SYNTHESIS AND PROCESSING
2.04 Processing of Silicon Carbide-Based Ceramics
2.04.5 Summary and Prospects
Due to its excellent intrinsic properties SiC can be regarded as one of the most commercially viable and important carbides. More than 100 years ago Edward Goodrich Acheson succeeded in synthesizing SiC raw materials for large-scale production. This was a good enough reason to start developing SiC-based ceramics.
Figure 78 Reaction bonded SiC-based ceramics (RBSC).
166 Processing of Silicon Carbide-Based Ceramics
First approaches used the processing knowledge of the classical silicate ceramics. By applying those pro- cessing principles SiC-based ceramics could be produced at fairly moderate temperatures. The properties of the corresponding silicate bonded SiC-based ceramics, however, could not meet all expectations. Thus their property levels proved to be too low to be used for structural applications. Therefore, it was tried to alter the kinds of sintering additives and to reduce their amount in order to evolve ceramics, whose properties should come close to the intrinsic characteristics of the compound SiC. Due to the low reactivity of the covalent bonded SiC compound this initiative proved to be difficult to be realized. In spite of reducing the grain size to submicron range first successful approaches could only be obtained through pressure-assisted sintering. A real breakthrough could be achieved after Svante Prochazka’s invention of SSiC, since from then on it was possible to use marketable SiC-based ceramics for structural applications even at elevated temperatures and in conjunction with severe chemical attacks. The ceramics, however, proved to be extremely brittle. Through LPS-SiC, the brittleness could be reduced not only due to a change of fracture mode but particularly clearly through in situ toughening effects. The LPS could even be utilized for the manufacture of nanostructured and high-temperature stress-resistant SiC-based ceramics. LPS and gas-phase sintering methods were used to evolve porous ceramics even with graded pore structures for specialfiltering requirements. In general the maximum consolidation temperatures for all these nonsilicate ceramic-derived sintered ceramics have been extremely high. Through reaction bonding the consolidation temperature could considerably be reduced. Three different reaction bonding approaches resulted in untoughened and ex situ fiber-reinforced SiC-based ceramics. In most cases small volume changes occurred during final consolidation. Reaction bonding could also be successfully used for converting natural products into SiC-based ceramics.
Though the history of SiC-based ceramics is relatively short, they frame a huge class of ceramic materials.
Some of them achieve high market shares like SiC grinding tools, SSiC, RSiC, SiSiC, CSiC and NSiC. Not all of these ceramics have been matter of intensive research activities. For others the sales volume is low or the ceramics are not scaled up from laboratory scale. Looking ahead to the future, challenges for the SiC-based ceramics should not only be faced by creating new processing techniques and new materials but also by scaling some powerful ceramics up from laboratory scale to industrial scale. The latter can generally be achieved through the transfer of research findings to industrial products, through restructuring and rationalization actions and thus through an improved cooperation between research institutes and industrial enterprises.
Acknowledgments
The author of this article is greatly indebted to all those people, who had provided him with image material and permitted him to reproduce it in this article.
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