Gelcasting of silicon carbide ceramics using phenolic resin and furfuryl alcohol as the gel former

A new non-aqueous gelcasting system of phenolic resin and furfuryl alcohol combined with a curing catalyst was developed for casting of reaction bonded silicon carbide ceramics. This gelling system could be carried out in air, and the surface exfoliation phenomenon that seems inherent to the acrylamide gelcasting system could also be eliminated. Polymerization of the premix solutions and rheological properties of the non-aqueous silicon carbide suspensions were studied. After curing and subsequent pyrolysis of the concentrated silicon carbide suspension, homogenous silicon carbide/carbon green body with a relatively high strength of about 18 MPa could be formed. Dense complex-shaped SiC ceramic parts with flexure strength of 300±20 MPa and fracture toughness of 3.87±0.19 MPa m1/2 can be successfully produced after reaction sintering at 1700 °C for 30 min under vacuum.