Silicon nitride (Si3N4) and SiAlONs can be self-toughened through the growt
h of elongated beta-Si3N4/beta-SiAlON grains in sintering. alpha-SiAlONs us
ually retain an equiaxed grain morphology and have a higher hardness but lo
wer toughness than beta-SiAlONs. The present work has demonstrated that elo
ngated alpha-SiAlON grains can also be developed through pressureless sinte
ring. alpha-SiAlONs with high-aspect-ratio grains in the calcium SiAlON sys
tem have exhibited significant grain debonding and pull-out effects during
fracture, which offers promise for in-situ-toughened alpha-SiAlON ceramics.