SiAlON

Introduction:
Sialon ceramics are a specialist class of high temperature refractory materials, with high strength (including at high temperature), good thermal shock resistance and exceptional resistance to wetting or corrosion by molten non-ferrous metals, compared to other refractory materials. Sialon are ceramic alloys based on the elements silicon (Si), aluminium (Al), oxygen (O) and nitrogen (N). The SiAlON developed as a more economical alternative to hot pressed silicon nitride. They are formed when silicon nitride (Si3N4), aluminium oxide (Al2O3) and aluminium nitride (AlN) are reacted together. It has complex chemistry with a wide range of properties. Here the substitution of silicon by aluminium with corresponding atomic replacement of nitrogen by oxygen, to satisfy valence requirements. The resulting 'solution' (SiAlON) has superior properties to the original pure solvent (silicon nitride).

History
It is developed in 1970s. Developed to solve the problem of silicon nitride (Si3N4) being difficult to fabricate. Due to higher hardness of Si3N4 we are using it as tool material but it is suffered from low sinterability due to its strong covalent bond. So it is difficult to get complex shape in hot pressing operation. Then attempts have been made to develop cutting tools from Silicon nitride materials. As the result of this ceramic material are composed mainly of a compound obtained by substituting Al and O respectively for part of Si and N in the crystal lattice of .

Forms Of SiAlON
SiAlON exist in three basic forms. -SiAlON, -SiAlON,( &-SiAlON also exist) and O-SiAlON Each form is iso structural with one of the two common forms of Si3N4 In the case of SiAlON, there is substitution for Si by Al and N with O, to satisfy valancy requirements

Production of Sialon
In the production of sialon there are basically three steps and an optional fourth stage.

 Each of these stages will influences the properties of the final product

Raw Material Processing

The raw material for Sialon Ceramics comes in the powder form. Normally using raw materials are of highest quality (purity & particle size). Particle sizes are usually sub-micron range for best Sialon ceramic

Steps
1) 3 or more of these powders need to be mixed together to form the stock material Normally three methods are used a) Spray Dried Powder method b) Aqueous Slip method c) Granulated Feedstock method

a) Spray Dried Powder method

Spray drying is a method of producing a dry powder from a liquid or slurry by rapidly drying with a hot gas (100-200m)

A=Solution or suspension to be dried in, B=Atomization gas in, 1= Drying gas in, 2=Heating of drying gas, 3=Spraying of solution or suspension, 4=Drying chamber, 5=Part between drying chamber and cyclone, 6=Cyclone, 7=Drying gas is taken away, 8=Collection vessel of product, arrows mean that this is co-current lab-spray dryer

Aqueous Slip Method

It is prepared by milling the raw materials in water along with an organic dispersant to produce a fluid. It produces highly concentrated slurry, which is used for slip and pressure casting to produce a high green density part

Granulated Feedstock
It is prepared by mixing the powders with blend organic binders. It will produce a plastic like material that is deformable under pressure, for example, by extrusion. The quality of these raw material feedstock becomes critical in the next stage of manufacture (Sintering shrinkage will affects)

2) Forming Process
Normally two steps are there

Consolidation aims to produce a near net shape part with sufficient strength Process includes uniaxial pressing, isostatic pressing, slip casting or extrusion

Slip Casting
Slip casting uses a highly fluid, which is poured into a porous mould (usually made from plaster).The water goes to plaster by capillary action, and the sialon powder mix deposited on the inside of the mould. Over time, the thickness of the cast increases. When the required thickness is achieved the remaining slip is drained from the mould.

Green Machining
Green machining is the machining of an un-fired, green or raw body. This need to be done when the consolidation method used cannot produce the required part. For this purpose we are using CNC lathes and milling machines.

3) Sintering Process
Sintering is the process during which the consolidated green; sialon part is fired to give a dense, advanced technical ceramic. For sialon, this occurs at around 1750C and the sintering process is known as liquid phase sintering. Liquid phase sintering, is a type of sintering process in which a part of the powder blend melts to produces a viscous glassy liquid. During the liquid phase sintering of sialon, firstly the particles rearrange due to capillary forces, giving better packing then at the points of contact between particles some of the solid particles begin to dissolve in the liquid and forms a good bonding.

4) Diamond Grinding process

Diamond grinding is a machining process which is carried out on a sintered part that needs to be tight tolerance. To go for an improved surface finish, or to remove surface flaws. Final machining process includes grinding, cutting, honing, lapping and polishing. We need diamond tooling due to the high hardness of sialon

Pipes made of Sialon

Microstructure of SiAlON

Mechanical Properties of SiAlON

Comparison of Properties

Advantages of Sialon
Sialon has high hardness and sinterability so it is used as tool material Its having higher wear resistance.

SiAlON exploit the following properties: Low density, High strength Superior thermal shock resistance, Moderate wear resistance Fracture toughness, Mechanical fatigue and creep resistance,

 Higher Oxidation resistance Low thermal expansion

Applications:
Metal feed tubes for aluminum die casting Burner and immersion heater tubes Injector and degassing for nonferrous metals Thermocouple protection tubes Crucibles and ladles In metal forming, Sialon is used as a cutting tool for machining chill cast iron, brazing and welding fixtures Sialon used in chemical industries due to its higher corrosion resistance Sialon are also used for other applications such as seals and bearings Sialon have been used in metal wire and tube drawing tools for non-ferrous metals such as copper and aluminium alloys Low electrical insulation, and thermal conductivity

References:
1) www.wikipedia.com 2) Essentials of Material Science and Engineering by Donald R Askland 3) www.syalon.com