nitridation of Si in the presence of CaO, MgO and Al(2)O(3)formation of reaction bonded silicon nitride ceramics (RBSN) having various microstructures indicated the possibility of different nitridation mechanisms operating. Experimental evidence suggested that, whereas the morphology of pores was controlled by nitridation of Si(g) in CaO-RBSN and SiO(g) in Al2O3-RBSN, a combination of these two reactions occurred during the nitridation of the MgO-RBSN. By inhibiting the growth of whiskers and maximizing the alpha/beta ratio, the CaO addition led to the formation of matte grains creating clean spherical cavities with d < 40 mu m and flexural strength of 0.8 MPa. In contrast, when using Al(2)O(3)additions, a microstructure with a very low alpha/beta ratio, fine inter-particle pores and 2.4 MPa flexural strength, reinforced with interlocking whiskers, was produced. The highest porosity (85%) and the lowest strength (0.3 MPa) occurred in the MgO-RBSN, which was composed of both matte grains and fine whiskers. Local supersaturation and low content of beta-nuclei led to the formation of anisotropic beta-grains with a bimodal microstructure in heat-treated CaO-RBSN while a unimodal microstructure was observed in heat-treated MgO-RBSN. No porosity loss or beta-grain growth occurred in the heat-treated Al2O3-RBSN.