稀土添加剂的类型对α-sialon陶瓷组织与性能的影响
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摘要
本文采用两步热压烧结法制备了不同稀土单一掺杂以及复合掺杂的α-sialon陶瓷。系统研究了α-sialon陶瓷的微观组织和力学性能的关系,揭示了长棒状α-sialon晶粒的形核和长大方式及自增韧机制。通过氧化试验,分析了稀土氧化物类型和含量对材料氧化性能的影响并探讨了氧化机理。
研究发现,小尺寸Yb~(3+)、Y~(3+)和Dy~(3+)稳定的α-sialon陶瓷只有单一的α-sialon相,而大尺寸稀土体系还含有少量晶间相M'(R2Si3-xAlxO~(3+)xN4-x)、甚至β-sialon和21R-AlN多型体。随着稀土离子尺寸增大,陶瓷中长棒状晶粒增多,长径比增大;断裂韧性升高,硬度略有下降。
选用高熔点Sc_2O_3为稳定剂制备的sialon陶瓷主要由β-sialon相组成,并含有少量12H-AlN多型体。12H'吸收大量Sc进入到它的结构中,为减少晶间相提供了一条有效途径。Sc-sialon陶瓷硬度较低,只有16 GPa;等轴晶粒形貌使得材料的强度和韧性偏低,只有541 MPa和3.8 MPa?m1/2。但以高熔点Lu2O3为稳定剂的α-sialon陶瓷则完全由α-sialon相构成,兼有少量晶间相J'(Lu4Si2-xAlxO7+xN2-x),其硬度很高,都在21 GPa以上。随着Lu2O3含量增加,晶间相增多,长棒状晶粒数目增多,长径比增大,强度和韧性升高,硬度略有下降;当过量Lu2O3含量超过4 wt.%时,晶粒径向尺寸明显变小,长度略有降低;过量Lu2O3含量为4 wt.%时,材料具有最高的韧性和强度,分别为4.7 MPa?m1/2和620.2 MPa。热处理使得Lu-α-sialon晶粒各向异性长大明显,晶间相分布趋向于三角晶界处,其固溶度增大,而α-sialon的固溶度减小,韧性和强度进一步升高。
首次将两种小尺寸稀土离子Sc~(3+)和Lu~(3+)复合掺杂制备α-sialon陶瓷,成功使得不能单独进入α-sialon结构的Sc~(3+)稳定存在于α-sialon中。材料主要由α-sialon相构成,兼有少量β-sialon、J'和含Sc的12H'相。材料具有高硬度、高韧性和抗弯强度,分别为20.4 GPa、5.2 MPa?m1/2和652 MPa。
HREM分析表明,单一掺杂的α-sialon陶瓷中,α-sialon和晶间相之间没有非晶层,但在α-sialon相之间则存在厚度1 nm左右的非晶层,即使热处理也不能完全消除;但在复合掺杂的ScLu-α-sialon中,α-sialon相之间以及和β-sialon相之间的界面都不存在非晶层。
(S)TEM分析表明,不同稀土体系α-sialon晶粒形核长大机制均是以α-Si3N4作为优先形核位置外延生长,且初始析出的α-sialon较之后沉淀析出的固溶度高,core、shell之间点阵连续,晶体结构和晶体学取向相同,由于成份及晶格常数的差异,界面存在错配位错及应变引起的衬度变化。棱柱面界面反应控制生长和基面(001)的扩散控制生长促使α-sialon晶粒各向异性长大并形成长棒状晶粒。
长棒状α-sialon晶粒的形成成功实现了α-sialon陶瓷的自增韧机制。通过长棒状晶粒的解离和拔出以及裂纹沿长棒状晶粒的偏转和桥接大大提高了陶瓷的断裂韧性,同时长棒状晶粒也促进了材料的强化。
Lu-和ScLu-α-sialon陶瓷都具有很高的高温强度,1400oC下仍达550 MPa以上,且抗氧化性能好,氧化层致密,1300oC下其氧化速率常数K≈2.5×10-6 - 4.2×10-6 mg2/(cm4?s),较Y-α-sialon陶瓷低一个数量级。氧化反应及元素扩散共同作用使得氧化层下方形成一个稀土元素消耗区,它与氧化层和基体连接紧密。
α-Sialons stabilized with different rare-earth cations or multi-cations were prepared by a two-step hot sintering. The relationship between microstructure and properties was systematically investigated. The nucleation and growth mode of elongatedα-sialon grains, as well as the self-toughening mechanism was revealed. The effect of type of rare-earth oxides on the oxidation behavior of materials was studied and the oxidation mechanism was also discussed.
