To develop materials suitable for aerospace applications, silicon nitride/boron nitride (Si${}_3$N${}_4$/BN) fibrous monolithic ceramics with varying BN contents were prepared. Employing analytical techniques such as XRD and SEM, coupled with mechanical testing equipment, the influence of BN concentration on the thermal shock resistance of Si${}_3$N${}_4$/BN fibrous monolithic ceramics was assessed. When the thermal shock differential is less than 800 °C, its residual flexural strength gradually decreases as the thermal shock differential increases. Conversely, when the differential exceeds 1000 °C, the residual flexural strength of the material increases. The residual strength of all samples reached its peak after undergoing a thermal shock assessment at a 1500 °C differential. When the BN mass fraction is 5 wt.%, the residual strength after a thermal shock at a temperature difference of 1500 °C is 387 ± 19 MPa, which is 124% higher than the original strength of the sample that did not undergo thermal shock (25 °C, 311 ± 18 MPa). The oxide layer formed on the thermal shock surface played a role in bridging defects introduced during material surface processing.

Silicon nitride ceramics are regarded as a promising material for high-temperature structural applications due to their remarkable characteristics, including high strength, hardness, thermal conductivity, low dielectric properties, and resistance to creep at elevated temperatures. However, their susceptibility to catastrophic fracture at high temperatures remains a concern. Herein, Si₃N₄/BN fibrous monolithic ceramics have been successfully prepared by employing wet-spinning and hot-pressing techniques. We delved into the design and optimization of the spinning slurry and examined how the Si₃N₄/BN fiber diameter affects the ceramics’ microstructure and mechanical properties. The spinning slurry exhibited exceptional stability and spinnability. Decreasing the fiber diameter contributed to material densification and improved mechanical properties. Notably, when the fiber diameter is 0.9 mm, the fabricated Si₃N₄/BN fibrous monolithic ceramics demonstrate a carbon content of 0.82%, a three-point bending strength of 357 ± 24 MPa, and a fracture toughness of 8.8 ± 0.36 MPa·m^1/2. This investigation offers valuable insights into producing high-performance Si₃N₄/BN composite ceramics utilizing hot-pressing technology.