Fabrication of porous SiC ceramics having pores shaped with Si grain templates

SiC porous ceramics were prepared by heating mixtures of Si powder and carbon black at 900 °C for 24 h in Na vapor. The grains of the Si powder were not only the source of Si for SiC but also served as templates for the pores in the SiC porous ceramics. Angular-shaped pores with sizes of 2-10, 10-150 and 50-150 μm were formed by angular Si grains with sizes of ≤10, ≤50 and ≤150 μm, respectively. The porosity of the SiC porous ceramics was around 55-59%. Spherical pores were also formed when spherical Si grains were used. A bending strength of 14 MPa was measured for the SiC porous ceramics prepared with the Si grains (≤50 μm).     

Biomorphic silicon/silicon carbide ceramics from birch powder

A novel process has been developed for the fabrication of biomorphic silicon/silicon carbide (Si/SiC) ceramics from birch powder. Fine birch powder was hot-pressed to obtain pre-templates, which were subsequently carbonized to acquire carbon templates, and these were then converted into biomorphic Si/SiC ceramics by liquid silicon infiltration at 1550 °C. The prepared ceramics are characterized by homogeneous microstructure, high density, and superior mechanical properties compared to biomorphic Si/SiC ceramics from birch blocks. Their maximum density has been measured as 3.01 g/cm³. The microstructure is similar to that of conventional reaction-bonded silicon carbide. The Vicker's hardness, flexural strength, elastic modulus, and fracture toughness of the biomorphic Si/SiC were 19.6 ± 2.2 GPa, 388 ± 36 MPa, 364 ± 22 GPa, and 3.5 ± 0.3 MPa m^1/2, respectively. The outstanding mechanical properties of the biomorphic Si/SiC ceramics are assessed to derive from the improved uniform microstructure of the pre-templates made from birch powder.     

The Role of Infiltration Temperature in the Reaction Bonding of Boron Carbide by Silicon Infiltration

The present paper is concerned on the effect of infiltration temperature on the components, microstructure, and mechanical properties of reaction‐bonded boron carbide (RBBC) ceramics. RBBC ceramics were fabricated by reactive infiltration of molten silicon (Si) into porous preforms containing boron carbide (B₄C) and free carbon. It has been found that infiltration temperatures have significant influence on the infiltration reactions involved and therefore the evolution of different phases formed in the RBBC ceramics. An increase in grain size of boron carbide particles through the coalescence of neighboring grains was observed at certain infiltration temperatures. The morphology of silicon carbide (SiC) phases developed from discontinuous and cloud‐like SiC to continuous and integrated SiC zones with the increase of infiltration temperatures. With increasing temperatures up to 1600°C, the hardness, flexural strength, and fracture toughness all increased. When the temperatures exceeded 1600°C, while the hardness and flexural strength decreased, the fracture toughness continued to increase.     

Effect of carbon and oxygen on the high-temperature properties of silicon carbide–hafnium carbide nanocomposite fiber

The polymer-derived ceramics (PDCs) technique enables relatively low-temperature fabrication of Si-based ceramics, with silicon carbide fiber as a representative product. Polycarbosilane (PCS) has Si-C backbone structures and can be converted to silicon carbide. In the PDCs method, residual or excess carbon is generated from the precursor (C/Si ratio = 2 for polycarbosilane). Because of the non-stoichiometry of SiC, the physicochemical properties of polymer-derived SiC are inferior to those of conventional monolithic SiC. Herein, a silicon carbide-hafnium carbide nanocomposite fiber was optimized by crosslinking oxygen into the PCS fiber by regulating the oxidation curing time. During pyrolysis, carbothermal reduction, and sintering, carbon was removed by reaction with hydrogen and cross-linked oxygen. Non-destructive techniques (X-ray diffraction, X-ray photoelectron spectroscopy, Raman spectroscopy, and high-temperature thermomechanical analysis) were used to investigate the effects of excess carbon. The microstructure of the near-stoichiometric SiC-HfC nanocomposite fiber was more densified, with superior high-temperature properties.     

