In the present study highly dense (open porosity < 1 %), light-weight (d £ 2.85 g/cm3) and Al4C3-free non-oxide ceramic-metal composites were produced at comparatively low temperatures ( 1250°C) by pressurless melt infiltration. Phase analysis of the SiC-B4C-Al composites revealed that a significant amount of hygroscopic Al4SiC4 and Al4C3 phases were formed. Si3N4 powder was added in different amounts to the SiC-B4C powder batches to suppress formation of these phases via in-situ reactions during the infiltration process. X-ray diffraction results of the SiC-B4C-Si3N4-Al composites confirmed that the incorporation of Si3N4 to the SiC-B4C system reduced or eliminated the formation of the hygroscopic phases and resulted in in-situ formation of AlN, SiC and Si phases in the composite.
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