The experimental results show that Yb-, Y- and Dy-α-sialon ceramics consist of onlyα-sialon phase, while a few M'(R2Si3-xAlxO~(3+)xN4-x), evenβ-sialon and 21R-AlN polytypoid are also found in large cation doped ceramics. With the increase of ionic radius, more elongated grains form and the aspect ratio tends to increase. The toughness increases, but the hardness decreases slightly.
Sc_2O_3 with high melting point was incorporated into sialon ceramic. Onlyβ-sialon as main crystalline phase exists together with a small amount of 12H-AlN polytypoid. The formation of scandium containing AlN-polytypoid can provide a valid way to reduce the amount of grain boundary phase. The Sc-sialon exhibits a typically low hardness of 16 GPa due to itsβ-sialon phase assemblage. Moreover, the equiaxed morphology ofβ-sialon grains, which is discovered for the first time, also results in a relatively lower fracture toughness and strength, 541 MPa and 3.8 MPa?m1/2, respectively. Whereas, sialon ceramics doped with high melting point Lu2O3 mainly consist ofα-sialon phase with a few intergranular phase J'(Lu4Si2-xAlxO7+xN2-x). Lu-α-sialons possess very high hardness of over 21 GPa. With increasing the Lu2O3 content, the amount of intergranular phase increases, and the number and aspect ratio of elongatedα-sialon grains increase, too. When the extra content of Lu2O3 goes beyond 4wt%, the radial size ofα-sialon grains decreases obviously and the length decreases slightly. Lu-α-sialons exhibit an enhanced toughness and strength with the peak value of 4.7 MPa?m1/2 and 620.2 MPa for the material containing 4 wt% extra Lu2O3. The post-heat treatment results in an anisotropic growth of Lu-α-sialon grains and a decreased solubility of Lu~(3+). The intergranular phases tend to distribute at the triple-grain pockets and the solubility of Lu~(3+) increases. The toughness and strength are further improved.
It is originally demonstrated that mixed cation scandium/lutetium dopedα-sialon was prepared. The addition of Lu2O3 in the composition promotes the Sc~(3+) to enter theα-sialon structure, and leads the producedα-sialon with elongated-grain morphology. The ScLu-α-sialon mainly consists ofα-sialon phase with small quantity ofβ-sialon, 12H' and J'. It possesses a high hardness, toughness and flexural strength with the values of 20.4 GPa, 5.2 MPa?m1/2 and 652.5 MPa, respectively.
HREM analysis shows that no amorphous layer at theα-sialon/intergranular phase interface exists, but there is only a ~1 nm amorphous layer betweenα- andα-sialon grains which cannot be eliminated completely even after heat treatment in single-cation dopedα-sialon ceramics. In multi-cation ScLu-α-sialon, there is no amorphous layer atα/α-sialon andα/β-sialon interfaces.
(S)TEM analyses indicate thatα-sialon always nucleates on initial unsolvedα-Si3N4 and then grows epitaxially on it. And the initial precipitation on theα-Si3N4 particle is rich in rare-earth and Al than the subsequent precipitation.
This mechanism of heterogeneous nucleation and growth is applicable for majority of Re-α-sialon systems. HREM analysis shows that the core and shell have the same structure and crystallographic orientation, and the interface is coherent. The misfit dislocations and the contrast variation caused by the misfit strain are observed due to the difference in compositions and lattice constants. The anisotropic growth ofα-sialon grains are mainly resulted from the different growth mechanisms between the prisms and the base surface. The interfacial reaction controlled kinetics on the prisms and diffusion-controlled kinetics on the base surface (001) are believed to take effect, respectively. The formation of elongatedα-sialon grains facilitates self-toughening mechanism successfully, such as pullout of elongated grains and deflection and bridging of crack. The toughness is greatly enhanced as well as the strength. The high temperature strength of Lu- and ScLu-α-sialon ceramics are very high and can reach over 550 MPa even at 1400 oC. They possess very good oxidation resistance, with thinner dense oxidation layer and parabolic rate constants K≈2.5×10-6 - 4.2×10-6 mg2/(cm4?s) at 1300oC, which is one order of magnitude lower than that of Y-α-sialon. One rare-earth depleted zone forms beneath the oxidation layer due to the oxidation reactions and the outward diffusion of cations into the scale. The rare-earth depleted layer contacts closely with the oxidation layer and theα-sialon matrix.
