Improved connectivity of gelcasted and solid-state-sintered SiC foams through synergetic poring mechanism

In order to improve the connectivity between pores of gelcasted and solid-state-sintered SiC (S-SiC) foams, we utilized the synergetic poring mechanism of direct foaming and sacrificial solid template through introducing organic micro-beads into aqueous foamed SiC-B4C-C suspensions. The addition of micro-beads accelerated the formation of more bubble-derived pores in S-SiC foams, and generated abundant bead-derived pores in the bubble-derived-pore struts and partial-sintering-derived pores between SiC grains as well. This multiple pore microstructures induced excellent connectivity between pores and an ultrahigh porosity of 89.5%. Consequently, an outstanding nitrogen gas permeability of 9.2 × 10−11 m2 was acquired under the condition of a superior compressive strength of 2.2 ± 0.4 MPa.