Enhanced mechanical properties of nanocrystalline B4C–SiC composites by in-situ high pressure reactive sintering

A unique optimized of core–shell structural B4C nanopowder, sintering aid additive of Si, and high-pressure sintering technique has been used to process nanocrystalline B4C–SiC ceramics with enhanced mechanical properties. C-coated B4C nanopowder was initially uniformly mixed with micron Si of different content by ball-milling. B4C–SiC composites with a homogenous distribution of SiC in B4C matrix were subsequently obtained by sintering the mixed powders at 6 GPa and 1600 °C. The added Si reacted with submicron amorphous carbon layer and amorphous carbon nanoshell to form dispersed SiC nanocrystals and Si–C phase filled at B4C grain boundaries and pores, respectively. The prepared composite had the most outstanding mechanical properties when the Si content in the precursor was 15 wt%, with a hardness reaching 37.8 GPa and a fracture toughness reaching 7.3 MPa·m1/2. Microstructural characterizations indicated that the multi deflection of nanoscale crack caused by intergranular fracture, the covalent bonding of Si–C phase at the grain boundary, and the abundant nanotwin substructure were jointly responsible for the superior performance in hardness and fracture toughness.