Pressureless Synthesis and Consolidation of the Entropy-Stabilized (Hf0.25Zr0.25Ti0.25V0.25)B2-B4C Composite by Ultra-Fast High-Temperature Sintering (UHS)

Entropy-stabilized Ultra High-Temperature Ceramics (UHTC) offer a groundbreaking solution to the challenges of extreme environments, showcasing enhanced mechanical properties, thermal stability, and resistance to oxidation at high temperatures. The consolidation of UHTC by ultra-fast high-temperature sintering (UHS) significantly reduces processing times and temperature and can produce dense high-performance ceramics with superior mechanical properties. This study reports the pressureless synthesis and consolidation of the entropy-stabilized (Hf0.25Zr0.25Ti0.25V0.25)B2-B4C composite through UHS within 1 minute, starting from transition metal diboride powders. B4C acts as an effective sintering aid, promoting the densification of the system and the formation of a nearly single-phase hexagonal diboride with a diboride-eutectic phase. Furthermore, a secondary minor hexagonal phase rich in V and Zr is formed close to the eutectic regions. Sintering currents of 40 A were necessary to reach densities higher than 90 % under pressureless conditions, achieving nano hardness higher than 27.3 GPa, comparable with high-entropy diborides produced by Spark Plasma Sintering. The study highlights the entropy-stabilized phase formation, diffusion, densification, and grain growth mechanisms involved during UHS. The work contributes to the understanding of entropy-stabilized ceramics produced by UHS as a faster and less energy-consuming process than conventional sintering methods.