Thermal Shock Behavior of Porous Silicon Carbide Ceramics

Using the water-quenching technique, the thermal shock behavior of porous silicon carbide (SiC) ceramics was evaluated as a function of quenching temperature, quenching cycles, and specimen thickness. It is shown that the residual strength of the quenched specimens decreases gradually with increases in the quenching temperature and specimen thickness. Moreover, it was found that the fracture strength of the quenched specimens was not affected by the increase of quenching cycles. This suggests a potential advantage of porous SiC ceramics for cyclic thermal-shock applications.     

Fracture Energies of Tape-Cast Silicon Nitride with β-Si3N4 Seed Addition

The fracture energies of the tape-cast silicon nitride with and without 3 wt% rod-like β-Si₃N₄ seed addition were investigated by a chevron-notched-beam technique. The material was doped with Lu₂O₃–SiO₂ as sintering additives for giving rigid grain boundaries and good heat resistance. The seeded and tape-cast silicon nitride has anisotropic microstructure, where the fibrous grains grown from seeds were preferentially aligned parallel to the casting direction. When a stress was applied parallel to the fibrous grain alignment direction, the strength measured at 1500°C was 738 MPa, which was almost the same as room temperature strength 739 MPa. The fracture energy of the tape-cast Si₃N₄ without seed addition was 109 and 454 J/m² at room temperature and 1500°C, respectively. On the contrary, the fracture energy of the seeded and tape-cast Si₃N₄ was 301 and 781 J/m² at room temperature and 1500°C, respectively, when a stress was applied parallel to the fibrous gain alignment. The large fracture energies were attributable primarily to the unidirectional alignment fibrous Si₃N₄ grains.     

Effect of Agglomeration on Mechanical Properties of Porous Zirconia Fabricated by Partial Sintering

Porous ZrO₂ ceramics were fabricated by compacting a fine ZrO₂ powder, followed by pressureless sintering. Two unidirectional pressures of 30 and 75 MPa were used to prepare the green compacts. The strength and the fracture toughness of porous ZrO₂ specimens sintered from the compacts prepared by 75 MPa were substantially higher than those by 30 MPa, especially for the specimens with low porosity. However, the corresponding Young's moduli were identical. This caused the strain to failure of these porous bodies to increase significantly with increasing compaction pressure. Microstructural analyses showed that a number of voids and small flaws existed in the green compacts prepared by the lower pressure, due to the agglomeration of fine ZrO₂ grains. It was revealed that the ZrO₂ agglomeration resulted in a localized nonuniform shrinkage and degraded the mechanical properties of porous ZrO₂ ceramics.     

Uniformly Porous Composites with 3-D Network Structure (UPC-3D) for High-Temperature Filter Applications

Uniformly porous composites with 3-D network structure (UPC-3D) have been recently developed via a pyrolytic reactive sintering process, which takes advantage of the evolved CO₂ gas from a decomposing carbonate source (e.g., dolomite, CaMg(CO₃)₂) and does not require any additional pore-forming agent nor long-time burning-out process. Through liquid formation via LiF doping, strong necks are formed between constituent particles before completion of the pyrolysis of carbonate, resulting in the formation of a strong 3-D network structure. The pore size distribution is very narrow (with typical pore size: ∼1 μm), and the porosity was controllable (∼30–60%) by changing the sintering temperature. This article presents the development details of UPC-3D, and reports the recent findings in CaZrO₃/MgAl₂O₄ system, which will be one of the more promising systems for practical applications.     

New Approach for Macro Porous RB‐SiC Derived from SiC/Novolac‐type Phenolic Composite

A novel fabrication route to make macroporous silicon carbide (SiC) has been proposed in this study. The route is composed of the following two steps: the fabrication of porous α‐SiC/novolac‐type phenolic composite using hexamethylenetetramine (HMT) as a curing/blowing agent for the novolac monomer and a conventional reaction‐bonded (RB) sintering of the composite. The α‐SiC/novolac‐type phenolic composite was carbonized at 800°C for 2 h in N₂ gas and then reacted with the molten silicon at 1450°C for 30 min under vacuum, resulting in the macroporous RB‐SiC with an open porosity of 48% and relatively large pore size of ~110 μm. The compressive strength of the macroporous RB‐SiC was 113 MPa, which is relatively high compared to those reported for macroporous SiC of equivalent porosities and pore sizes.     

Fracture Resistance Behavior of High‐Thermal‐Conductivity Silicon Nitride Ceramics

Silicon nitride ceramics were prepared from a high‐purity silicon powder doped with 2 mol% Y₂O₃ and 5 mol% MgO as sintering additives via a route of sintering of reaction‐bonded silicon nitride (SRBSN). The materials sintered at 1900°C for 3, 6, 12, and 24 h had thermal conductivities of 109, 125, 146, and 154 W/m/K, and four‐point bending strengths of 786, 676, 608, and 505 MPa, respectively. The fracture toughness values, determined by the single‐edge‐precracked‐beam (SEPB) method, were 8.4, 8.6, 9.7, and 10.7 MPa m^1/2 for the materials sintered for 3, 6, 12, and 24 h, respectively, which were similar to the results measured by the chevron‐notched‐beam (CNB) test method. The materials sintered for longer times (12 and 24 h) showed stronger R‐curve behaviors over longer range of crack extension, in comparison with the materials sintered for shorter times (3 and 6 h).     

Long Crack R-Curve of Aligned Porous Silicon Nitride

Long crack R -curve of a porous Si₃N₄ with aligned fibrous grains was investigated, using a chevron-notched beam technique. A crack was constrained to propagate normal to the grain alignment. The crack growth resistance of aligned porous Si₃N₄ was much larger compared with that of dense Si₃N₄ ceramics. Microstructure observations showed that pullouts of fibrous grains in aligned porous Si₃N₄ markedly increased during crack propagation relative to those of dense Si₃N₄, due to the existence of pores. The efficient grain pullouts in porous Si₃N₄ increased the bridging stress at the crack wake.     

Pore structure of porous ceramics synthesized from water-based slurry by freeze-dry process

A unique porous ceramic with complex pore structure was synthesized by the freeze-dry process. A water-based ceramic slurry was frozen while controlling the growth direction of ice, and sublimation of the ice were generated by drying it at a reduced pressure. By sintering this green body, a porous ceramic with complex pore structure was obtained, where macroscopically aligned open pores exceeding 10 m in size contained minute pores of about 0.1 m in their internal walls. Wide control of the porosity was possible by changing the concentration of the starting slurry. The pore size distribution as well as the microstructure were substantially affected by the freezing and sintering temperatures. Optimization of the synthesis conditions was investigated in order to obtain the desired pore structure.