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A thermoset hybrid sol for the syntheses of zirconium carbide–silicon carbide foam via replica method

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Abstract

Zirconium carbide–silicon carbide (ZrC–SiC) ceramics are amongst the promising candidate materials for thermal protection structures in hypersonic re-entry space vehicles. A thermoset hybrid sol for the syntheses of monolithic ZrC–SiC composites was prepared by a simple sol–gel method. Furfuryl alcohol, polyzirconoxane and tetraethyl orthosilicate were used as raw materials. The as-synthesized sol can be cured at 85 °C for 24 h to obtain a bulk gel. The cured gel is converted into porous ZrC–SiC monolith with porosity of 44.1% after pyrolysis at 1500 °C for 1 h in vacuum. The ZrC–SiC monolith is composed of well distributed nano-sized ZrC and SiC particles. Highly porous ZrC–SiC ceramic foam with density of 0.34 g/cm3 and porosity of 78.1% is prepared by replica method using the hybrid sol as precursor and melamine foam as templates. The hybrid sol and ZrC–SiC composites are characterized by FT-IR, TG–DTA, XRD, SEM, EDS and TEM.

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Acknowledgements

Financial support from the National Natural Science Foundation of China (No. 51602324, 51532009) and the Fundamental Research Funds for the Central Universities (No. 2232018D3-32) are gratefully acknowledged.

Author information

Author notes

  1. Fei Li & Guo-Jun Zhang

    Present address: State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, Institute of Functional Materials, Donghua University, Shanghai, 201620, China

Authors and Affiliations

  1. Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 200050, China

    Fei Li, Weichao Bao, De-Wei Ni & Xiao Huang

  2. University of Chinese Academy of Sciences, Beijing, 100049, China

    Weichao Bao

Authors
  1. Fei Li
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  2. Weichao Bao
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  3. De-Wei Ni
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  4. Xiao Huang
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  5. Guo-Jun Zhang
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Contributions

FL and XH conceived the concept of the study and prepared the manuscript. FL and D-WN carried out samples preparation. FL and WB conducted microstructural characterization. All authors contributed with discussion of results and manuscript revision.

Corresponding authors

Correspondence to Fei Li or Xiao Huang.

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Li, F., Bao, W., Ni, DW. et al. A thermoset hybrid sol for the syntheses of zirconium carbide–silicon carbide foam via replica method. J Porous Mater 26, 409–417 (2019). https://doi.org/10.1007/s10934-018-0618-z

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  • DOI: https://doi.org/10.1007/s10934-018-0618-z

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