Thickness effects on the sinterability, microstructure, and nanohardness of SiC-based ceramics consolidated by spark plasma sintering

This study aimed to investigate the effects of the original thickness on the densification, microstructure, and nanoindentation hardness of silicon carbide (SiC) ceramics prepared by the spark plasma sintering (SPS) process. The densification of SiC ceramics with different initial thicknesses ranging from 50 to 2000 µm was investigated in combination with varying SPS sintering temperature at 1700–1900°C. The results indicated that the densification of SiC sample with the initial thickness of 50 µm was complete after sintering at 1700°C. On the contrary, when the initial thickness exceeded 50 µm, it resulted in a porous microstructure. When the initial thickness varied from 50 to 100 µm, dense SiC monolithic could be obtained after sintering at 1800°C. All the samples were fully densified after sintering at 1900°C. The predominant factors for the thickness effect were mainly derived from the unique characteristics of SPS. The hardness of SiC ceramics was measured using nanoindentation, and it was found to have a strong correlation with the initial thickness, mainly attributed to the densification status. The dense SiC product demonstrated nanoindentation hardness with high values of ∼28.0 GPa.