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The effect of a number of compaction parameters on the pore size distribution in silicon nitride powder compacts has been investigated by mercury porosimetry. The powder was compacted in a uniaxial die and the parameters of interest included uniaxial load, loading rate, polymer additives and stress relaxation. The use of a low-viscosity polymer solution as a lubricant, the allowance of stress relaxation following loading and heat treatment above the glass transition temperature of the polymer lead to a more uniform pore size distribution in the green samples. The more uniform green samples, in turn, showed a more uniform pore size distribution after initial stage sintering. The potential of the present techniques for improving the microstructural uniformity in ceramic bodies is discussed.

Pore size distribution during compaction and early stage sintering of silicon nitride