Papers by Author: Ferhat Kara

Abstract: In the present study highly dense (open porosity < 1 %), light-weight (d £ 2.85 g/cm3) and Al4C3-free non-oxide ceramic-metal composites were produced at comparatively low temperatures ( 1250°C) by pressurless melt infiltration. Phase analysis of the SiC-B4C-Al composites revealed that a significant amount of hygroscopic Al4SiC4 and Al4C3 phases were formed. Si3N4 powder was added in different amounts to the SiC-B4C powder batches to suppress formation of these phases via in-situ reactions during the infiltration process. X-ray diffraction results of the SiC-B4C-Si3N4-Al composites confirmed that the incorporation of Si3N4 to the SiC-B4C system reduced or eliminated the formation of the hygroscopic phases and resulted in in-situ formation of AlN, SiC and Si phases in the composite.

Abstract: An effective approach for preparing electrically conductive SiAlON-TiN composites was developed. Granules of a designed composition of α- SiAlON was obtained by spray drying and coated with varying amounts of TiO2 powder homogenously by mechanical mixing. Fully dense composites were obtained by spark plasma sintering (SPS) under a pressure of 50 MPa at 1650°C for 5min. According to the SEM analysis, unique microstructures containing continuously segregated in-situ formed TiN phase in 3-D were achieved. Additionally, XRD studies revealed that all TiO2 was successfully converted to TiN. The resistivity of the α-β SiAlON (1x1011 .m) was drastically reduced with the addition of only 5 vol. % TiO2 (2x10-4 .m).

Abstract: Si3N4-B4C composites containing fine and coarse B4C particles were produced using Al2O3 and Y2O3 as sintering additives via spark plasma sintering (SPS) technique. Phase assemblages of the produced composites were determined by XRD analysis. Si3N4, B4C and in situ formed SiC, h-BN and Si phases were observed. Even when incorporated in significant amounts, B4C was consumed readily in the Si3N4 based system. Consequently, full densification of these composites was found to be a very difficult task due to the simultaneous in-situ reactions, even in fast sintering process. Electrical resistivity measurements carried out at room temperature indicated that addition of both fine and coarse B4C particles decreased the electrical resistivity by several orders of magnitude due to the formation of electrically conductive in-situ phases, mainly SiC and metallic Si.

Abstract: - SiAlON ceramics were produced from different starting Si3N4 powders including β-Si3N4 and α-Si3N4 powders and mixtures of these powders. Gas pressure sintering was used for sintering. After sintering, resultant fracture toughness values were correlated with microstructure and starting powders. By optimizing chemistry and process parameters; - SiAlON ceramics with reasonable fracture toughness can be produced from rather coarse β-Si3N4 powder. This could improve the economic viability of SiAlON ceramics since -Si3N4 powders are less costly.

Abstract: In the present study, interactions between AlN and SiAlON laminated couples were investigated after gas pressure (GPS) and spark plasma sintering (SPS) by scanning electron microscopy (SEM) and energy dispersive x-ray analysis (EDX) with the aim to produce laminated composites. In the laminated couples sintered by GPS, a significant reaction zone (~100-150 μm), containing a high aspect ratio of elongated polytypoid grains, was observed at the interface. However, in the case of laminated couples sintered by SPS, a considerably thin reaction region (~2-3 μm) was observed, elongated polytypoid grain formations were also detected.

Abstract: 25α:75β SiAlON composition was designed with different cations and at different molar ratios. Effect of the type of cations both on the composition and the type of intergranular phase investigated after gas pressure sintering and further post sintering heat treatment.