Materials Chemistry and Physics, Vol.218, 77-86, 2018
Optimization of a novel process for preparation of silicon carbide foams
Silicon carbide (SiC) was mixed with alumina and kaolin to obtain porous alumino-silicate bonded SiC specimens. These mixtures contain 40 to 80 mass% SiC while the alumina contents of their bonding materials are 60-80 mass%. Porous SiC specimens were prepared from mixtures of silicon carbide, calcined alumina and Klabsha kaolin using the foaming method. The employed technique of foaming introduces pores into SiC specimens as a result of chemical reaction between aluminum powder (Al) and calcium carbide (CaC (2)) in presence of water which liberates acetylene and hydrogen gases. The reaction and process are assisted by adding sodium meta-silicate and a stabilizer. The shaped specimens were dried and then fired up to 1450 degrees C for 2hrs. The chemical composition and firing temperature of foamed specimens are responsible for all changes occurring in their physical properties, microstructure characteristics and mineral composition. The result indicated that CaC2 mass% and CaC2/Al mass ratio of 1 and 3.3 are considered to be more suitable amounts for using in this foaming method and firing temperature as low as 1350 degrees C is used to prepare more porous specimens. Also on increasing the water content from 25 to 30 mass%, specimens of higher open porosities and lower bulk densities are obtained. Under these conditions, porous SiC specimens having bulk density, open porosity and mean pore size of 0.88-1 g/cm(3), 65-70% and less than 25 mu m are obtained, respectively.