Reaction sintered Fe–Sialon ceramic composite: Processing, characterization and high temperature erosion wear behavior

Fe–Sialon ceramic matrix composite has been newly developed from ferro-silicon alloy and commercial-grade industrial alumina powders by reaction sintering under a nitrogen atmosphere. The phase composition, mechanical properties and impact erosion wear behavior were investigated. The solid particle erosion tests have been conducted at elevated temperatures ranging from 25 °C to 1200 °C. Sharp SiC particles between 325 and 830 μm in diameter were employed as impact abrasives. The results showed that Fe–Sialon ceramic consisted of β-Sialon and Fe3Si phases. The Z value of the as-formed β-Sialon varied from 0 to 3.2 with increasing the alumina content in the starting powders. The bending strength and Rockwell hardness gradually increased with raising the alumina addition. The erosion rate of Fe–Sialon ceramic is highly dependent on the testing temperature. The minor erosion took place at room temperature or 1200 °C, while the major erosion occurred at 600–1000 °C. Fe–Sialon composites showed better erosion wear resistance than the control material of alumina ceramic at 1200 °C, although having much lower density and slightly lower bending strength.