A silicon-containing composite body that would otherwise be brittle can be engineered
to exhibit enhanced fracture toughness. Specifically, a silicon-ceramic composite
body is produced, preferably by a reactive infiltration technique. The ceramic
is selected such that it has a higher coefficient of thermal expansion (CTE) than
does the silicon phase. At least at some point during processing, the silicon phase
is at a temperature above its normal ductile/brittle transition temperature of
about 500 C., and preferably above its melting point. The formed composite
body containing the silicon phase is then cooled below its ductile/brittle transition.
During cooling, the ceramic phase shrinks more than does the silicon phase, thereby
placing the latter in a state of compressive stress. By the time the composite
body has cooled to substantially ambient temperature, the induced compressive stress
in the silicon phase is sufficient as to impart a measurable degree of semi-ductile
character to the silicon phase. This pseudo-ductility manifests itself in the composite
body as a significant increase in the fracture toughness of the body. For example,
when the ceramic reinforcement was boron carbide particulate instead of silicon
carbide (which has a CTE similar to that of silicon), fracture toughness increased
by almost 30 percent.