Macroporous polymer-derived SiO2/SiOC monoliths freeze-cast from polysiloxane and amorphous silica derived from rice husk

A freeze-casting route towards macroporous SiOC/SiO₂ ceramic nanocomposites from preceramic polymers was developed. Amorphous SiOC/SiO₂ monolith with pore channels aligned along the freezing direction were obtained from commercially available methyl-phenyl-vinyl-hydrogen polysiloxane (Silres® H62C) and amorphous silica derived from rice husk ash freeze-cast with water or tert-butyl alcohol, crosslinked and pyrolyzed at 1100 °C in nitrogen. The influence of processing parameters such as solvent (tert-butyl alcohol or water), polymer to silica ratio (2:1, 1:1, 1:2), cooling rate (2, 4, 6 °C/min) and pre-crosslinking of polysiloxane on the porosity and structure of the obtained ceramic nanocomposites were assessed by X-ray tomography, XRD, solid state NMR, scanning electron microscopy and mercury porosimetry. The microstructure of SiOC ceramics derived from the Silres H62C polysiloxane was studied as well.     

Effect of pyrolysis temperature on the pore structure evolution of polysiloxane-derived ceramics

Homogeneous silicon oxycarbide (SiOC) ceramic powders were prepared by pyrolysis of cross-linked polysiloxane at different temperatures (1250–1500 °C) under vacuum. The effect of pyrolysis temperature on the pore structure evolution was investigated by means of N₂ adsorption, SEM, XRD, IR and element analysis (EA). Studies showed that predominate mesoporous ceramics with the average pore size in the range of 2–13 nm were obtained after pyrolysis in this temperature range. The pore structure transformation is strongly correlated with the thermolytic decomposition process of the used precursor, such as phase separation and carbothermal reduction. At relatively lower temperature (1250–1350 °C), the ceramics had a relative small specific surface areas (35 m²/g) owing to the low degree of carbothermal reduction. However, as the carbothermal degree had an obvious augment at relative higher temperature (1400–1450 °C), the specific surface areas and total pore volume increased and reached to the maximum of 66 m²/g and 0.214 cm³/g, respectively, and subsequently decreased rapidly after 1500 °C for the reason of partial sintering of the nano-sized SiC derived from polysiloxane.     

Single-source-precursor synthesis of soft magnetic Fe3Si- and Fe5Si3-containing SiOC ceramic nanocomposites

We present here the single-source-precursor synthesis of Fe₃Si and Fe₅Si₃-containing SiOC ceramic nanocomposites and investigation of their magnetic properties. The materials were prepared upon chemical modification of a hydroxy- and ethoxy-substituted polymethylsilsesquioxane with iron (III) acetylacetonate (Fe(acac)₃) in different amounts (5, 15, 30 and 50 wt%), followed by cross-linking at 180 °C and pyrolysis in argon at temperatures ranging from 1000 °C to 1500 °C. The polymer-to-ceramic transformation of the iron-modified polysilsesquioxane and the evolution at high temperatures of the synthesized SiFeOC-based nanocomposite were studied by means of thermogravimetric analysis (TGA) coupled with evolved gas analysis (EGA) as well as X-ray diffraction (XRD). Upon pyrolysis at 1100 °C, the non-modified polysilsesquioxane converts into an amorphous SiOC ceramic; whereas the iron-modified precursors lead to Fe₃Si/SiOC nanocomposites. Annealing of Fe₃Si/SiOC at temperatures exceeding 1300 °C induced the crystallization of Fe₅Si₃ and β-SiC. The crystallization of the different iron-containing phases at different temperatures is considered to be a consequence of the in situ generation of a Fe–C–Si alloy within the materials during pyrolysis. Depending on the Fe and Si content in the alloy, either Fe₃Si and graphitic carbon (at 1000–1200 °C) or Fe₅Si₃ and β-SiC (at T > 1300 °C) crystallize. All SiFeOC-based ceramic samples were found to exhibit soft magnetic properties. Magnetization versus applied field measurements of the samples show a saturation magnetization up to 26.0 emu/g, depending on the Fe content within the SiFeOC-based samples as well as on the crystalline iron silicide phases formed during pyrolysis.     

