Toughened carbon nanotube–iron–mullite composites prepared by spark plasma sintering

Carbon nanotube–iron–mullite nanocomposite powders were prepared by a direct method involving a reduction in H2–CH4 and without any mechanical mixing step. The carbon nanotubes are mostly double- and few-walled (3–6 walls). Some carbon nanofibers are also observed. The materials were consolidated by spark plasma sintering. Their electrical conductivity is 2.4 S/cm whereas pure mullite is insulating. There is no increase in fracture strength, but the SENB toughness is twice than the one for unreinforced mullite (3.3 vs. 1.6 MPa m1/2). The mechanisms of carbon nanotube bundle pullout and large-scale crack-bridging have been evidenced.