研究发现,小尺寸Yb~(3+)、Y~(3+)和Dy~(3+)稳定的α-sialon陶瓷只有单一的α-sialon相,而大尺寸稀土体系还含有少量晶间相M'(R2Si3-xAlxO~(3+)xN4-x)、甚至β-sialon和21R-AlN多型体。随着稀土离子尺寸增大,陶瓷中长棒状晶粒增多,长径比增大;断裂韧性升高,硬度略有下降。
选用高熔点Sc_2O_3为稳定剂制备的sialon陶瓷主要由β-sialon相组成,并含有少量12H-AlN多型体。12H'吸收大量Sc进入到它的结构中,为减少晶间相提供了一条有效途径。Sc-sialon陶瓷硬度较低,只有16 GPa;等轴晶粒形貌使得材料的强度和韧性偏低,只有541 MPa和3.8 MPa?m1/2。但以高熔点Lu2O3为稳定剂的α-sialon陶瓷则完全由α-sialon相构成,兼有少量晶间相J'(Lu4Si2-xAlxO7+xN2-x),其硬度很高,都在21 GPa以上。随着Lu2O3含量增加,晶间相增多,长棒状晶粒数目增多,长径比增大,强度和韧性升高,硬度略有下降;当过量Lu2O3含量超过4 wt.%时,晶粒径向尺寸明显变小,长度略有降低;过量Lu2O3含量为4 wt.%时,材料具有最高的韧性和强度,分别为4.7 MPa?m1/2和620.2 MPa。热处理使得Lu-α-sialon晶粒各向异性长大明显,晶间相分布趋向于三角晶界处,其固溶度增大,而α-sialon的固溶度减小,韧性和强度进一步升高。
首次将两种小尺寸稀土离子Sc~(3+)和Lu~(3+)复合掺杂制备α-sialon陶瓷,成功使得不能单独进入α-sialon结构的Sc~(3+)稳定存在于α-sialon中。材料主要由α-sialon相构成,兼有少量β-sialon、J'和含Sc的12H'相。材料具有高硬度、高韧性和抗弯强度,分别为20.4 GPa、5.2 MPa?m1/2和652 MPa。
HREM分析表明,单一掺杂的α-sialon陶瓷中,α-sialon和晶间相之间没有非晶层,但在α-sialon相之间则存在厚度1 nm左右的非晶层,即使热处理也不能完全消除;但在复合掺杂的ScLu-α-sialon中,α-sialon相之间以及和β-sialon相之间的界面都不存在非晶层。
(S)TEM分析表明,不同稀土体系α-sialon晶粒形核长大机制均是以α-Si3N4作为优先形核位置外延生长,且初始析出的α-sialon较之后沉淀析出的固溶度高,core、shell之间点阵连续,晶体结构和晶体学取向相同,由于成份及晶格常数的差异,界面存在错配位错及应变引起的衬度变化。棱柱面界面反应控制生长和基面(001)的扩散控制生长促使α-sialon晶粒各向异性长大并形成长棒状晶粒。
长棒状α-sialon晶粒的形成成功实现了α-sialon陶瓷的自增韧机制。通过长棒状晶粒的解离和拔出以及裂纹沿长棒状晶粒的偏转和桥接大大提高了陶瓷的断裂韧性,同时长棒状晶粒也促进了材料的强化。
Lu-和ScLu-α-sialon陶瓷都具有很高的高温强度,1400oC下仍达550 MPa以上,且抗氧化性能好,氧化层致密,1300oC下其氧化速率常数K≈2.5×10-6 - 4.2×10-6 mg2/(cm4?s),较Y-α-sialon陶瓷低一个数量级。氧化反应及元素扩散共同作用使得氧化层下方形成一个稀土元素消耗区,它与氧化层和基体连接紧密。
α-Sialons stabilized with different rare-earth cations or multi-cations were prepared by a two-step hot sintering. The relationship between microstructure and properties was systematically investigated. The nucleation and growth mode of elongatedα-sialon grains, as well as the self-toughening mechanism was revealed. The effect of type of rare-earth oxides on the oxidation behavior of materials was studied and the oxidation mechanism was also discussed.