Synthesis and characterization of carbon-enriched silicon oxycarbides

Polyhydridomethylsiloxane (PHMS) is a very practical and versatile source for a broad range of silicon oxycarbide (SiOC) and other silicon containing ceramic materials. PHMS modifications and crosslinking is conveniently achieved by dehydrocoupling and hydrosilylation reactions. The molecularly level mixed carbon content of the derived SiOC can be incrementally increased by reacting PHMS with 0–40 mol% of divinylbenzene (DVB) using 5 ppm of Pt catalyst relative to PHMS. With ceramic yields exceeding 80 wt.% and a dense microstructure, the derived carbon-enriched SiOCs exhibit significantly higher chemical stability compared with other high-carbon content polymer derived ceramics. Phase separation and nanocrystallinity are inhibited to at least 1200 °C for all the evaluated samples and the materials are completely amorphous. Very fine nanocomposite microstructures are obtained at 1450 °C, consisting of 5–10 nm graphite regions and amorphous SiOC domains with no significant porosity. Synthesis and microstructure characterization of the new carbon-enriched SiOC are discussed in comparison to the sole PHMS pyrolyzed product.     

Mechanical characterization of a polysiloxane-derived SiOC glass

Silicon oxycarbide glass with the composition Si_1.0O_1.6C_0.8 was synthesized from a commercial polysiloxane by polymer pyrolysis. Dense SiOC samples were obtained by cross linking of the polysiloxane followed by warm pressing to form cylindrical samples and subsequent pyrolysis of the shaped polymer at 1100 °C in Ar. Hardness (H), Young's modulus (E) and Poisson's ratio (ν) of the as-prepared SiOC glass were evaluated from indentation studies and from acoustic microscopy. Indentation studies showed that E depends on the applied load and amounts to 90 GPa for low load and to 180 GPa for high load. Average values of 6.4 and 101 GPa were obtained for H and E, respectively, by the Vickers indentation method. Acoustic microscopy analysis yielded values of 96 GPa and 0.11 for E and ν, respectively. Compared to vitreous silica, the Young's modulus of the SiOC glass is about 1.3–1.5 times higher. To the knowledge of the present authors, the measured Poisson's ratio (ν = 0.11) is the lowest reported so far for glasses and polycrystalline ceramics.     

Polymer-derived mullite–SiC-based nanocomposites

Ceramic mullite–SiC nanocomposites were successfully produced at temperatures below 1500 °C by the polymer pyrolysis technique. An alumina-filled poly(methylsilsesquioxane) compound was prepared by mechanically mixing and cross-linking via a catalyst prior to pyrolysis. Heat treatment of warm pressed alumina/polymer bulk samples under the exclusion of oxygen (inert argon atmosphere) up to 1500 °C initiated crystallization of mullite even at pyrolysis temperatures as low as 1300 °C. The influence of the filler and of the pyrolysis temperature on the crystallization behavior of the materials has been investigated. Based on thermal analysis in combination with elemental analysis and X-ray powder diffraction studies four polymer mixtures differing in type and content of nano-alumina powders were examined. Nano-sized γ-Al₂O₃ powders functionalized at the surface by octylsilane groups proved to be more reactive towards the preceramic polymer leading to the formation of a larger weight fraction of mullite crystals at lower processing temperatures (1300 °C) as compared to native nano-γ-Al₂O₃ filler. Moreover, the functionalized nano-alumina particles offer an enhanced homogeneity of the distribution of alumina nano-particles in the starting polysiloxane system. In consequence, the received ceramic samples exhibited a nano-microstructure consisting of crystals of mullite with an average dimension in the range of 60–160 nm and silicon carbide crystals in the range of 1–8 nm.     

Lithium insertion into dense and porous carbon-rich polymer-derived SiOC ceramics

Two polymer-derived SiOC ceramics with different amount of carbon were synthesized either as dense or porous SiOC powders. The dense materials were produced up to a maximum temperature of 1400 °C and show a phase separated nanostructure consisting of SiO₂-rich clusters, nanocrystalline SiC and nanocrystalline carbon phase. The corresponding porous materials were obtained by etching the silica phase of the dense SiOC with 20% HF solution. The electrochemical properties of the dense and porous SiOC ceramics in terms of lithium insertion/extraction were studied. Accordingly, the SiOC materials show a first lithium insertion capacity between 380 and 648 mAh g^?1 followed by significantly lower extraction capacities between 102 and 272 mAh g^?1. We consider the free carbon phase present in the ceramic as the major lithium intercalating agent. The porous samples show a stable electrochemical behavior up to 30 cycles while for the dense materials the efficiency drops to almost zero after 10 cycles.     

