Fabrication of ZrB2-SiC ceramic composites by optimized gel-casting method

The ZrB2-SiC ceramics with homogenous microstructures were successfully fabricated by the optimized gel-casting method and pressureless sintering. The effects of the processing parameters, including the monomer content, cross-linker/monomer ratios, initiator addition, catalyst concentration and polymerization temperature, on the final gel properties were systematically investigated. The rheological behavior and stability of ZrB2-SiC suspensions were evaluated, and the microstructures and mechanical properties of sintered ceramics were also analyzed. The homogenous gel networks containing low monomer content (4 wt%) and without catalysts had been successfully obtained, which could be mainly attributed to the homogeneous distribution of crosslinking points and temperature-induced gelation. The crack-free and complex-shaped ZrB2-SiC ceramic composites were achieved by the optimized gel-casting, which could reach the highest relative density of 97.2% and the flexural strength of 402 ± 57 MPa, respectively. This study provides an optimized gel-casting process for fabricating ZrB2-SiC ceramics with excellent properties by low colloidal additives and without catalysts.