Rapid and cost-effective fabrication of SiC from Si scrap through flash sintering

A rapid, cost-effective and eco-friendly approach for fabricating SiC using Si particles derived from Si scrap is highly recommended from both economic and environmental standpoints. Herein, we demonstrate the fabrication of β-SiC effectively in argon atmosphere at 1500°C by utilizing combustion synthesis followed by flash sintering in a single-step experiment for the first time. Synthesis of β-SiC was relied on exothermic reaction between Si and C elements present in the powder compact whereas densification was accomplished eventually through flash sintering. In addition, the effects of different flash sintering conditions on the properties of β-SiC are examined with and without Y2O3 sintering additive. A high relative density of 85% was realized when a current density of 60mA/mm2 was applied for 60min with Y2O3 addition. This novel one-step fabrication approach has the potential to reduce production cost of β-SiC significantly and has both commercial and environmental advantages.