Additive and pyrolysis atmosphere effects on polysiloxane-derived porous SiOC ceramics

Porous silicon oxycarbide (SiOC) is emerging as a much superior ultrahigh surface area material that can be stable up to high temperatures with great tailorability through composition and additive modifications. In this study, bulk SiOCs were fabricated from a base polysiloxane (PSO) system by using different organic additives and pyrolysis atmospheres followed by hydrofluoric acid (HF) etching. The additives modify the microstructural evolution by influencing the SiO₂ nanodomain formation. The SiOC ceramics contain significantly less SiC and more SiO₂ with Ar + H₂O atmosphere pyrolysis compared to Ar atmosphere pyrolysis. Water vapor injection during pyrolysis also causes a drastic increase in specific surface areas. The addition of 10 wt% tetraethyl orthosilicate (TEOS) with Ar + H₂O pyrolysis produces a specific surface area of 1953.94 m²/g, compared to 880.09 m²/g for the base PSO pyrolyzed in Ar. The fundamental processes for the composition and phase evolutions are discussed as a novel pathway to creating ultrahigh surface area materials. The ability to drastically increase the specific surface area through the use of pyrolysis atmosphere and organic additives presents a promising processing route for highly porous SiOC ceramics.     

Synthesis of hierarchical porous silicon oxycarbide ceramics from preceramic polymer and wood biomass composites

Hierarchical porous SiOC ceramics were successfully prepared using a polysiloxane preceramic polymer mixed with wood biomass by annealing at different temperatures under Ar atmosphere. These SiOC ceramics display a trimodal pore size distribution in the micro-, meso- (micropores + mesopores, 1.7–14 nm) and macro-size scale (1–15 μm). The mesopores and micropores mainly originate from the formation of large amounts of SiC crystals and nanowires, graphite-like microcrystallites, and nm-scale pores of ray parenchyma cells and pits of the wood biomass. The SiOC sample prepared at a higher temperature processes the specific surface area up to 180.5 m²/g. The specific surface area, pore volume and average pore width of the samples can be controlled by adjusting the pyrolysis temperature.     

Influence of processing conditions in TEOS/PDMS derived silicon oxycarbide materials. Part 1: Microstructure and properties

Fully dense bulk silicon oxycarbide (SiOC) derived materials have been prepared using the conventional ceramic route. Tetraethylortosilicate/Polydimethylsiloxane (TEOS/PDMS) organic–inorganic hybrids were used as starting materials. These hybrids were thermal treated, attrition milled and pyrolyzed at 1100 °C. SiOC powders were shaped employing uniaxial and/or isostatic pressing and finally were sintered up to 1550 °C for 4, 8 and 16 h. Bulky defect free SiOC ceramics without porosity were obtained displaying enhanced both mechanical properties and oxidation resistance compared to silica glasses. These SiOC materials present maximum values of microindentation hardness and flexural strength of 11.7 GPa and 153 MPa, respectively, and a high oxidation resistance at 1550 °C for 100 h, a very low coefficient of thermal expansion of 1.35 × 10^?6 °C^?1, a high glass transition temperature of 1325 °C, and an electrical resistivity of 3.15 × 10⁵ Ω m.     

Dielectric and magnetic properties of BiFeO3 ceramics prepared by hydrothermal synthesis

Single-phase BiFeO₃ powders were prepared at a temperature of 200 °C by a hydrothermal synthesis. BiFeO₃ ceramics were prepared with the powders by a conventional ceramic process. The BiFeO₃ ceramics with no impurity phase were prepared at the sintering temperature of 650–800 °C. The dense microstructure was observed in the BiFeO₃ ceramics sintered at a temperature of 700 °C and higher. BiFeO₃ ceramics show linear M–H curves in low H, which are antiferromagnetic behaviors. The dielectric dispersion was observed at the frequency range of 10 kHz to 1 MHz in the BiFeO₃ ceramic sintered at 700 °C or lower. The dielectric constant and loss of the BiFeO₃ ceramics sintered at 750 °C or higher were about 85 and 0.4 at 100 kHz, respectively.     

Effect of sintering temperature on the microstructure and transparency of Nd,Y:CaF2 ceramics

1 at% Nd, 3 at% Y doped CaF₂ transparent ceramics were obtained by hot pressing at the sintering temperature varing from 500 to 800 °C under vacuum environment with co-precipitated CaF₂ nanopowders. Transmission electron microscopy (TEM) and X-ray diffraction (XRD) analysis showed that the obtained nanoparticles were single fluorite phase with grain size around 26 nm. Scanning electron microscopy (SEM) observations of the Nd, Y: CaF₂ ceramics indicated that the mean grain size of the ceramic sintered at 800 °C was about 748 nm. The influence of the temperature on the grain size, microstructure and optical transmittance was investigated. For the ceramic sintered at 800 °C, the transmittance was 85.49% at the wavelength of 1200 nm. The room temperature emission spectra of Nd: CaF₂ and Nd, Y: CaF₂ ceramics were measured and discussed.     

