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Aiming to provide key materials in order to improve the fracture toughness of ZrB 2 ceramics, ZrB 2 -SiC composite powders with in situ grown SiC whiskers were successfully synthesized via a simple molten-salt-assisted ferrous-catalyzed carbothermal reduction method. Thermodynamic calculations on the ZrO 2 -SiO 2 -B 2 O 3 -C-Fe system were carried out. The effects of heating temperature and ferrous catalyst amount on the growth behavior of SiC whiskers in ZrB 2 -SiC composite powders were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), X-ray energy dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). The results showed that the aspect ratio of SiC whiskers and the relative content of ZrB 2 particles increased with increasing heating temperature (1523-1723 K) and a molar ratio of Fe to ZrSiO 4 from 0:1 to 0.2:1. Phase-pure ZrB 2 -SiC composite powders were obtained at 1723 K when the molar ratio of raw materials was 0.2:0.5:1:1.5:8.4 (Fe:NaCl:ZrSiO 4 :B 2 O 3 :C). Single crystalline β-SiC whiskers with a mean diameter of 0.15 μm and an aspect ratio of 70-120 were homogeneously distributed in the final composite powders. A molten-salt-assisted iron-catalyzed vapor-solid mechanism was promoted for the growth mechanism of in situ grown SiC whiskers.

In Situ Growth Behavior of SiC Whiskers with High Aspect Ratio in the Synthesis of ZrB2-SiC Composite Powders