Enhancing densification rate and the unusual 4H-SiC polytype stabilization in ultrafast high-temperature sintering of α-SiC

Novel Powder medium-based Ultrafast High-temperature Sintering (P-UHS) technique brings unexplored opportunities for the ultrarapid consolidation of large-sized and difficult-to-sinter ceramics with a complex shape. Herein, the P-UHS was demonstrated to be very effective means for the densification of large-sized α-SiC bulks (~16 cm3) with boron and carbon additions under heating rates exceeding 1500 °C/min. Bulk ceramics with ~97% density and homogenous microstructure were obtained within only 6 minutes. The ultrafast heating led to two orders of magnitude increase in the densification rate contributing to an energy saving of 90% if compared to conventional sintering process. In addition, the preferential 4H-SiC polytype stabilization was observed only when ultrafast heating rate was employed. The non-equilibrium transient chemistry and the ultrarapid shrinkage were considered as the major drivers for this unusual phenomenon.