BN-ZrO 2 ceramic composites reinforced with hybrid SiC whiskers (SiCw) and particles (SiCp) were fabricated via spark plasma sintering. Results show that the SiCw/SiCp ratio governs densification kinetics, microstructure, mechanical properties, and service-related properties. The optimal composition, with 15 wt% SiCw and 10 wt% SiCp (denoted W3P2), achieves the best overall mechanical properties: flexural strength of 234.8 ± 9.5 MPa, fracture toughness of 3.35 ± 0.06 MPa·m 1/2, Vickers hardness of 1.14 ± 0.04 GPa, and the lowest wear rate of 1.26× 10 -3 mm 3·N -1·m -1. These enhancements are attributed to synergistic strengthening and toughening mechanisms: (i) stacking faults within SiCw and twins in ZrO 2 grains, (ii) grain boundary stress at SiCw/ZrO 2 interfaces, (iii) coherent SiCp/ZrO 2 interfaces with low lattice mismatch, (iv) SiCw-induced randomization of BN platelet. The wear mechanism shifts from severe adhesive/oxidative to mild oxidative wear at this composition. Furthermore, increasing the SiCw content enhances oxidation resistance by promoting a continuous and stable SiO 2/ZrSiO 4 passivation layer that impedes oxygen diffusion. This work provides a foundation for hybrid-reinforced BN-based ceramic composites targeting demanding thermo-mechanical applications, particularly as side dam materials in thin strip continuous casting systems.
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