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Starting from a powder mixture of  α -Si 3 N 4 , A1N and Ca 3 N 2 , calcium  α -sialon ceramics with extensive compositions on the line of Si 3 N 4  – l/2Ca 3 N 2  : 3A1N (with a nominal composition of Ca  m /2 Si 12   –    m  Al  m  N 16 ) ranged from  m  = 0.5 up to  m  = 6.0 were hot pressed at 1700 °C for 1 h under 20 MPa. The sintering behavior of the sample was found to be significantly composition-dependent, and full densification was achieved for all compositions. The solubility of Ca 2+  in the present  α -sialon was defined in the range of 0.5  ≤ x  ≤ 1.7, which was wider than that in the Ca- α- sialon prepared from CaO. The single-phase samples revealed a similar microstructure comprising the matrix  α -sialon grains and a grain boundary phase as the usual  α -sialons. The energy dispersive X-ray spectroscopy analysis showed that 70 – 85 % Ca 2+  ions entered the  α -sialon structure accompanying the Si substitution by Al.

Preparation of Ca-α-sialon Ceramics with Compositions along the Si 3 N 4 -1/2 Ca 3 N 2 :3AIN Line