Microstructure formation on exposure of silicon carbide surfaces to the partial oxidation of methane

Gas-phase silicon-based species, produced on exposure of silicon carbide (SiC) surfaces to the partial oxidation of methane, can be transported away from the site of corrosion to form surface nano- and microstructures. These structures can be divided into two groups, silicon-based structures and silicon/carbon-based structures. Silicon oxide nanowires are the most prevalent of the silicon-based structures, and form on SiC surfaces downstream of the combustion zone. The silicon/carbon-based structures, formed towards the end of the combustion zone, are core–shell heterostructured fibres and take the form of either conical fibres or cross-linked fibre lattices. Low reactive gas concentrations, high temperatures and low methane/oxygen ratios enhance microstructure formation. The effect of gas-phase chemistry and fluid flow on surface behavior is discussed.

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► Silicon and carbon-based microstructures can form on silicon carbide surfaces exposed to the partial oxidation of methane.
► These structures include core–shell heterostructured fibres, cross-linked fibre lattices and silicon oxide nanowires.
► Low reactive gas concentrations, high temperatures and low methane/oxygen ratios exacerbate microstructure formation.