Synthesis, processing and properties of TaC–TaB2–C ceramics

Multi-phase ceramics in the TaC–TaB2–C system were prepared from TaC and B4C mixtures by reactive pressureless sintering at 1700–1900 °C. The pressureless densification was promoted by the use of nano-TaC and by the presence of active carbon in the reaction products. The presence of TaB2 inhibited grain growth of TaC and increased the hardness compared to pure TaC. If a coarse TaC powder was used, the compositions did not densify. In contrast, pure nano-TaC was pressureless sintered at 1800 °C by the addition of 2 wt.% carbon introduced as carbon black or graphite. The introduction of carbon black resulted in fully dense TaC ceramics at temperatures as low as 1500 °C. The grain size of nominally pure TaC ceramics was a strong function of carbon stoichiometry. Enhanced grain size in sub-stoichiometric TaC, compared to stoichiometric TaC, was observed. Additional work is necessary to optimize processing parameters and evaluate the properties of ceramics in the TaC–TaB2–C system.