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The present work merges two key strategies for the manufacturing of advanced ceramics, in particular, the development of functionally graded materials (FGMs) and the addition of graphene-based fillers into a ceramic matrix. A silicon nitride/reduced graphene oxide FGM composite is produced, in one step, from a single powder composition using the spark plasma sintering (SPS) technique with an asymmetric setting of the punches and die to create a continuous temperature gradient along the cross section of the powder compact. A deep microstructural and mechanical characterization has been done across the specimen thickness. The FGM composite exhibits bottom-top gradients in both the matrix grain size (150% increase) and α-phase content (89→1%). The FGM bottom surface is 10% harder than the top one and, on the other hand, the latter is 15% tougher. The presence of reduced graphene oxide sheets homogeneously distributed within the ceramic composite reduces the mechanical gradients compared to the monolithic silicon nitride FGM, although allows reaching a maximum long-crack toughness value of 9.4 MPa·m1/2. In addition, these graphene-based fillers turn the insulating ceramics into an electrical conductor material.

In Situ Graded Ceramic/Reduced Graphene Oxide Composites Manufactured by Spark Plasma Sintering