In-situ formation of titanium carbide in carbon-rich silicon oxycarbide ceramic for enhanced thermal stability

Silicon oxycarbide (SiOC) ceramic has attracted great attention as fascinating candidate of high-temperature material, however, its thermal stability is significantly limited by the phase separation at high temperature. Here, a TiC/SiOC ceramic was prepared by pyrolysis of a tetrabutyl titanate modified carbon-rich polysiloxane (TBT/PSO) precursor. The TiC phase is in-situ formed by the carbothermal reaction of TBT-derived amorphous TiO₂ phase with excess free-carbon phase during pyrolysis, and its size and amount increase with the pyrolysis temperature. The SiC phase appears at a higher temperature than the TiC phase and is hindered by the increased Ti content in the TBT/PSO precursor. Thus, the TiC/SiOC ceramic exhibits better thermal stability and crystallization resistance than the TiC-free SiOC ceramic under the thermal treatment (1500 °C) in argon atmosphere. The in-situ formation of metal carbide into the carbon-rich SiOC ceramic would further expand its application at high temperature environments.     

Microwave dielectric properties of Pb2MoO5 ceramic with ultra-low sintering temperature

Ultra-low firing microwave dielectric ceramic Pb₂MoO₅ with monoclinic structure was prepared via a conventional solid state reaction method. The sintering temperature ranged from 530 °C to 650 °C. The relative densities of the ceramic samples were about 97% when the sintering temperature was greater than 570 °C. The best microwave dielectric properties were obtained in the ceramic sintered at 610 °C for 2 h with a permittivity ∼19.1, a Q × f value about 21,960 GHz (at 7.461 GHz) and a temperature coefficient value of −60 ppm/°C. From the X-ray diffraction, backscattered electron image results of the co-fired samples with 30 wt% silver and aluminum additive, the Pb₂MoO₅ ceramics were found not to react with Ag and Al at 610 °C for 4 h. The microwave dielectric properties and ultra-low sintering temperature of Pb₂MoO₅ ceramic make it a promising candidate for low temperature co-fired ceramic applications.     

Preparation and characterization of polymer-derived Zr/Si/C multiphase ceramics and microspheres with electromagnetic wave absorbing capabilities

Precursors for Zr/Si/C multiphase ceramics were synthesized by the reactions of dilithiozirconocene complex with dichlorodimethylsilane, methyltrichlorosilane and dichloromethylvinylsilane, respectively. The precursor-to-ceramic process of the precursor was investigated by TG-GC–MS and TG-FTIR analyses, confirming a complete transformation from organometallic polymers into ceramics below 800 °C. Annealing experiments of the derived ceramics at temperatures from 1000 °C to 2000 °C indicated the crystallization from ZrSiO₄, ZrO₂ to ZrC. Furthermore, micrometer-sized Zr/Si/C ceramic microspheres were successfully fabricated from the precursor at 1000 °C, showing surface morphology like wrinkled pea. According to the XRD, HRTEM and XPS analyses, such multiphase ceramic microspheres consist of ZrSiO₄, ZrO₂, and amorphous SiO_xC_y. Interestingly, the ceramic microspheres performed satisfactory electromagnetic wave absorbing capacity with the RL_max reaching −34 dB, which could be potential candidates for electromagnetic micro-devices.     

Synthesis of SiC–TiO2 hybrid aerogel via supercritical drying combined PDCs route

The SiC-TiO₂ hybrid aerogels were obtained from polycarbosilane (PCS) and tetrabutyltitanate (TBT) as precursors using supercritical drying and polymer derived ceramics route. The polymer to ceramic conversion and the crystallization behavior were studied by X-ray diffraction (XRD) and transmission electron microscopy (TEM), suggesting the preceramic aerogels converted to the SiC-TiO₂ ceramic aerogels through pyrolysis process at different temperatures. At 1200 °C, the ceramic aerogels were homogeneous with well-distributed element components, composed of rutile TiO₂ and the β-SiC crystalline phases. The results show that the SiC-TiO₂ ceramic aerogels with netwoks structure have 23.36 nm average pore size, high surface area (58 m²/g) and pore volume (0.22 cm³/g).     

