Oxidation Resistance, Compressive Strength and Thermal Shock Resistance of SiC Ceramics Prepared by Two Processing Routes

Abstract

In the present paper, direct foaming technique and sacrificial template method were used to prepare porous alumino-silicate bonded SiC ceramics from mixtures of silicon carbide, kaolin and calcined alumina. The direct foaming process depends on generating bubbles inside the slurry of SiC mixtures through a reaction between CaC2 and Al powder in presence of H2O to form C2H2 and H2 gases in two steps of the reaction. In the sacrificial template method, the pores were created in the prepared SiC specimens after burning out the used sacrificial template, corn and potato starch. Some fired specimens were selected to study the effect of their composition and preparation conditions on their oxidation resistivity, compressive strength and thermal shock resistivity. Based on purity and homogenous microstructure, the present study offers SiC specimens with good oxidation resistance where they exhibit (0.1 to 2 mg/cm2) increase in mass after oxidation in air at a temperature of 1100 ̊C for 65 h, despite their high open porosity values. The present SiC specimens have high thermal shock resistivity. However, the foamed specimens showed better resistivity than those prepared by the sacrificial template method. Using the extruder for shaping the latter specimens improves their resistivity to thermal shock. The compressive strength of both groups of specimens is affected by their composition and preparation conditions.

This is a preview of subscription content, access via your institution.

References

  1. 1.

    Taslicukur Z, Balaban C, Kuskonmaz N (2007) Production of ceramic foam filters for molten metal filtration using expanded polystyrene. J Eur Ceram Soc 27(2–3):637–640

    CAS  Article  Google Scholar 

  2. 2.

    Moreira EA, Innocentini MDM, Coury JR (2004) Permeability of ceramic foams to compressible and incompressible flow. J Eur Ceram Soc 24(10–11):3209–3218

    CAS  Article  Google Scholar 

  3. 3.

    Chen W, Miyamoto Y (2014) Fabrication of porous silicon carbide ceramics with high porosity and high strength. J Eur Ceram Soc 34(3):837–840

    CAS  Article  Google Scholar 

  4. 4.

    Baitalik S, Kayal N, Chakrabarti O (2017) Processing and properties of porous SiC ceramics prepared by yttrium aluminium garnet infiltration. Int J Appl Ceram Technol 14(4):652–664

    CAS  Article  Google Scholar 

  5. 5.

    Zhu X, Jiang D, Tan S (2002) Preparation of silicon carbide reticulated porous ceramics. Mater Sci Eng A 323(1–2):232–238

    Article  Google Scholar 

  6. 6.

    She J, Ohji T, Deng ZY (2002) Thermal shock behaviour of porous silicon carbide ceramics. J Am Ceram Soc 85(8):2125–2127

    CAS  Article  Google Scholar 

  7. 7.

    Kovalčíková A, Sedláček J, Lenčéš Z, Bystrický R, Dusza J, Šajgalík P (2016) Oxidation resistance of SiC ceramics prepared by different processing routes. J Eur Ceram Soc 36(15):3783–3793

    Article  Google Scholar 

  8. 8.

    Vedula VR, Green DJ, Hellman JR (1999) Thermal shock resistance of ceramic foams. J Am Ceram Soc 82(3):649–656

    CAS  Article  Google Scholar 

  9. 9.

    Eom J-H, Kim Y-W, Raju S (2013) Processing and properties of macroporous silicon carbide ceramics: a review. J Asian Ceram Soc 1(3):220–242

    Article  Google Scholar 

  10. 10.

    Lee YJ, Kim SR, Kim YH, Shin DG, Won JY, Kwon WT (2014) Characterization of microstructure on porous silicon carbide prepared by polymer replica template method. J Korean Ceram Soc 51(6):539–543

    CAS  Article  Google Scholar 

  11. 11.

    Oschatz M, Lee JT, Kim H, Nickel W, Borchardt L, Cho WI, Ziegler C, Kaskel S, Yushin G (2014) Micro-and mesoporous carbide-derived carbon prepared by a sacrificial template method in high-performance lithium-sulfur battery cathodes. J Mater Chem A 2(41):17649–17654

    CAS  Article  Google Scholar 

  12. 12.

    Jana DC, Sundararajan G, Chattopadhyay K (2017) Effect of porosity on structure, Young's modulus, and thermal conductivity of sic foams by direct foaming and gel casting. J Am Ceram Soc 100(1):312–322

    CAS  Article  Google Scholar 

  13. 13.

    Ohji T, Fukushima M (2012) Macro-porous ceramics: processing and properties. Int Mater Rev 57(2):115–131

    CAS  Article  Google Scholar 

  14. 14.

    Zhu S et al (2007) Preparation and characterization of SiC/cordierite composite porous ceramics. Ceram Int 33(1):115–118

    CAS  Article  Google Scholar 

  15. 15.

    Hanna SB, Awaad M, Ajiba NA, Saad EA (2018) Characterization of porous Alumino-silicate bonded SiC-ceramics prepared by hand-pressing and extrusion methods. Silicon 10:1961–1972. https://doi.org/10.1007/s12633-017-9708-9

    CAS  Article  Google Scholar 

  16. 16.

    Hanna SB, Awaad M, Ajiba NA (2018) Optimization of a novel process for preparation of silicon carbide foams. Mater Chem Phys 218:77–86

    CAS  Article  Google Scholar 

  17. 17.

    Razak HA, Mahde AK, Yahya AH (2002) Chemical cellulation technique for lightweight clay bricks. Br Ceram Trans 101(4):172–176

    CAS  Article  Google Scholar 

  18. 18.

    She JH, Ohji T, Kanzaki S (2004) Oxidation bonding of porous silicon carbide ceramics with synergistic performance. J Eur Ceram Soc 24(2):331–334

    CAS  Article  Google Scholar 

  19. 19.

    Roy J, Chandra S, Das S, Maitra S (2014) Oxidation behaviour of silicon carbide-a review. Rev Adv Mater Sci 38(1):29–39

    CAS  Google Scholar 

  20. 20.

    Ren F, Zhai G, Ma Z, Chen X, Volinsky AA (2011) Microstructure and quality of SiC foam filters for casting. J Ceram Process Res 12(6):691–694

    Google Scholar 

  21. 21.

    Aramaki S, Roy R (1962) Revised phase diagram for the system Al2O3—SiO2.". J Am Ceram Soc 45(5):229–242

    CAS  Article  Google Scholar 

Download references

Author information

Affiliations

Authors

Corresponding author

Correspondence to N. A. Ajiba.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Hanna, S.B., Awaad, M. & Ajiba, N.A. Oxidation Resistance, Compressive Strength and Thermal Shock Resistance of SiC Ceramics Prepared by Two Processing Routes. Silicon 12, 761–772 (2020). https://doi.org/10.1007/s12633-019-00147-z

Download citation

Keywords

  • Porous silicon carbide
  • Calcium carbide
  • Alumino-silicate
  • Starch
  • Oxidation resistance
  • Thermal shock resistance