Chemical Vapor Deposition Synthesis Carbon Nanosheet-Coated Zirconium Diboride Particles for Improved Fracture Toughness

Carbon nanosheet–coated micron zirconium diboride particles were achieved by an atmospheric chemical vapor deposition in the presence of methane gas without catalyst. The microstructures and carbon structure for the novel particles were characterized by scanning electron microscopy, transmission electron microscopy, and Raman spectroscopy. In addition, the growth process of hybrid particles was analyzed by thermodynamic theory. The results showed that zirconium diboride particles were coated by carbon nanosheets uniformly. The carbon nanosheets/zirconium diboride particles were employed to fabricate ceramic composite using spark plasma sintering process. The fracture toughness of the composite was improved up to 5.9 MPa·m0.5 with only 0.9 wt% of carbon nanosheets, which was 40.9% higher than that of the composite without carbon nanosheets. The toughening mechanisms were mainly known as carbon nanosheets crack bridging and pulling out which lead to the formation of crack deflection in the novel composite.