Preparation, structure and mechanical properties of Sialon ceramics by transition metal-catalyzed nitriding reaction

Sialon ceramics were prepared by the nitridation of Si, Al and Al2O3 powders with the transition metals (Fe, Co, Ni) catalysts. The phase composition, microstructure and mechanical properties of specimens were studied. Compared with the catalyst-free specimen, the addition of Fe, Co and Ni greatly promoted the nitridation process of Sialon ceramics and improved the weight gain rate and mechanical properties of specimens. With the increased content of catalysts, the apparent porosity of the products decreased first and then increased, contrary to flexural strength and compressive strength. The specimen with 2.5 wt% Fe had the highest flexural strength 145.8 MPa, and it exhibited the highest compressive strength of 594.6 MPa when Co content was 2.5 wt%, whereas they were 71.9 and 78.7 MPa, respectively, when without catalyst.