Microstructure and mechanical properties of porous SiC ceramics by carbothermal reduction and subsequent recrystallization sintering

Porous SiC ceramics were prepared by a new approach combination of carbothermal reduction and subsequent recrystallization sintering. Firstly, micro-sized SiC particles were used as the skeleton, and SiC spherical nanocrystals were in-situ synthesized by the vapor-solid reaction between carbon nanoparticles and silicon monoxide vapor. The shape and diameter of SiC nanocrystals are related to the pristine carbon nanoparticles, showing a shape memory effect. After recrystallization sintering, high purity α-SiC porous ceramics with tailored necking area were obtained by the evaporation-condensation of SiC nanocrystals. A linear relation was revealed between the flexural strength and the value of d/d0 of porous recrystallized SiC (RSiC) ceramics (the neck diameter to coarse micron-sized grains diameter ratio). The necking area and d/d0 value increased with the SiC nanocrystals content, due to the higher saturated vapor pressure resulted in high mass mobility to neck area of SiC nanoparticles. As a result, a remarkable value of d/d0 ~ 99% and outstanding flexural strength of 75.7 MPa could be achieved for the porous RSiC ceramics with ~42% porosity by adding 20 wt.% nano-sized SiC sintered at 1950°C for 2 h.