Formation behavior, microstructure and mechanical properties of multi-cation α-sialons containing calcium and neodymium

Dual modifying cation (Ca+Nd) α-sialons were hot pressed for the x=1.0 composition ((Ca,Nd)xSi12-3nAl3nOnN16-n) with mixtures of CaO:Nd2O3 in the molar ratios of 0:1, 0.3:0.7, 0.5:0.5, 0.7:0.3 and 1:0. Experimental results showed that except for pure Nd- and Ca-α-silaon compositions, the main crystalline phase in samples hot-pressed at 1750°C for 1 h was α-sialon together with a small amount of melilite solid solution and AlN polytypoid. The higher CaO:Nd2O3 ratio in the starting composition, the higher α-sialon content and the lower melilite solid solution content in the final phase assembly. The α-sialon lattice also expanded with increasing substitution of Ca for Nd. Elongated grain morphology was observed in (Ca+Nd) α-sialon. EDS analysis revealed higher solubility of Ca than Nd in the α-sialon lattice and lower solubility of Ca than Nd in the intergranular phase. The hardness increased, ranging from 15.87 to 18.79 MPa, when the amount of α-sialon phase in the material became higher. The fracture toughness varied from 4.2 to 5.1 MP am1/2 for (Ca+Nd) α-sialon compositions, in which the composition with CaO:Nd2O3=0.5:0.5 possessed the highest value.