Fabrication of Zr₃AlC₂ by Spark Plasma Sintering

Abstract

This study reports the synthesis of the Zr₃AlC₂ MAX phase from ZrH₂, Al, and ZrC as raw materials by means of spark plasma sintering (SPS). The crystal structure of the resulting product was analyzed by X-ray diffraction (XRD), and the microstructure was examined using scanning electron microscopy (SEM). We investigated the influence of sintering temperature and process parameters on the Zr₃AlC₂ content within the sintered product. We also introduce a novel two-layer powder filling approach that significantly enhances the purity of Zr₃AlC₂ in the final product. This method leverages a specific stacking mechanism to control phase distribution, achieving a Zr₃AlC₂ content as high as 93%.

Fig. 11 SEM image of fracture surface of sample No. 4. (online color)