Effects of CaO Additives on the Phase Evolution of ZrO2-SiC Composites from Zircon by Carbothermal Reduction

Abstract

In this study, Ca2+ stabilized ZrO2-SiC composite materials were prepared via carbothermal reduction, using natural zircon ore as raw material, CaO as additive, and black carbon as the reducing agent. The effects of synthesis temperature and CaO content on the phase composition of the products were investigated by XRD. The microstructure and micro-area chemical analysis of the products were characterized by SEM and EDS. The results indicate that: (1) Ca2+ stabilized ZrO2-SiC composite materials could be prepared from natural zircon ore with CaO addition between 1500°C and 1600°C for 4 hours by carbothermal reduction process. (2) The synthetic temperature has an important influence on the phase composition of the carbothermal reduction products of zircon. The production of m-ZrO2 and t-ZrO2 got obviously enhanced with increasing temperature from 1500°C to 1600°C. (3) At the same synthetic temperature, Ca2+ stabilized ZrO2 got enhanced with increasing adding amount of CaO. The optimized synthesis condition of Ca2+ stabilized cubic-ZrO2/SiC composite materials is sintering at 1600°C for 4 hours with adding 40 mol% CaO as additive.