Lightweight boron carbide materials with improved mechanical properties and process for their manufa

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This disclosure describes sintered bodies comprising about 90 wt % to about 99 wt % of boron carbide, having a B : C atomic ratio ranging from 3.8 to 4.5 : 1; 0 to 1 wt % free carbon; 0 to 1 wt % BN or AlN, remainder an oxide binder phase; said sintered body having a uniform microstructure composed of substantially equiaxed grains of said boron carbide; the oxide binder phase comprising at least a rare earth aluminate and optionally Al2O3 or other ternary or binary phases of rare earth oxide-alumina systems; the binder phase being present in form of pockets at the multiple grain junctions and the density of no more than 2.6 g/cm3. Also described is a manufacturing process for the above described substantially pore-free, sintered boron carbide materials with high strength and fracture toughness, which can be used for production of large-area parts. This is achieved by liquid phase low temperature-low pressure hot pressing of boron carbide in an argon atmosphere.