Paper derived SiC–Si3N4 ceramics for high temperature applications

Biomorphic Si₃N₄–SiC ceramics have been produced by chemical vapour infiltration and reaction technique (CVI-R) using paper preforms as template. The paper consisting mainly of cellulose fibres was first carbonized by pyrolysis in inert atmosphere to obtain carbon bio-template, which was infiltrated with methyltrichlorosilane (MTS) in excess of hydrogen depositing a silicon rich silicon carbide (Si/SiC) layer onto the carbon fibres. Finally, after thermal treatment of this Si/SiC precursor ceramic in nitrogen-containing atmosphere (N₂ or N₂/H₂), in the temperature range of 1300–1450 °C SiC–Si₃N₄ ceramics were obtained by reaction bonding silicon nitride (RBSN) process. They were mainly composed of SiC containing α-Si₃N₄ and/or β-Si₃N₄ phases depending on the nitridation conditions. The SiC–Si₃N₄ ceramics have been characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX) and Raman spectroscopy. Thermal gravimetric analysis (TGA) was applied for the determination of the residual carbon as well as for the evaluation of the oxidation behaviour of the ceramics under cyclic conditions. The bending strength of the biomorphic ceramics was related to their different microstructures depending on the nitridation conditions.     

Reaction forming of silicon carbide ceramic using phenolic resin derived porous carbon preform

SiC ceramics were prepared with porous carbon preforms derived from phenolic resin by a reaction-forming method. The effects of the structure of the preform pores and the infiltration process on the properties of SiC ceramics were investigated, and components with complex shapes were fabricated by combining this process with stereolithography (SLA). Dense SiC ceramics were obtained from carbon preforms with high apparent porosities, but SiC ceramics with many macrodefects resulted from a carbon preform with an apparent porosity of 39%. The infiltration of molten silicon into the preform pore channel was accelerated under vacuum pressure, resulting in an increase in the depth of the Si infiltration. The growth of SiC was predominantly controlled by carbon diffusion at the last stage of the reaction. The extended grain growth caused the SiC grains to coalesce and some free Si was enveloped in the SiC grains. SiC components with complex geometries were fabricated by combining reaction forming with SLA. The geometry was controlled by SLA.     

Fast production of monolithic carbide-derived carbons with secondary porosity produced by chlorination of carbides containing a free metal phase

Hierarchical structured carbide-derived carbons (CDC) are produced by high temperature chlorination of silicon carbides containing free silicon (Si/SiC). The influence of free silicon in the precursor carbide on the resulting pore and carbon structure and production rate is studied. The two phases – free silicon and silicon carbide – of Si/SiC gives the possibility to synthesize a monolithic carbon with the typical microporous character and narrow pore size distribution combined with larger voids in the micrometer range, while the carbon structure itself stays unchanged. The study revealed that using Si/SiC material increases the production rate for carbide-derived carbons dramatically, due to higher reactive surface area and lower mass transfer limitations, which allows for the time effective production of larger monoliths.     

The effect of SiC substrate microstructure and impurities on the phase formation in carbide-derived carbon

Carbon layers were obtained by etching of different silicon carbides with Cl₂/H₂ gas mixtures at high temperatures (carbide-derived carbon). The resulting layers were studied by analytical and high resolution transmission electron microscopy. It was found, that etching of high purity single crystal SiC wafers exclusively yields amorphous carbon. The development of graphite-like and nanodiamond inclusions was observed using commercially available sintered SiC and polymer-derived SiC, which both contained boron- and carbon-rich phases. The presence of turbostratic graphite regions and isolated diamond particles in the bulk of non-chlorinated sample was revealed in the commercial polycrystalline SiC substrate. This fact points to the possible nucleation and growth of diamond phases during sintering of the commercial SiC substrate. Chlorination of boron-implanted single crystal SiC wafer showed that the presence of boron-rich dopants in the SiC alone does not trigger the nucleation of diamond phases. An initial surplus of carbon in the SiC substrates appeared to be required as could be shown for boron doped polycarbosilane derived SiC. Thermodynamic considerations assisted by quantum chemical calculations showed the low effect of hydrogen in the Cl₂/H₂ gas mixtures during SiC chlorination for the nucleation of diamond phases.     

