Abstract: An electro-conductive ceramic comprising a non-electroconductive matrix ceramic, an electro-conductive ceramic in relatively large proportion to permit efficient electro-discharge machining (EDM) of the ceramic and ceramic whiskers of low aspect ratio and short length dispersed in the ceramic body to provide high fracture toughness, stength and hardness despite the relatively large proportion of electro-conductive ceramic. Complex geometries and features such as holes, chamfers, slots, angles, changing radii an complex curves can be electro-discharge machined into the ceramic body after hot processing or hot-isostatic pressing to achieve maximum density and mechanical properties. A particularly advantageous high temperature extrusion die, powder metal compacting die hardware and cutting tools formed of Al.sub.2 O.sub.3, TiC and SiC whiskers have been produced and tested.

Abstract: A method for forming a silicon nitride article is set forth. An article having silicon particles therein is formed in a manner which provides a degree of porosity for the article. The silicon particles of the article are reactable with nitrogen to form silicon nitride. The article is heated to a temperature below a significant reaction temperature at which nitrogen gas reacts with the silicon particles at a measurable rate. The article is surrounded with an atmosphere containing nitrogen gas. A reaction zone is established on at least a portion of the surface area of the article. The reaction zone has a temperature above the significant reaction temperature whereby the silicon particles in the reaction zone are reacted at a measurable rate with the nitrogen gas to form silicon nitride. The reaction zone is moved in a controlled manner from the surface of the article into the interior of the article whereby the article is progressively nitrided inwardly into its bulk from the surface thereof.