Fabrication of Si3N4 ceramic balls by SPS method with SiC powder bed

Spark plasma sintering (SPS) is an ultrafast sintering method for the preparation of ceramics and ceramic composites with simple geometrical shapes, with the combined application of uniaxial pressure. This study aims to propose an SPS densification method for Si(3)N(4 )ceramic balls without necessitating alterations to tools and equipment. The Si3N4 ceramic balls intended for sintering are positioned within a SiC powder bed inside the conventional die used in SPS. The study systematically investigates the effects of presintering temperature (1400 degrees C, 1500 degrees C, and 1600 degrees C) and SPS temperature (1600 degrees C, 1700 degrees C, and 1800 degrees C) on the sphericity, relative density, phase composition, microstructure, and mechanical properties of Si3N4 ceramic balls. Experimental findings reveal that Si3N4 ceramic balls exhibiting an optimal combination of sphericity (0.94 +/- 0.02), relative density (98.4%), and mechanical properties (Vickers hardness: 17.5 +/- 0.4 GPa, fracture toughness: 6.4 +/- 0.1 MPa<middle dot>m(1/2)) were successfully achieved at a pre-sintering temperature and SPS temperature of 1600 degrees C, coupled with the use of a SiC powder bed and SPS method. Consequently, the SPS method demonstrates its capability to fabricate Si(3)N(4 )ceramic balls with excellent performance.