Fabrication and characterization of cordierite-bonded porous SiC ceramics

A reaction bonding technique was used for the preparation of cordierite-bonded porous SiC ceramics in air from α-SiC, α-Al₂O₃ and MgO, using graphite as the pore-forming agent. Graphite was burned out to produce pores and the surface of SiC was oxidized to SiO₂ at high temperature. With further increasing the temperature, SiO₂ reacted with α-Al₂O₃ and MgO to form cordierite. SiC particles were bonded by the cordierite and oxidation-derived SiO₂. The reaction bonding characteristics, phase composition, open porosity, pore size distribution and mechanical strength as well as microstructure of porous SiC ceramics were investigated. The pore size and porosity were strongly dependent, respectively, on graphite particle size and volume fraction. The porous SiC ceramics sintered at 1350 °C for 2 h exhibited excellent combination properties, the flexural strength of 26.0 MPa was achieved at an open porosity of 44.51%.     

Effects of SiC addition on the structure and properties of reticulated porous mullite ceramics

Reticulated porous mullite ceramics (mullite RPCs) were produced by the polymer replica method using alpha alumina and kaolin to form in situ mullite. Up to 30% particulate silicon carbide (SiCp) was added to ceramic mixtures to explore its effect on the structure and properties of the sintered products. The ceramic slurry was coated onto polyurethane sponge using preset roller method, then recoating was applied by the spray coating technique. The strength of the mullite RPCs was found to depend greatly on the phase composition of the structures and on the amount of SiCp addition.     

Effects of SiC whisker addition on mechanical,thermal, and permeability properties of porous silica-bonded SiC ceramics

The effects of SiC whisker addition into nano-SiC powder-carbon black template mixture on flexural strength, thermal conductivity, and specific flow rate of porous silica-bonded SiC ceramics were investigated. The flexural strength of 1200°C-sintered porous silica-bonded SiC ceramics increased from 9.5 MPa to 12.8 MPa with the addition of 33 wt% SiC whisker because the SiC whiskers acted as a reinforcement in porous silica-bonded SiC ceramics. The thermal conductivity of 1200°C-sintered porous silica-bonded SiC ceramics monotonically increased from 0.360 Wm^–1K^–1 to 1.415 Wm^–1K^–1 as the SiC whisker content increased from 0 to 100 wt% because of the easy heat conduction path provided by SiC whiskers with a high aspect ratio. The specific flow rate of 1200°C-sintered porous SiC ceramics increased by two orders of magnitude as the SiC whisker content increased from 0 to 100 wt%. These results were primarily attributed to an increase in pore size from 125 nm to 565 nm and secondarily an increase in porosity from 49.9% to 63.6%. In summary, the addition of 33 wt% SiC whisker increased the flexural strength, thermal conductivity, and specific flow rate of porous silica-bonded SiC ceramics by 35%, 133%, and 266%, respectively.     

Effects of SDBS and ZrO2 additives on the microstructure and properties of silicon-bonded SiC porous ceramics

Porous silicon-bonded silicon carbide (SBSC) ceramics were prepared under argon atmosphere, with silicon as pore former and bonding material, simultaneously, sodium dodecyl benzene sulfonate (SDBS) and ZrO₂ as sintering additives, the effects of SDBS and ZrO₂ on the porosity, pore size, mechanical, physical and thermal properties and microstructures were investigated. The results suggested that suitable content of SDBS and ZrO₂ could not only effectively lower the sintering temperature to 1450 °C due to the sticky flow of molten silicon, but also increase the pore structure and improve the bending strength. The reason for this is that SDBS decomposed into Na₂O which reacted with ZrO₂ and impurity SiO₂, which was the native oxide film on the surface of SiC particles, to form a bonding phase between SiC particles to improve the bending strength; meanwhile, the disappearances of impurity SiO₂ would benefit the bond of molten silicon and silicon carbide particles, and silicon melt leaving pores in its original position to increase the pore structure. The optimal apparent porosity, bending strength, average pore size, gas permeance and residual bending strength after thermal shock cycles of SBSC porous ceramic sintered at 1450 °C with 5 wt% SDBS and 6 wt% ZrO₂ were 38.33%, 55.4 MPa, 11.3 μm, 106.4 m³/m²·h·kPa and 28.2 MPa, respectively.     

