SiAlONs were developed as a more cost-effective substitute for hot pressed silicon nitride.

They
have a complex chemistry, and should be considered a family of alloys with a broad range of
properties. SiAlONs are formed when silicon nitride (Si3N4), aluminium oxide (Al2O3) and
aluminium nitride (AlN) react. The materials combine to form a wide range of chemical
compositions.
Fully dense polycrystalline bodies can be formed via pressureless sintering if sintering aids, such
as yttrium oxide or magnesium oxide, are added to the compact. This innovative technique
allows near net complex shaped components to be produced in a cost-effective way. The two
most common crystalline phases formed in sialon ceramics are β-SiAlON and α SiAlON, where
combinations of both phases can be incorporated into a single monolithic ceramic with
compositions being developed to suit specific applications.
Key Properties
SiAlONs can exhibit the following properties:
 low density
 high strength
 superior resistance to thermal shock
 excellent wear resistance
 fracture toughness
 mechanical fatigue and creep resistance
 oxidation resistance
In comparison to hot-pressed silicon nitride, the very high temperature-resistance properties of
SiAlON materials produced via pressureless sintering are limited by the glassy phases that form
at grain boundaries during the sintering process. These materials are only suitable for long term
use at temperatures < 1200 °C.
β–SiAlON is built on the atomic arrangement existing in β–Si3N4. In this material, some Si is
substituted by Al, with corresponding replacement of N by O. Subsequently, up to two–thirds of
the silicon in β–Si3N4 can be replaced by Al without causing a structural change. The chemical
replacement consists of exchanging Si–N bonds for Al–O bonds. The bond lengths are
approximately the same for the two cases, but the Al–O bond strength is significantly higher than
that of Si–N. In SiAlONs, the Al is co–ordinated as AlO4 and not as AlO6 as in alumina
(Al2O3). Consequently, in β–SiAlON the bond strength is 50% stronger than in Al2O3. Thus
SiAlONs intrinsically display superior properties than both Si3N4 and Al2O3. β-SiAlON grains
have a long and needle-like, and orientate themselves randomly within the microstructure. This
forms an interlocking structure of strong crystalline grains within the glassy-phase matrix, and is
the reason for β-SiAlON ceramic’s high bend strength and toughness.
β–SiAlON is produced by International Syalons using and marketed under the trade name Syalon
101. During sintering at temperatures exceeding 1400 °C, the oxides react to form an oxynitride
liquid with the sintering additives which is necessary for densification. This viscous liquid then
forms an intergranular glass on cooling. Syalon 101 is a fully dense ceramic characterized by
high strength and toughness.
As a solid solution, the vapour pressure of β–SiAlON is lower than that of Si3N4, thus the
SiAlON will form more liquid at a lower temperature with the presence of sintering additives.
SiAlON is hence more easily densified using normal sintering techniques. Furthermore, it is
significant that the lower vapour pressure of SiAlON reduces decomposition at high
temperatures so that the SiAlON is more thermodynamically stable than Si3N4.
These β–SiAlONs are particularly useful in applications such as non–ferrous molten metal
handling. During this process, thermal shock resistance and chemical stability when in contact
with molten metals is critical for SiAlONs as components in thermocouple protection sheaths
and in heater and riser tubes.