Microstructural evolution and microwave transmission/absorption transition in polymer-derived SiOC ceramics

Herein, we present the structural evolution of polymer-derived SiOC ceramics with the pyrolysis temperature and the corresponding change in their microwave dielectric properties. The structure of the SiOC ceramics pyrolyzed at a temperature lower than 1200 °C is amorphous, and the corresponding microwave complex permittivity is pretty low; thus, the ceramics exhibit wave transmission properties. The Structural arrangement of free carbon in the SiOC ceramics mainly happens in the temperature range of 1200 °C-1300 °C due to the separation from the Si–O–C network and graphitization, while the structural arrangement of the Si-based matrix mainly occurs in the range of 1300 °C-1400 °C owing to the separation of SiC₄ from the Si–O–C network to form nanocrystalline SiC. In pyrolysis temperature range of 1200 °C-1400 °C, the microwave permittivity of SiOC shows negligible change. At a pyrolysis temperature exceeding 1400 °C, the carbothermal reaction of free carbon and the Si–O backbone becomes significant, leading to the formation of crystalline SiC. The as-formed SiC and residual defective carbon improve the polarization loss of SiOC ceramics. In this case, the SiOC ceramics show significantly increased complex permittivity, exhibiting electromagnetic absorption characteristics. These characteristics promote the application of polymer-derived SiOC ceramics to high-temperature electromagnetic absorption materials.     

Raman spectroscopy studies of the high-temperature evolution of the free carbon phase in polycarbosilane derived SiC ceramics

The Raman spectra of a number of SiC ceramics synthesized from polycarbosilane at 1200 °C and annealed at 1400, 1600, 1800 and 2000 °C have been recorded using laser excitation wavelength of 532 nm. The peak positions, their intensities (I_D/I_G) and full width at half maximum (FWHM) were used to obtain information about the degree of disorder in the free carbon phases. The increasing ordering with annealing temperature was confirmed by lower FWHM values and G-peak positions obtained from the SiC ceramics annealed at higher temperature. However, the I_D/I_G has shown to be the highest point at 1600 °C, which illustrates that the temperature is one critical point of the microstructure evolution of the free carbon phase changing amorphous to turbostratic with increasing temperatures. Obviously, the oxidation behaviors of the SiC ceramics are significantly affected by the microstructures of the free carbon phases. In the SiC ceramics with above 1600 °C annealing, the oxidation temperatures of the SiC phases are postponed more than 100 °C, because they are surrounded by the free carbon phases.     

Effect of thickness of SiC films on compression and thermal properties of SiC/CF composites

Commonly, carbon foam derived from commercially available melamine foam showed brittle characteristics. In this paper, the carbon foam was prepared via the direct carbonization of the melamine foam, and chemical vapor deposition was employed to deposit ultra-thin SiC films on the CF skeleton. The evolution, microstructure, mechanical strength, and thermal properties of the as-prepared SiC/CF composites were investigated. Test results showed that a novel SiC skeleton with a three-dimensional interconnected network was prepared successfully. The thickness of the SiC filmes had a significant influence on the compression and thermal properties of the composites. The SiC/CF-II possessed a higher compression performance than that of SiC/CF-I, while the thermal insulation was relatively much poorer. This present work had some reference meaning to the correlation studies of the thermal insulation material for the potential applications while bearing live loads.     

Corrosion of Ceramics in Aqueous Hydrofluoric Acid

A variety of commercially available ceramic-based oxides, carbides, nitrides, and borides were evaluated for chemical attack in an azeotropic aqueous hydrofluoric acid (HF) test protocol at 90°C. Weight change measurements and microstructure analysis showed that HF corrosion in polycrystalline ceramics generally occurred at grain boundaries by the dissolution of grain boundary phases although the bulk single crystal may inherently resist attack. Virtually all commercially prepared polycrystalline oxide ceramics (i.e., Al₂O₃, TiO₂, ZrO₂) and nonoxide ceramics (i.e., Si₃N₄, AlN, BN) were extensively corroded while polycrystalline pure carbides (i.e., SiC, TiC, B₄C, WC) resisted corrosion. Equilibrium thermodynamic calculations show that these materials are soluble in HF; however, the kinetics of dissolution are slow enough in some cases to permit useful engineering lifetimes.     

