α-SiAlON/α-SiC composites with 0–40 wt%α-SiC were synthesized by spark plasma sintering for 5 min at 1800°C under 20 MPa pressure. A self-reinforcing microstructure with both elongated α-SiAlON and α-SiC grains, was formed. Flexural strength and fracture toughness were significantly improved due to the in situ reinforcement. High fracture toughness up to 8.2 MPa·m1/2 was obtained in the 40 wt% SiC composition.
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