Dynamic consolidation of superhard materials

Shock consolidation experiments were conducted via flyer impact on synthetic diamond (6-12 ^m) and cubic boron nitride (c-BN) (4-8 /im) admixed with SiC whisker (SCW), Si3N4 whisker (SNW), SiC powder, and Si powder contained in stainless steel capsules under the shock pressure range of 10-30 GPa. Scanning electron microscopy and transmission electron microscopy imaging of the samples revealed no plastic deformation or melting of diamond and virtually no deformation of c-BN, whereas the SCW and SNW were extensively melted and recrystallized into bundle-shaped crystallites. In contrast, SiC powder mixed with diamond was also melted but demonstrated equant grain growth. A new method to calculate the shock temperature and melt fraction is formulated on the basis of Milewski's sphere-rod packing data. The new method assigns excess bulk volume to the zone around whiskers and yields a better description of the energy deposition mechanism of the consolidation of powder-whisker systems. Some of the experiments employed Sawaoka's post-shock annealing technique, in which the sample is sandwiched between two layers of a mixture of titanium powder plus carbon. Very well consolidated samples were obtained with post-shock heating under shock pressures of only about 11 GPa. Micro-Vickers hardness values up to 27 GPa were obtained for c-BN plus SCW at a low impact velocity of 1.45 km/s with post-shock heating. This hardness is similar to that obtained at a higher impact velocity of 1.95 km/s without post-shock heating. To understand the post-shock heating process, one-dimensional time dependent temperature profile calculations were conducted for the sample and Ti + C layers. Post-shock heating appears to be very important in the consolidation of powder and whisker admixture. The calculated optimum Ti + C thickness is about 0.8-1.7 mm at a porosity of 40% for a typical sample thickness of 2 mm. The heating and cooling time is a few milliseconds. Good compacts with micro-Vickers hardness values up to 28 GPa were also obtained upon shock consolidation of diamond plus Si admixtures.