Superhard material

Abstract: The hardness, toughness and chemical stability of the well-known superhard material cubic boron nitride have been improved by using a synthesis technique based on specially prepared ‘onion-like’ precursor materials. Superhard polycrystalline cubic boron nitride, second only to diamond in hardness, is superior to diamond in terms of thermal and chemical stability and is used widely as an abrasive. The hardness of many materials can be improved by decreasing the grain size, and here Yongjun Tian and colleagues use this principle in a new synthesis technique — based on specially prepared 'onion-like' precursor materials — capable of increasing the hardness of cubic boron nitride. The structure of the resulting polycrystalline material is dominated by nanometre-scale twin domains, yielding a solid combining ultrahigh hardness (exceeding that of a synthetic diamond single crystal) with a high oxidization temperature and extreme fracture toughness. If nanotwins at similar scales can be reproduced in polycrystalline diamond, it may be possible to raise diamond itself to new levels of hardness and stability. Cubic boron nitride (cBN) is a well known superhard material that has a wide range of industrial applications. Nanostructuring of cBN is an effective way to improve its hardness by virtue of the Hall–Petch effect—the tendency for hardness to increase with decreasing grain size1,2. Polycrystalline cBN materials are often synthesized by using the martensitic transformation of a graphite-like BN precursor, in which high pressures and temperatures lead to puckering of the BN layers3. Such approaches have led to synthetic polycrystalline cBN having grain sizes as small as ∼14 nm (refs 1, 2, 4, 5). Here we report the formation of cBN with a nanostructure dominated by fine twin domains of average thickness ∼3.8 nm. This nanotwinned cBN was synthesized from specially prepared BN precursor nanoparticles possessing onion-like nested structures with intrinsically puckered BN layers and numerous stacking faults. The resulting nanotwinned cBN bulk samples are optically transparent with a striking combination of physical properties: an extremely high Vickers hardness (exceeding 100 GPa, the optimal hardness of synthetic diamond), a high oxidization temperature (∼1,294 °C) and a large fracture toughness (>12 MPa m1/2, well beyond the toughness of commercial cemented tungsten carbide, ∼10 MPa m1/2). We show that hardening of cBN is continuous with decreasing twin thickness down to the smallest sizes investigated, contrasting with the expected reverse Hall–Petch effect below a critical grain size or the twin thickness of ∼10–15 nm found in metals and alloys.