Alkali-bonded SiC based foams

Silicon carbide (SiC) foams were developed by using a low temperature process such as chemical consolidation that is suitable to replace the sintering step. An alkali aluminosilicates binder, also known as geopolymer, was used. It was prepared from metakaolin, as aluminosilicatic raw powder, and KOH/K2SiO3 aqueous solution. The foaming agent was the metallic silicon present as impurity in SiC powders. Different grades of SiC were used as the main component (90 wt%) of the foams and the micro and macrostructures varied with the morphologies of the SiC raw powders. The surface of SiC grains participates to the geopolymeric process because of the dissolution of the silica layer into the alkaline solution. SiC foams were tested and characterized under oxidative atmospheres up to 1200 °C.