Is spark plasma sintering suitable for the densification of continuous carbon fibre - UHTCMCs?

For the first time we show that spark plasma sintering can efficiently replace hot pressing for the densification of UHTCMCs, in the present case ZrB2/SiC composites reinforced with continuous carbon fibres. To this purpose, the same materials were first produced by hot pressing as baseline samples and then by spark plasma sintering (SPS) to compare microstructure and basic mechanical properties. A special emphasis was given to the study of interfaces, in case of both coated and uncoated carbon fibres. SPS allowed for faster sintering but required an adjustment of the temperature to avoid fibre degradation compared to hot pressing. With similar porosity levels, we observed a slight decrease of flexural strength (300 vs 470 MPa), and an improvement of fracture toughness (15 vs 10 MPaVm) for SPSed samples. SPS was proved to be an effective method for the consolidation of continuous fibre reinforced UHTC composites.