A novel method of strong and tough Si3N4 ceramic from the particle‐stabilized foam.

The brittleness of Si3N4 ceramics has always limited its wide application. In this paper, Si3N4 ceramics were prepared based on foam. Combining the unique honeycomb structure of the ceramic foams and the self‐toughening mechanism of Si3N4, the strengthening and toughening of Si3N4 ceramics can be further achieved by adjusting the microstructure of Si3N4 ceramic foams. The powder particles are self‐assembled by particle‐stabilized foaming to form a foam body with a honeycomb structure. It was pretreated at different temperatures (1450–1750°C). The microstructure evolution of foamed ceramics at different pretreatment temperatures and the conversion rate of α‐Si3N4 to β‐Si3N4 at different pretreatment temperatures were explored. Then the foamed ceramics with different microstructures are hot‐press sintered to prepare Si3N4 dense ceramics. The effects of different microstructures of foamed ceramics on the strength and toughness of Si3N4 ceramics were analyzed. The experimental results show that the relative density of Si3N4 ceramics prepared at a particle pretreatment temperature of 1500°C is 97.8%, and its flexural strength and fracture toughness are relatively the highest, which are 1089 ± 60 MPa and 12.9 ± 1.3 MPa m1/2, respectively. Compared with the traditional powder hot‐pressing sintering, the improvement is 21% and 33%, respectively. It is shown that this method of preparing Si3N4 ceramics based on foam has the potential to strengthen and toughen Si3N4 ceramics. [ABSTRACT FROM AUTHOR]