On the enhancement of the spark-plasma sintering kinetics of ZrB2–SiC powder mixtures subjected to high-energy co-ball-milling

The spark-plasma sintering (SPS) kinetics of ZrB2–SiC powder mixtures was investigated as a function of the degree of high-energy co-ball-milling and of the SiC content (5, 17.5, or 30 vol%). As in ZrB2 without SiC, it was found that the crystal size refinement induced by the continued milling progressively enhances the SPS kinetics of ZrB2–SiC, again only moderately if the refinement is to the ultra-fine range, but very marked if the refinement is to the nanoscale. It was also found that the SiC addition further enhances the SPS kinetics of ZrB2, although the improvement did not scale directly with the SiC content, and became less relevant with the refinement of the ZrB2 crystal sizes to the nanoscale. The improved kinetics induced by the SiC addition was identified as being due to the formation of amorphous borosilicate from the oxide passivating layers on the ZrB2 and SiC particles. This not only speeds up the interparticle diffusion, but also it is segregated under the application of pressure into the multi-grain joints, filling pores. The enhanced kinetics induced by the progressive milling is due to the continuous reduction of the diffusion distances and to the development of a greater density of grain boundaries available as faster diffusion paths, together with the greater formation of amorphous borosilicate. Implications of interest for the ultra-high-temperature ceramics community are discussed.