耐熱結構材於高溫環境應用之自主開發下，從超高溫陶瓷(Ultrahigh temperature ceramics, UHTCs)中選擇高熔點(>3000 ℃)、低密度、較佳機械與熱性質之二硼化鋯做為本研究熱結構材之基體，且為提升二硼化鋯之燒結性、機械性質與熱穩定性，添加碳化物如碳化矽與碳化鋯並透過火花電漿燒結(Spark plasma sintering, SPS)技術成型，製備高燒結性之二硼化鋯基陶瓷複合材料，在機械和耐熱試驗下彰顯碳化物添加相強化之效益與實務應用。火花電漿燒結之電漿加熱階段，其產生局部高溫可以使粉末之原生氧化層蒸發，碳化矽添加輔以燒結過程之氧化還原效果以得高致密度之塊材；更在提升緻密度下，碳化鋯的添加通過其自身高硬度與固溶強化之效果，增強維氏硬度、抗彎強度等機械性質之表現。其中因燒結冷卻後碳化物之熱殘留應力使裂紋在材料內部傳播時出現裂紋偏移、裂紋分支與裂紋架橋等現象促使材料增強韌性，提升材料抗撕裂之能力。另一方面，添加碳化矽不只能提升整體之熱傳導係數，在2000 ℃氧乙炔火炬衝擊60秒之熱衝擊實驗下，其氧化還原效果能提升材料抵禦熱沖刷與抗氧化之能力。除此之外，在火花電漿燒結之石墨模具與銅柱電極間置入碳纖維強化碳基複合材料，其低熱傳導係數減少熱源從銅柱電極流失，提升模具整體系統之保溫性並同時降低SPS燒結過程設備所須輸出之功率，有效降低能源損耗。

From the independent development of heat-resistant structural materials for high-temperature environment applications, zirconium diboride (ZrB2) with high melting point (>3000 ℃), low density, better mechanical performance and thermostability was employed from ultrahigh temperature ceramics (UHTCs) in this present study. In order to enhance the sinterability, mechanical responses and thermal stability of ZrB2, carbides such as silicon carbide (SiC) and zirconium carbide (ZrC) were added as well as fabricated ZrB2-based ceramic composites with high sinterability through spark plasma sintering (SPS) technology, demonstrating the benefits and practical applications of carbide reinforced additives under mechanical and thermal tests. Initially, in the plasma heating stage during spark plasma sintering, the original oxide layer of the powder was evaporated in the local high temperature generated. The reduction-oxidation reaction of the sintering process was launched with SiC enhanced to obtain a high-density as-SPSed bulk; meanwhile, performance of mechanical properties such as Vickers hardness and flexural strength were improved by adding ZrC through its own high hardness and solid solution strengthening effect. Further, increasing toughness since resisting cracks propagation inside the material by letting cracks deflection, branching, and bridging, due to the thermal residual stresses of the carbide additives after sintering/cooling processes. On the other hand, adding SiC not only the overall thermal conductivity but the ability to withstand thermal erosion and oxidation, under a thermal shock test using a 2000 °C oxyacetylene torch for 60 seconds. In addition, carbon fiber reinforced carbon-based composites (CFRC) were placed between the spark plasma sintering graphite molds and the copper electrodes since its low thermal conductivity for reducing heat loss started from copper electrodes. The thermal insulation in the entire mold system therefore power output of SPS during sintering was conserved. Thus, the energy consumption saved was also performed.

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