Spheroidization of SiC powders and their improvement on the properties of SiC porous ceramics

Spherical SiC powders were prepared at high temperature using commercial SiC powders (4.52 µm) with irregular morphology. The influence of spherical SiC powders on the properties of SiC porous ceramics was investigated. In comparison with the as-received powders, the spheroidized SiC powders exhibited a relatively narrow particle size distribution and better flowability. The spheroidization mechanism of irregular SiC powder is surface diffusion. SiC porous ceramics prepared from spheroidized SiC powders showed more uniform pore size distribution and higher bending strength than that from as-received SiC powders. The improvement in the performance of SiC porous ceramics from spheroidized powder was attributed to tighter stacking of spherical SiC particles. After sintering at 1800 °C, the open porosity, average pore diameter, and bending strength of SiC porous ceramics prepared from spheroidized SiC powder were 39%, 2803.4 nm, and 66.89 MPa, respectively. Hence, SiC porous ceramics prepared from spheroidized SiC powder could be used as membrane for micro-filtration or as support of membrane for ultra/nano-filtration.     

木炭添加量对多孔莫来石陶瓷性能的影响

为了改善以木炭为造孔剂的多孔莫来石陶瓷的性能,以烧结莫来石(0.25~0.3 mm)、SiO2微粉、Al2O3微粉、滑石粉、球黏土、膨润土、甲基纤维素、木炭粉(≤0.044 mm)为原料,研究了不同量的木炭粉(外加质量分数分别为0、2%、4%、6%、8%、10%、12%)对多孔莫来石坯体的成型外观、烘干后的常温耐压强度及1 400℃保温3 h热处理后的显气孔率和常温耐压强度的影响,并对不同木炭添加量的多孔莫来石试样进行了显微结构分析。结果表明:外加质量分数≤8%的木炭,制成的多孔莫来石坯体可较好成型;外加质量分数2%~8%木炭的莫来石坯体与不添加木炭的相比,烘干后试样的常温耐压强度明显提高;多孔莫来石热处理后的显气孔率随着木炭添加量的增加而增加,常温耐压强度随之降低。综合考虑多孔莫来石陶瓷各项性能,木炭外加质量分数不宜超过8%。     

Fabrication and microstructure of porous SiC ceramics with Al2O3 and CeO2 as sintering additives

In the present study, porous silicon carbide ceramics were prepared via spark plasma sintering at relatively low temperatures using Al₂O₃ and CeO₂ as sintering additives. Sacrificial template was selected as the pore forming mechanism, and gelcasting was used to fix the slurry in a short time. The evolution process of the microstructures during different steps was observed by SEM. The influence of the sintering temperature and sintering additives on the shrinkage and porosity of the samples was studied. The microstructures of different samples were characterized, and the mechanical properties were also evaluated.     

Processing and properties of cordierite-silica bonded porous SiC ceramics

Cordierite-silica bonded porous SiC ceramics were fabricated by infiltrating a porous powder compact of SiC with cordierite sol followed by sintering at 1300–1400 °C in air. The porosity, average pore diameter and flexural strength of the ceramics varied 30–36 vol%, ~ 4–22 µm and ~ 13–38 MPa respectively with variation of sintering temperature and SiC particle sizes. In the final ceramics SiC particles were bonded by the oxidation-derived SiO₂ and sol-gel derived cordierite. The corrosion behaviour of sintered SiC ceramics was studied in acidic and alkaline medium. The porous SiC ceramics were observed to exhibit better corrosion resistance in acid solution.     

Effects of gelatin addition on the microstructure of freeze-cast porous hydroxyapatite ceramics

Porous hydroxyapatite (HAP) ceramics was prepared by freeze casting and gelatin was used to adjust the pore morphology and microstructure of the porous HAP ceramics. With the gelatin concentration increase, the viscosity of HAP slurry was increased, and the linear shrinkage ratio of the specimen sintered at 1300 °C was also increased. The gelatin addition had great effects on the pore size and pore morphology of the porous HAP ceramics. The experimental results showed that the pore morphology of HAP ceramics was changed from a two-dimensional flat pore to a three-dimensional reticulated pore after gelatin addition.     

Effect of bentonite addition on fabrication of reticulated porous SiC ceramics for liquid metal infiltration

SiC with different particles and a clay mineral bentonite (montmorillonite) were mixed in water to prepare ceramic slurry. The slurry was then infiltrated high porous polyurethane sponge. Excess slurry was squeezed out to adjust ceramic rate in the infiltrated body. The pore walls were coated with ceramic mix after the infiltrated body was dried. The polyurethane containing SiC particles and bentonite was fired in a box furnace to burn out the polyurethane from the body at 500 °C for 30 min. The remaining porous ceramic bodies were sintered at elevated temperatures to give strength. SiC particles with bentonite surface coating took polyurethane pore forms after firing the sponge. Bentonite was both used as binder for ceramic slurry at room temperatures and the sintering additives at elevated temperatures. Therefore, increasing bentonite addition gives higher strength to the resulting ceramic performs.     

