Flash Sintering of Non-Oxide Ceramics for Armour

Context and impact. The most effective armour systems for military personnel rely on plates of non-oxide ceramics such as SiC to defeat incoming projectiles. These ceramics are expensive and difficult to produce because temperatures of ~2000C, often with the simultaneous application of pressure, are needed to densify them. We have recently shown, however, that SiC can be densified without pressure at furnace temperatures less than 1200C in just a few seconds in a new process known as "flash sintering" in which an electric field is applied to the ceramic during sintering. Use of this to produce armour has the potential to reduce the cost of the armour (less energy used, cheaper furnaces, pressure not needed) and to produce more complex shapes (the requirement for applied pressure in conventional processing means only simple shapes are possible). There is also the possibility that improved microstructures and properties might be achieveable.

Aims and objectives. The aim of this project is to understand the mechanisms responsible for these remarkable improvements in sintering and hence to establish the advantages in cost, ballistic performance and manufacturing versatility for armour manufacture. The research will involve ceramic processing via flash sintering, microstructural characterisation and mechanical and ballistic testing.

Novelty. ISI Web of Knowledge lists on 6 papers on the flash sintering of SiC, 3 of which are by the present supervisor. This illustrates the fact that the essential novelty is in the process of flash sintering non-oxides itself. All information on how it works and what the microstructure and properties of the sintered ceramics are like is novel.

Alignment with EPSRC's strategies and research areas. The proposal is very well aligned with the "Productive Nation" heading of the EPSRC Delivery Plan, which aims to "introduce the next generation of innovative and disruptive technologies" by means of "advanced materials research to drive new processes, products and sustainable solutions". It also fits well with the Research Areas "Manufacturing Technologies" and "Materials Engineering - Ceramics" in the Manufacturing the Future Theme and "Energy Efficiency" in the Energy theme.

Companies and collaborators. The project is an iCASE award with Dstl as the industrial sponsor. Their main contributions will be guidance of the direction of the project and direct collaboration on ballistic testing of materials produced. There will also be collaboration via Dstl with Kennametal (Newport) who own SPS/hot pressing equipment involving field assisted processing of SiC which was part paid for by Dstl. Possible collaboration with academics with interests in flash sintering (e.g. Prof. M.J. Reece, QMUL) is also anticipated.

NCE for this voucher made in error - end date of 31/01/22 correct.