The use of self-reinforcement by larger elongated grains in silicon nitride ceramics requires judicious control of the microstructure to achieve high steady-state toughness and high fracture strength. With a distinct bimodal distribution of grain diameters, such as that achieved by the addition of 2% rodlike seeds, the fracture resistance rapidly rises with crack extension to steady-state values of up to 10 MPaؒm 1/2 and is accompanied by fracture strengths in excess of 1 GPa. When the generation of elongated reinforcing grains is not regulated, a broad grain diameter distribution is typically generated. While some toughening is achieved, both the plateau (steady-state) toughness and the R-curve response suffer, and the fracture strength undergoes a substantial reduction. Unreinforced equiaxed silicon nitride exhibits the least R-curve response with a steady-state toughness of only 3.5 MPaؒm 1/2 coupled with a reduced fracture strength.

Significant improvements in the fracture resistance of self‐reinforced silicon nitride ceramics have been obtained by tailoring the chemistry of the intergranular amorphous phase. First, the overall microstructure of the material was controlled by incorporation of a fixed amount of elongated ß‐Si3N4 seeds into the starting powder to regulate the size and fraction of the large reinforcing grains. With controlled microstructures, the interfacial debond strength between the reinforcement and the intergranular glass was optimized by varying the yttria‐to‐alumina ratio in the sintering additives. It was found that the steady‐state fracture toughness value of these silicon nitrides increased with the Y:Al ratio of the oxide additives. The increased toughness was accompanied by a steeply rising R‐curve and extensive interfacial debonding between the elongated ß‐Si3N4 grains and the intergranular glassy phase. Microstructural analyses indicate that the different fracture behavior is related to the Al (and O) content in the ß´‐SiAlON growth layer formed on the elongated ß‐Si3N4 grains during densification. The results imply that the interfacial bond strength is a function of the extent of Al and Si bonding with N and O in the adjoining phases with an abrupt structural/chemical interface achieved by reducing the Al concentration in both the intergranular phase and the ß´‐SiAlON growth layer. Analytical modeling revealed that the residual thermal expansion mismatch stress is not a dominant influence on the interfacial fracture behavior when a distinct ß´‐SiAlON growth layer forms. It is concluded that the fracture resistance of self‐reinforced silicon nitrides can be improved by optimizing the sintering additives employed.

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