Multifunctional silicon nitride ceramic nanocomposites using single-walled carbon nanotubes

High-temperature ceramics, such as silicon nitride, are considered the best-suited materials for use in extreme environments because they posess high melting temperatures, high strength and toughness, and good thermal shock resistance. The goal of this research is to create bulk multifunctional high-temperature ceramic nanocomposites using single-wall carbon nanotubes in order to tailor electrical and thermal conductivity properties, while also enhancing the mechanical properties of the monolith. Colloidal processing methods were used to develop aqueous single-walled carbon nanotube (SWNT)-Si₃N₄ suspensions that were directly fabricated into bulk parts using a rapid prototyping method. High-density sintered nanocomposites were produced using spark plasma sintering, at temperatures greater than 1600 °C, and evidence of SWNTs in the final sintered microstructure was observed using scanning electron microscopy and Raman spectroscopy. The multifunctional nanocomposites show exceptional fracture toughness (8.48 MPa-m^1/2) properties and was directly measured using conventional fracture toughness testing methods (ASMT C41 ). Our results suggest that the use of SWNTs in optimized sintered ceramic microstructures can enhance the toughness of the ceramic by at least 30% over the monolith. In addition, the observation of hallmark toughening mechanisms and enhanced damage tolerance behavior over the monolith was directly observed. The nanocomposites also measured for reductions in electrical resistivity values over the monolith, making them high-temperature electrical conductors. These novel nanocomposites systems have enhanced electrical conductivity, and enhanced toughness over the monolith which make them unique high-temperature multifunctional nanocomposites.