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Formation of dense silicon carbide by liquid silicon infiltration of carbon with engineered structure

Published online by Cambridge University Press:  31 January 2011

Jesse C. Margiotta ,
Dajie Zhang ,
Dennis C. Nagle  and
Caitlin E. Feeser
Jesse C. Margiotta*
Affiliation:
Department of Materials Science and Engineering, Johns Hopkins University, Baltimore, Maryland 21211
Dajie Zhang
Affiliation:
Advanced Technology Laboratory, Johns Hopkins University, Baltimore, Maryland 21211
Dennis C. Nagle
Affiliation:
Advanced Technology Laboratory, Johns Hopkins University, Baltimore, Maryland 21211
Caitlin E. Feeser
Affiliation:
Department of Chemical Engineering, Widener University, Chester, Pennsylvania 19013
*
a)Address all correspondence to this author. e-mail: jmargiotta@jhu.edu
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Abstract

Fully dense and net-shaped silicon carbide monoliths were produced by liquid silicon infiltration of carbon preforms with engineered bulk density, median pore diameter, and chemical reactivity derived from carbonization of crystalline cellulose and phenolic resin blends. The ideal carbon bulk density and minimum median pore diameter for successful formation of fully dense silicon carbide by liquid silicon infiltration are 0.964 g cm−3 and approximately 1 μm. By blending crystalline cellulose and phenolic resin in various mass ratios as carbon precursors, we were able to adjust the bulk density, median pore diameter, and overall chemical reactivity of the carbon preforms produced. The liquid silicon infiltration reactions were performed in a graphite element furnace at temperatures between 1414 and 1900 °C and under argon pressures of 1550, 760, and 0.5 Torr for periods of 10, 15, 30, 60, 120, and 300 min. Examination of the results indicated that the ideal carbon preform was produced from the crystalline cellulose and phenolic resin blend of 6:4 mass ratio. This carbon preform has a bulk density of 0.7910 g cm−3, an actual density of 2.1911 g cm−3, median pore diameter of 1.45 μm, and specific surface area of 644.75 m2 g−1. The ideal liquid silicon infiltration reaction conditions were identified as 1800 °C, 0.5 Torr, and 120 min. The optimum reaction product has a bulk density of 2.9566 g cm−3, greater than 91% of that of pure β–SiC, with a β–SiC volume fraction of approximately 82.5%.

Keywords

CarbonizationInfiltration (chemical reaction)Reactivity
Type
Articles
Information
Journal of Materials Research , Volume 23 , Issue 5 , May 2008 , pp. 1237 - 1248
Copyright
Copyright © Materials Research Society 2008

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