Effects of V2O5 addition on the synthesis of columnar self-reinforced mullite porous ceramics

Spearhead columnar mullite was synthesized by in-situ reaction with V₂O₅ as additive. When the content of V₂O₅ was 7 wt%, the length of the spearhead columnar mullite was the longest with an aspect ratio of about 3.5. Furthermore, columnar self-reinforced mullite porous ceramics were prepared by a foam-gelcasting method, and the effects of V₂O₅ content on the rheological and gelling properties of mullite slurries as well as the microstructure, physical property and thermal insulation property of the prepared mullite porous ceramics were studied. The results showed that the flexural strength and compressive strength of the porous ceramics with 63% porosity prepared by using 2 wt% V₂O₅ additive were respectively as high as 13.9 and 41.3 MPa, and the thermal conductivity was about 1.04 W m^?1 K^?1.     

Effects of porosity on electrical and thermal conductivities of porous SiC ceramics

The effects of porosity on the electrical and thermal conductivities of porous SiC ceramics, containing Y₂O₃–AlN additives, were investigated. The porosity of the porous SiC ceramic could be controlled in the range of 28–64 % by adjusting the sacrificial template (polymer microbead) content (0–30 wt%) and sintering temperature (1800–2000 °C). Both electrical and thermal conductivities of the porous SiC ceramics decreased, from 7.7 to 1.7 Ω⁻¹ cm⁻¹ and from 37.9 to 5.8 W/(m·K), respectively, with the increase in porosity from 30 to 63 %. The porous SiC ceramic with a coarser microstructure exhibited higher electrical and thermal conductivities than those of the ceramic with a finer microstructure at the equivalent porosity because of the smaller number of grain boundaries per unit volume. The decoupling of the electrical conductivity from the thermal conductivity was possible to some extent by adjusting the sintering temperature, i.e., microstructure, of the porous SiC ceramic.     

Effect of CeO2 addition on the sintering behavior of the alumina-rich calcium aluminate ceramics

In this work, the CaAl₄O₇ ceramics and CaAl₁₂O₁₉ ceramics were fabricated by the solid-state sintering technology and the effects of CeO₂ as the additive on their sintering behavior subjected to sintering at temperatures of 1500°C, 1550°C, and 1600°C were investigated. It was demonstrated that the bulk densities of the CaAl₄O₇ ceramics and CaAl₁₂O₁₉ ceramics increased about 23.8% and 24.2% after adding 3.0 wt% of CeO₂ than that of the samples without additives. Meanwhile, an increase in lattice parameters occurred in the CaAl₄O₇ ceramics and CaAl₁₂O₁₉ ceramics. The CeO₂ could form the solid solution in the CaAl₄O₇ ceramics, inducing the lattice distortion and the activation of the lattice. The Ce⁴⁺ in CeO₂ could be dissolved in the structure of CaAl₁₂O₁₉ phase and result in the structural defects, which would accelerate ion exchange and promote the in situ reaction of synthetic products. These behaviors could promote the sintering process of the CaAl₄O₇ ceramics and CaAl₁₂O₁₉ ceramics and improve their sinterability. Moreover, a considerable increase in bulk density occurred in both CaAl₄O₇ ceramics and CaAl₁₂O₁₉ ceramics with increasing sintering temperatures due to the greater densification obtained from the enhanced mass transport at elevated temperatures.     

Microstructure and properties of porous SiC ceramics by LPCVI technique regulation

A new gradient pore structure in porous SiC ceramics was fabricated by low pressure chemical vapor infiltration (LPCVI). Effects of deposition duration on the mechanical properties and permeability of porous SiC ceramics were investigated. Results demonstrated that pore diameter and shapes decreased from the surface to the interior along with LPCVI duration. Porous SiC ceramics with deposition duration of 160 h exhibited flexural strength of 48.05 MPa and fracture toughness of 1.30 MPa m^1/2, where 221% and 189% improvements were obtained compared to porous SiC ceramics without LPCVI, due to CVI-SiC layer strengthening effect. Additionally, at the same gas velocity, pressure drop increase rate was faster due to apparent porosity and pore size change.     

Effects of inert filler addition on the structure and properties of porous SiOC ceramics derived from silicone resin

Porous SiOC ceramics were obtained from a new self-blowing precursor silicone resin DC217, by pyrolysis at 1200 °C in argon. Silicon carbide powders were incorporated into the silicone resin as inert fillers. The effects of the mean particle size of SiC fillers on the porosity, compressive strength and microstructure of the porous ceramics were investigated. With the mean particle size of SiC powders increasing from 5 μm to 10 μm, the porosity (total and open) of the porous ceramic increased and the compressive strength decreased. However, the porosity, compressive strength and cell morphology of the porous ceramics showed no evident changes when the mean particle size of fillers increased from 10 μm to 15 μm. Micrographs indicated that, when the mean particle size of fillers exceeded 5 μm, the porous ceramics could have a well-defined and regular pore structure. Furthermore, comparing with the porous ceramics which fabricated under the same condition with the SiOC powders as fillers, the cell morphology was similar. But the compressive strength and the oxidation resistance of the porous ceramics with SiC powders as fillers were much better.     

