Fabrication of Complex-Shaped SiC Parts Based on Polymerization -Induced Phase Separation and Pyrolysis Technique

A route based on a technique of polymerization - induced phase separation and pyrolysis (PIPSP) has been developed to fabricate complex-shaped SiC parts. The capability of this process to produce complex component shapes has been demonstrated, and corresponding reactive mechanisms have been also discussed. Three types of porous carbon preforms, i.e. mesoporous carbon monoliths (MCMs), hierarchical porous carbon monoliths (HCMs) and porous carbon foam (PCFs) were obtained, which has different pore size distributions. The pore structures of the preforms can be controlled through changing starting mixture composition and polymerizing conditions. The apparent porosity of the preform was changed from 19.9 to 60%, which was a key parameter to obtain dense SiC parts. After reactive infiltration of the preform with Si, the SiC parts were obtained. Geometry of SiC parts were controlled by molds. The dimension shrinkage of SiC parts was less than 3% before/after siliconization and no distortion occurred. Compared with other molds assistance route, the wax mold assistance route was a most potential technique to fabricate SiC parts industrially because of its suitable forming precision, recycled mold materials and low-cost. The mechanism of the reactive infiltration of MCMs was different from that of the reactive infiltration of preforms with bigger pore size, i.e. the pore channels of MCMs were restructured at transitional stage of reaction.