The synthesis of high sinterability (Zr, Hf)C and SiC hybrid nanocrystalline particles by sol-gel method

Multi-phase UHTCs are favoured for their superior ablation resistance and mechanical properties. In this work, to improve the efficiency and decrease the sintering temperature and pressure, the (Zr, Hf)C and SiC hybrid nanocrystalline particles were prepared via the sol-gel method combining carbothermal reduction at 1600 °C. Utilizing their high sinterability, a relative density of 96.1% (Zr, Hf) C-SiC composite was obtained at the conditions of 1900 °C and 30 MPa using SPS technology. XPS and FT-IR results demonstrate that Zr, Hf, and Si were successfully trapped in the cross-linking structure of the precursors. Precursors of Zr, Hf, and Si reached a molecular-level mixture in the gel phase. SEM, XPS, and XRD characterization showed that the Si-C bond was formed preferentially, leading to the emergence of SiC whiskers and SiC wrapped (Zr, Hf)C with increasing temperature. And, the (Zr, Hf)C can be easily generated during solid solution reaction. Eventually, a nanoscale mixture of (Zr, Hf)C and SiC particles was successfully obtained at 1600 °C. The hardness and compressive strength of the (Zr, Hf)C-SiC composite were 12.94 GPa and 622 MPa, respectively. Comparing usual sintering processes (over 2000 °C and 35MPa), the reason for the improved sinterability can be attributed to the high sintering activity of the (Zr, Hf)C and SiC hybrid particles, and the existence of the solid solution and nano-SiC.