Low thermal expansion porous SiC–WC composite ceramics

Low thermal expansion porous SiC–WC composite ceramics were prepared by solid state reaction of Si and WC at 1560 °C, with NH₄HCO₃ as a pore generating agent. Phase composition, thermal expansion, flexural strength, and microstructure of the carbide ceramics were examined. Presence of the SiC, WC and WC_1−X phases were detected in the carbide ceramics. As Si content increased from 2 to 14 wt%, the coefficient of thermal expansion first decreased and then increased, with a minimum of 4.11 × 10⁻⁶ °C at 8 wt% Si, whereas the flexural strength decreased gradually, from 143.9 to 82.7 MPa. Pores of SiC–WC ceramics were less than 2 μm in diameter, because of the stacking interstice of carbide particles and volatilization of silicon. However in the presence of NH₄HCO₃, pores of SiC–WC ceramics were bimodally distributed, the stacking interstice of carbide particles loosened from 1 to 4 μm and pores larger than 5 μm were also formed.     

Porous Silicon Carbide Ceramics Produced by a Carbon Foam Derived from Mixtures of Mesophase Pitch and Si Particles

Carbon foam templates were prepared from a mixture of mesophase pitch (MP) and Si particles, followed by foaming and carbonization. Subsequent molten Si infiltrated into the carbon foam at 1500°C for 4 h in an inert atmosphere resulted in the formation of porous SiC ceramics. Micrographs were investigated by a scanning electron microscope (SEM), and phase identification of porous SiC ceramics was performed by X-ray diffraction (XRD). The flexural strength and bulk density of porous SiC ceramics were also measured and calculated. The results revealed that the flexural strength of porous SiC ceramics increases with increasing Si content and decreasing porosity. The addition of Si in MP results in an increased densification of porous SiC struts. With 50 wt% Si, porous SiC ceramics with a high flexural strength of 23.9 MPa and a porosity of 55% were obtained.     

液态聚硼硅氮烷的陶瓷化过程

采用Fourier红外光谱、热重–差热以及X射线衍射分析对新型液态SiBNC先驱体进行了结构表征,重点研究了先驱体的陶瓷化过程。结果表明：先驱体以—CH3和—CH=CH2为侧链基团,含有C—H、C=C、Si—H、B—N、N—H、Si—N等化学键;N2气氛保护下的陶瓷产率约为85%,质量损失主要发生在300～800℃;随着温度的升高,聚合物中有机基团逐渐减少,900℃完成无机化转变,得到含有自由碳的非晶态SiBNC陶瓷,1200℃以上非晶态SiBNC陶瓷开始晶化,1500℃得到由C、SiC、Si3N4和BN组成的复相陶瓷。     

Fabrication of ceramic nanofibers using polydimethylsiloxane and polyacrylonitrile polymer blends

Nanofibers with several hundred of nanometers were successfully fabricated using electrospinning process and a mixture of two types of polymers which are: polydimethylsiloxane and polyacrylonitrile as precursors. After stabilization and carbonization at 1000 °C, three phases which are: silicon carbide (SiC), carbon, and oxy‐SiC were presented. Spectroscopic and microscopic techniques had confirmed the presence of nanocrystalline SiC and turbostratic carbons. These phases formed an intertwined network at the nanometric scale. In addition, the resulted fibers showed a core‐skin effect with skin richer in carbon and a core mainly dominated by silicon‐based phases in the form SiC or Si? O? C ceramics. A significant improvement was observed in both tensile strength and elastic modulus in these hybrid fibers. In term of crystallography, these nanofibers seem to exhibit similar microstructure that was observed in Nicalon fiber. However, it was difficult to determine the ratio of these phases and their influence on the physical properties of these hybrid fibers. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45967.     

Improved mechanical properties of reaction-bonded SiC through in-situ formation of Ti3SiC2

Reaction-bonded SiC is a ceramic with excellent thermal properties, good corrosion resistance and the characteristic of near-net-shape manufacturing. However, the poor fracture toughness of free Si limits the applications of reaction-bonded SiC. In this study, TiC was added to reaction-bonded SiC and reacted with free Si to form Ti₃SiC₂. The effects of TiC and carbon black on the mechanical properties of reaction-bonded SiC were investigated. The results demonstrated that the in-situ formation of Ti₃SiC₂ and decrease in the content and size of free Si improved the mechanical properties of reaction-bonded SiC ceramics. The mechanical properties of TiC-added reaction-bonded SiC with 17.5 wt% carbon black were superior to those of TiC-added reaction-bonded SiC with 15 wt% carbon black. Moreover, increasing the TiC content of reaction-bonded SiC with 17.5 wt% carbon black from 0 to 7.5 wt% caused an increase in its bending strength from 183.92 to 424.43 MPa and an increase in fracture toughness from 3.7 to 5.24 MPa m^1/2.     

