The synthesis and consolidation of hard materials by spark plasma sintering

Dense ceramic matrix composites consisting of boron carbide, titanium diboride, hafnium diboride were synthesized by spark plasma sintering (SPS). Specifically, a functionally graded boron carbide–aluminum composite with a precipitous microstructural gradient was created by a unique SPS die/punch off-set technique. Additionally, pseudo eutectic titanium diboride–boron carbide composites were synthesized by SPS using mechanically alloyed elemental powders. Lastly, hafnium diboride–20 vol.% silicon carbide composites were created from high energy ball milled precursor powders. This work demonstrates the SPS equipment’s promising potential to synthesize bulk, hard, refractory composites.