Synthesis and ceramic conversion of a novel processible polyboronsilazane precursor to SiBCN ceramic

Polyboronsilazane (PBSZ) precursors for SiBCN ceramics were prepared by using 9-borabicyclo-[1,3,3] nonane (9-BBN) and copolysilazanes (CPSZ) as starting materials, involving the hydroboration reaction between vinyl groups of PSZ and BH groups of 9-BBN under mild conditions. The as-synthesized PBSZ was obtained as a soluble liquid, which was characterized by FT IR and NMR. The polymer-to-ceramic conversion of PBSZ at a ceramic yield of 62.2–79.9% was investigated by means of FT IR and TGA. The crystallization behavior and microstructures of PBSZ-derived SiBCN ceramics were studied by XRD, SEM and HRTEM. The SiBCN ceramic began to crystallize at 1600 °C. Further heating at 1800 °C induced partial crystallization to give mixed XRD patterns for SiC, Si₃N₄, and BN(C). It is observed that the introduction of boron improves the thermal stability of SiBCN ceramics, especially under high temperatures of 1600–1800 °C. In addition, the introduction of boron significantly improves the ceramic density while inhibits the SiC crystallization.     

Amorphous Si(Al)OC ceramic from polysiloxanes: bulk ceramic processing,crystallization behavior and applications

Here we report on bulk Si–Al–O–C ceramics produced by pyrolysis of commercial poly(methylsilsesquioxane) precursors. Prior to the pyrolysis the precursors were cross-linked with a catalyst, or modified by the sol-gel-technique with an Al-containing alkoxide compound, namely alumatrane. This particular procedure yields amorphous ceramics with various compositions (Si_1.00O_1.60C_0.80, Si_1.00Al_0.04O_1.70C_0.48, Si_1.00Al_0.07O_1.80C_0.49, and Si_1.00Al_0.11O_1.90C_0.49) after thermal decomposition at 1100 °C in Ar depending on the amount of Al-alkoxide used in the polymer reaction synthesis. The as-produced ceramics are amorphous and remain so up to 1300 °C. Phase separation accompanied by densification (1300–1500 °C) and formation of mullite at T > 1600 °C are the stages during heat-treatment. Bulk SiAlOC ceramics are characterized in terms of microstructure and crystallization in the temperature regime ranging from 1100 to 1700 °C. Aluminum-free SiOC forms SiC along with cracking of the bulk compacts. In contrast, the presence of Al in the SiOC matrix forms SiC and mullite and prevents micro cracking at elevated temperatures due to transient viscous sintering. The nano-crystals formed are embedded in an amorphous Si(Al)OC matrix in both cases. Potential application of polysiloxane derived SiOC ceramic in the field of ceramic micro electro mechanical systems (MEMS) is reported.     

Joining of SiC ceramics via a novel liquid preceramic polymer (V-PMS)

A novel liquid preceramic polymer (V-PMS) was synthsized by modifying polymethylsilane (PMS) with 1,3,5,7-tetramethyl-1,3,5,7-tetravinylcyclotetrasiloxane ([CH₃(CH₂CH)SiO]₄, D4Vi), for joining SiC ceramics under ambient pressure. The obtained V-PMS with a viscosity of 125 Pas at room temperature exhibits excellent thermal properties and bonding strength. The ceramic yield of V-PMS treated at 1200 °C under Ar atmosphere is 84.5%, which is 38.3% higher than the original PMS. The shear strengths of the SiC joints joined by V-PMS at 800 °C, 1000 °C and 1200 °C under N₂ atmosphere are 11.9 MPa, 34.5 MPa and 29.9 MPa, respectively. The excellent performances make the obtained V-PMS promising candidates for joining SiC ceramics in high-temperature applications.     

Influence of Li2O–B2O3–SiO2 glass on the sintering behavior and microwave dielectric properties of BaO–0.15ZnO–4TiO2 ceramics

This paper reports the investigation of the performance of Li₂O–B₂O₃–SiO₂ (LBS) glass as a sintering aid to lower the sintering temperature of BaO–0.15ZnO–4TiO₂ (BZT) ceramics, as well as the detailed study on the sintering behavior, phase evolution, microstructure and microwave dielectric properties of the resulting BZT ceramics. The addition of LBS glass significantly lowers the sintering temperature of the BZT ceramics from 1150 °C to 875–925 °C. Small amount of LBS glass promotes the densification of BZT ceramic and improves the dielectric properties. However, excessive LBS addition leads to the precipitation of glass phase and growth of abnormal grain, deteriorating the dielectric properties of the BZT ceramic. The BZT ceramic with 5 wt% LBS addition sintered at 900 °C shows excellent microwave dielectric properties: ε_r=27.88, Q×f=14,795 GHz.