Microstructural characterization using orientation imaging microscopy of cellular Si/SiC ceramics synthesized by replication of Indian dicotyledonous plants

Woods from three dicotyledonous plants of local origin (mango Mangifera indica), jackfruit (Artocarpus integrifolia) and teak (Tectona grandis) were transformed by pyrolysis into carbonaceous preforms and subsequently converted into cellular Si/SiC ceramics by liquid Si-infiltration and reaction. The pyrolyzed mango, jackfruit and teak were characterized in terms of pyrolysis weight loss, shrinkages, bulk density and microstructures. The Si-infiltrated pyrolyzed woods were found to have densities and porosities in the range of 2.46–2.60 gm cm⁻³ and 1.5–3.6 vol.% respectively. SEM imaging confirmed the preservation of microcellular tissue anatomy of the precursor wood structure in the morphologies of final ceramics. The end ceramics were investigated for the phases present and for crystallographic microtexture. A combination of XPS (X-ray photoelectron spectroscopy), XRD (X-ray diffraction) and OIM (orientation imaging microscopy) was used to establish the presence and the relative locations of silicon (Si), silicon carbide (SiC) and graphite (C). Fine SiC grains did typically surround coarse crystals of Si – the latter had significant presence of Σ3 twin boundaries. Graphite was primarily present in the regions containing SiC and was more textured than the SiC. Distinct orientation relationship could be established between the graphite crystals and the Si grains containing them.     

Survey on wetting of SiC by molten metals

Good wetting and low reactivity of metal/ceramic couples are key factors in many technological processes, in particular in metal/ceramic joining, to avoid degradation of ceramics and to achieve the desired properties during service. Silicon carbide is a covalent material of great technological interest due to its excellent overall properties. Starting from a survey of the surface energies of SiC and liquid metals, the reactivity and wettability of pure metal/SiC systems, as well as the wetting behavior and mechanisms of (liquid metal + Si)/SiC systems are reviewed for understanding the interfacial bonding and for supporting the development of application-oriented processes like non-reactive brazing. Silicon chemisorption and interactions between the molten alloys and SiC at the metal/substrate interface and the intrinsic properties of the alloys or of the pure metals are considered to play the key roles in interfacial bonding. In particular, additions of Si can limit or even suppress the substrate dissolution leaving the solid–liquid interface nearly undisturbed. At the same time, oxidation–deoxidation processes at the SiC surface are the basic mechanisms to be controlled in order to allow the liquid phases to contact a “pure” SiC surface. The need of further investigations, covering basic interfacial phenomena including both experiments and ab-initio modeling of the solid–liquid interfaces is strongly underlined.     

Synthesis of ZrC–SiC Powders by a Preceramic Solution Route

Homogenous liquid precursor for ZrC–SiC was prepared by blending of Zr(OC₄H₉)₄ and Poly[(methylsilylene)acetylene]. This precursor could be cured at 250°C and converted into binary ZrC–SiC composite ceramics upon heat treatment at 1700°C. The pyrolysis mechanism and optimal molar ratio of the precursor were investigated by XRD. The morphology and elements analyses were conducted by SEM and corresponding energy‐dispersive spectrometer. The evolution of carbon during ceramization was studied by Raman spectroscopy. The results showed that the precursor samples heat treated at 900°C consisted of t‐ZrO₂ (main phase) and m‐ZrO₂ (minor phase). The higher temperature induced phase transformation and t‐ZrO₂ converted into m‐ZrO₂. Further heating led to the formation of ZrC and SiC due to the carbothermal reduction, and the ceramic sample changed from compact to porous due to the generation of carbon oxides. With the increasing molar ratios of C/Zr, the residual oxides in 1700°C ceramic samples converted into ZrC and almost pure ZrC–SiC composite ceramics could be obtained in ZS‐3 sample. The Zr, Si, and C elements were well distributed in the obtained ceramics powders and particles with a distribution of 100 ~ 300 nm consisted of well‐crystallized ZrC and SiC phases.