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Si3N4 ceramic as a tool material shows promising application prospects in high-speed machining fields; however, the required high mechanical properties and low-cost preparation of Si3N4 ceramic tool materials restrict its application. Herein, synergistic reinforced Si3N4 ceramic tool materials were fabricated by adding β-Si3N4 seeds, inexpensive Si3N4 whiskers and TiC particles into coarse commercial Si3N4 powder (D50 = 1.5 μm), then sintering by hot-pressing with low temperature and short holding time (1600 °C—30 min—40 MPa). The phase assemblage, microstructure evolution and toughening mechanisms were investigated. The results reveal that the sintered Si3N4 ceramics with synergistic reinforcement, compared to those with individual reinforcement, present an enhancement in relative density (from 94.92% to 97.15%), flexural strength (from 467.56 ± 36.48 to 809.10 ± 45.59 MPa), and fracture toughness (from 8.38 ± 0.19 to 10.67 ± 0.16 MPa·m1/2), as well as a fine Vickers hardness of 16.86 ± 0.19 GPa. Additionally, the various reinforcement modes of Si3N4 ceramics including intergranular fracture, crack deflection, crack bridging and whiskers extraction were observed in crack propagation, arising from the contributions of the added β-Si3N4 seeds, Si3N4 whiskers and TiC particles. This work is expected to serve as a reference for the production of ceramic cutting tools.

Abstract A nanostructured laminar W-La2O3 alloy (WL10) with improved ductility was prepared using a surface mechanical attrition treatment (SMAT). φ1.5 mm ZrO2 WL10 balls subjected to SMAT (called φ1.5 mm ZrO2 ball SMATed WL10) samples possess the best surface profile and excellent integrated mechanical properties (the ductile-brittle transition temperature (DBTT) value decreases by approximately 200 °C, and the bending strength decreases by 100 Mpa). A highly dense group of laminates was detected near the surface of the φ1.5 mm ZrO2 ball SMATed WL10 sample. The SMATed WL10 laminates were composed of a micro-grain layer, an ultrafine-grain layer and a nanosized-grain layer. The nanostructured laminar surface layer of the φ1.5 mm ZrO2 ball SMATed WL10 sample is approximately 1–2 μm. The top surface of the WL10 plates with and without the SMAT process possesses residual compressive stress of approximately −883 MPa and −241 MPa, respectively, in the y direction and −859 MPa and −854 MPa, respectively, in the x direction. The SMAT process could be a complementary method to further improve the toughness of tungsten-based materials.