Silicon nitride (Si
3N
4) coated with lutetium disilicate (Lu
2Si
2O
7) layer through the intermediate silica (SiO
2)-rich phase was fabricated by reaction sintering after dip-coating. The Lu
2Si
2O
7 layer with a thickness of 3-29 μm was formed on Si
3N
4 substrate. It was relatively dense with several pores, and strongly jointed to the substrate through the intermediate phase. Oxidation resistance and strength retention of the coated Si
3N
4 were investigated and compared with those of the uncoated Si
3N
4. Apparent activation energy for oxidation at 1300-1500°C in air increased up to 523.1 kJ/mol with increasing thickness of the coating layer, which was about 1.7 times higher than that of the uncoated Si
3N
4 (310.3 kJ/mol). After long-term cycling oxidation at 1500°C for up to 1000 h in air, the total weight gain decreased by up to 51%, indicating that oxidation resistance improved by about 100%. The improvement was attributed to the protection of the substrate from an oxidative environment by the Lu
2Si
2O
7 layer and underlying SiO
2-rich phase. Flexural strength of the coated Si
3N
4 was not deteriorated before and after the cycling oxidation at 1500°C for up to 1000 h in comparison with that of the uncoated Si
3N
4. However, the high-temperature strength at 1400-1500°C in air was a little less than that of the uncoated Si
3N
4. The deterioration was attributed to the softening of amorphous SiO
2 phase, which existed in the intermediate phase (between the Lu
2Si
2O
7 layer and substrate) and inside the substrate.
View full abstract