In order to reduce the sintering temperature and improve the mechanical properties of B4C ceramics, ZrB2 was formed in situ using the SPS sintering method with ZrO2 and B4C as raw materials. Thermodynamic calculations revealed that CO pressure affected the formation of ZrB2 at temperatures from 814 °C to 1100 °C. The experimental results showed that the ZrB2 grain size was <5 µm and that the grains were uniformly distributed within the B4C ceramics. With an increase in ZrO2 content, the Vickers hardness and flexural strength of the B4C ceramics first increased and then decreased, while the fracture toughness continuously increased. When the content of ZrO2 was 15 wt%, the Vickers hardness, fracture toughness and flexural strength of B4C ceramics were 35.5 ± 0.63 GPa, 3.6 ± 0.24 MPa·m1/2 and 403 ± 10 MPa, respectively. These results suggest that ZrB2 inhibits B4C grain growth, eliminates crack tip stress, and provides fine grain to strengthen and toughen B4C ceramics.
Keywords: Zirconium Diboride (ZrB2); boron carbide (B4C); reaction sintering; spark plasma sintering (SPS).