Novel joining of dissimilar ceramics in the Si3N4–Al2O3 system using polytypoid functional gradients

A unique approach to crack-free joining of heterogeneous ceramics is demonstrated by the use of sialon polytypoids as Functionally Graded Materials (FGM) as defined by the phase diagram in the system, Si3N4-Al2O3. Polytypoids in the Al2O3-Si3N4 system offer a path to compatibility for heterogeneous ceramics. This paper describes successful hot press sintering of multilayered FGM's with 20 layers of thickness 500 mm each. Transmission Electron Microscopy was used to identify the polytypoids at the interfaces of different areas of the joint. It has been found that the 15R polytypoid was formed in the Al2O3-contained layers and the 12H polytypoid was formed in the Si3N4-contained layers.