The experimental results show that Yb-, Y- and Dy-α-sialon ceramics consist of onlyα-sialon phase, while a few M'(R2Si3-xAlxO~(3+)xN4-x), evenβ-sialon and 21R-AlN polytypoid are also found in large cation doped ceramics. With the increase of ionic radius, more elongated grains form and the aspect ratio tends to increase. The toughness increases, but the hardness decreases slightly.
Sc_2O_3 with high melting point was incorporated into sialon ceramic. Onlyβ-sialon as main crystalline phase exists together with a small amount of 12H-AlN polytypoid. The formation of scandium containing AlN-polytypoid can provide a valid way to reduce the amount of grain boundary phase. The Sc-sialon exhibits a typically low hardness of 16 GPa due to itsβ-sialon phase assemblage. Moreover, the equiaxed morphology ofβ-sialon grains, which is discovered for the first time, also results in a relatively lower fracture toughness and strength, 541 MPa and 3.8 MPa?m1/2, respectively. Whereas, sialon ceramics doped with high melting point Lu2O3 mainly consist ofα-sialon phase with a few intergranular phase J'(Lu4Si2-xAlxO7+xN2-x). Lu-α-sialons possess very high hardness of over 21 GPa. With increasing the Lu2O3 content, the amount of intergranular phase increases, and the number and aspect ratio of elongatedα-sialon grains increase, too. When the extra content of Lu2O3 goes beyond 4wt%, the radial size ofα-sialon grains decreases obviously and the length decreases slightly. Lu-α-sialons exhibit an enhanced toughness and strength with the peak value of 4.7 MPa?m1/2 and 620.2 MPa for the material containing 4 wt% extra Lu2O3. The post-heat treatment results in an anisotropic growth of Lu-α-sialon grains and a decreased solubility of Lu~(3+). The intergranular phases tend to distribute at the triple-grain pockets and the solubility of Lu~(3+) increases. The toughness and strength are further improved.
It is originally demonstrated that mixed cation scandium/lutetium dopedα-sialon was prepared. The addition of Lu2O3 in the composition promotes the Sc~(3+) to enter theα-sialon structure, and leads the producedα-sialon with elongated-grain morphology. The ScLu-α-sialon mainly consists ofα-sialon phase with small quantity ofβ-sialon, 12H' and J'. It possesses a high hardness, toughness and flexural strength with the values of 20.4 GPa, 5.2 MPa?m1/2 and 652.5 MPa, respectively.
HREM analysis shows that no amorphous layer at theα-sialon/intergranular phase interface exists, but there is only a ~1 nm amorphous layer betweenα- andα-sialon grains which cannot be eliminated completely even after heat treatment in single-cation dopedα-sialon ceramics. In multi-cation ScLu-α-sialon, there is no amorphous layer atα/α-sialon andα/β-sialon interfaces.
(S)TEM analyses indicate thatα-sialon always nucleates on initial unsolvedα-Si3N4 and then grows epitaxially on it. And the initial precipitation on theα-Si3N4 particle is rich in rare-earth and Al than the subsequent precipitation.
This mechanism of heterogeneous nucleation and growth is applicable for majority of Re-α-sialon systems. HREM analysis shows that the core and shell have the same structure and crystallographic orientation, and the interface is coherent. The misfit dislocations and the contrast variation caused by the misfit strain are observed due to the difference in compositions and lattice constants. The anisotropic growth ofα-sialon grains are mainly resulted from the different growth mechanisms between the prisms and the base surface. The interfacial reaction controlled kinetics on the prisms and diffusion-controlled kinetics on the base surface (001) are believed to take effect, respectively. The formation of elongatedα-sialon grains facilitates self-toughening mechanism successfully, such as pullout of elongated grains and deflection and bridging of crack. The toughness is greatly enhanced as well as the strength. The high temperature strength of Lu- and ScLu-α-sialon ceramics are very high and can reach over 550 MPa even at 1400 oC. They possess very good oxidation resistance, with thinner dense oxidation layer and parabolic rate constants K≈2.5×10-6 - 4.2×10-6 mg2/(cm4?s) at 1300oC, which is one order of magnitude lower than that of Y-α-sialon. One rare-earth depleted zone forms beneath the oxidation layer due to the oxidation reactions and the outward diffusion of cations into the scale. The rare-earth depleted layer contacts closely with the oxidation layer and theα-sialon matrix.
引文
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