ZrO2 对堇青石多孔陶瓷性能和显微结构的影响

以高岭土、滑石和αAl2O3微粉为主要原料,按堇青石的理论组成配料后,外加10%的化学纯活性炭为造孔剂,同时分别外加0、0.25%、0.5%、0.75%和1.0%的分析纯ZrO2,经湿混、干燥、造粒、成型和1340℃保温5h烧成后,制成不同ZrO2含量的堇青石多孔陶瓷,并研究了ZrO2外加量对试样热膨胀系数、显气孔率、吸水率及烧成收缩率的影响,并用XRD和SEM分析了试样的物相组成和断面形貌。结果表明:与未加ZrO2的相比,外加0.25%ZrO2时,试样的热膨胀系数显著降低,但超过0.25%时,热膨胀系数随ZrO2外加量的增加而略有升高;随ZrO2外加量的增加,试样的显气孔率和吸水率逐渐增大,而烧成收缩率降低;与未加ZrO2的试样相比,外加1.0%ZrO的试样内扁平状气孔的数量较多,且气孔在试样内分布较均匀。     

Effects of ZnO nanoparticulate addition on the properties of PMNT ceramics

This research was conducted in order to study the effect of ZnO nanoparticulate addition on the properties of 0.9 Pb(Mg_1/3Nb_2/3)O₃-0.1PbTiO₃ [PMNT] ceramics. The PMNT ceramics were prepared by a solid-state reaction. The ZnO nanoparticles were added into PMNT ceramics to form PMNT/xZnO (x = 0, 0.05, 0.1, 0.5, and 1.0 wt.%). The PMNT/xZnO ceramics were investigated in terms of phase, microstructure, and mechanical and electrical properties. It was found that the density and grain size of PMNT ceramics tended to increase with an increasing amount of ZnO content. Moreover, a transgranular fracture was observed for the samples containing ZnO, while pure PMNT ceramics showed only a intergranular fracture. An addition of only 0.05 wt.% of ZnO was also found to enhance the hardness and dielectric and ferroelectric properties of the PMNT ceramics.     

Effects of TiN content on the properties of hot pressed TiB2–SiC ceramics

This research intended to study the impacts of different contents of the TiN additive on the mechanical properties and microstructural features of the TiB₂–SiC-based composites. Three different samples of TiB₂-15 vol% SiC- x vol% TiN (x = 0, 3.5, and 7) were produced by hot-pressing at 2000 °C under 35 MPa for 120 min. Thanks to advancement of some reactions among the TiB₂ surface oxides and the SiC reinforcement, two in-situ phases of TiC and SiO₂ were produced during the sintering. Nevertheless, the TiN incorporation resulted in generating another in-situ compound (TiC_0.3N_0.7) in the relevant as-sintered ceramics. Moreover, introducing TiN significantly refined the microstructure of the composites, leading to higher mechanical characteristics. Finally, the highest flexural strength (781 MPa) and Vickers hardness (27.1 GPa) values were attained for the sample introduced by 7 vol% TiN.     

生物SiC多孔陶瓷的研究进展

介绍了生物SiC多孔陶瓷的研究现状,并对生物碳模板的分类、制备方法进行了详尽的叙述,同时对生物SiC多孔陶瓷的各项性能进行了综述,最后对生物SiC多孔陶瓷的发展趋势作了总结。     

Effect of recoating slurry compositions on the microstructure and properties of SiC reticulated porous ceramics

Silicon carbide reticulated porous ceramics (SiC RPCs) were fabricated by polymer sponge replica technique, followed by recoating with SiC slurries of two different sintering additives of MgO–Al₂O₃–SiO₂ (Slurry 1) and polycarbosilane (Slurry 2). The sintering temperature of SiC RPCs recoated with Slurry 2 was 1100 °C, which was 200 °C lower than that for one recoated with Slurry 1. The prepared SiC RPCs exhibited homogeneous microstructure and contained pores with different sizes which was entrapped in the strut of SiC RPCs, small pores with diameter lower than 4 μm and large pores with diameter higher than 10 μm. Bending strength of SiC RPCs recoated with Slurry 1 was two times higher than that for the non-recoated samples, which was 1.88 MPa and was a little higher than that for one recoated with slurry 2. At the same time, high thermal shock resistance and high refractoriness were achieved for SiC RPCs recoated with Slurry 2.