Floating zone partial re-melting of B4C infiltrated with molten Si

Green compacts of B4C or B4C added with 1 vol% graphite were infiltrated with molten Si and subsequently were subject of processing by floating zone partial re-melting (FZPR). In FZPR only the low temperature fusible component, in this case Si, is melted. A fully dense B4C-based ceramic is obtained. It contains free-Si, SiC and B4C. In the center of the FZPR ceramic without graphite addition, the amount of Si is decreased when compared to the infiltrated material. Some impurity elements such as Al, Fe, or Ti detected in the raw B4C powder are preferentially gathered at the edges of the sample. In the sample added with graphite, formation of a high amount of SiC in the infiltrated material hinders Si shift from the center to the edges. The pulling rate and the particle size of the B4C raw powders are also important. It is recognized that sintering of powders larger than 10-20 µm is usually difficult: our approach is demonstrated to be suitable for processing of B4C powders with a very different particle size, from 10 to 250 µm. The FZPR ceramic had a Vickers hardness of 9-38 GPa depending on location of the indentation imprint and on the sample. A tensile strength of 114-188 MPa that is up to about 2-3 times higher than for the infiltrated material was recorded. Work indicates that the proposed processing approach offers extended control possibilities towards fabrication of new composite materials not available by traditional technologies.