Polymer-Derived Si-Based Ceramics: Recent Developments and Perspectives

Engineering a Hierarchy of Disorder: A New Route to Synthesize High-Performance 3D Nanoporous All-Carbon Materials*

A new nanoporous amorphous carbon (NAC) structure that achieves both ultrahigh strength and high electrical conductivity, which are usually incompatible in porous materials is reported. By using modified spark plasma sintering, three amorphous carbon phases with different atomic bonding configurations are created. The composite consisted of an amorphous sp2-carbon matrix mixed with amorphous sp3-carbon and amorphous graphitic motif. NAC structure has an isotropic electrical conductivity of up to 12 000 S m-1, Young's modulus of up to ≈5 GPa, and Vickers hardness of over 900 MPa. These properties are superior to those of existing conductive nanoporous materials. Direct investigation of the multiscale structure of this material through transmission electron microscopy, electron energy loss spectroscopy, and machine learning-based electron tomography revealed that the origin of the remarkable material properties is the well-organized sp2/sp3 amorphous carbon phases with a core-shell-like architecture, where the sp3-rich carbon forms a resilient core surrounded by a conductive sp2-rich layer. This research not only introduces novel materials with exceptional properties but also opens new opportunities for exploring amorphous structures and designing high-performance materials.

A Polymer-Based Metallurgical Route to Produce Aluminum Metal-Matrix Composite with High Strength and Ductility

In this investigation, an attempt was made to develop a new high-strength and high-ductility aluminum metal-matrix composite. It was achieved by incorporating ceramic reinforcement into the metal which was formed in situ from a polymer by pyrolysis. A crosslinked PMHS polymer was introduced into commercially pure aluminum via friction stir processing (FSP). The distributed micro- and nano-sized polymer was then converted into ceramic particles by heating at 500 °C for 10 h and processed again via FSP. The produced composite showed a 2.5-fold increase in yield strength (to 119 MPa from 48 MPa) and 3.5-fold increase in tensile strength (to 286 MPa from 82 MPa) with respect to the base metal. The ductility was marginally reduced from 40% to 30%. The increase in strength is attributed to the grain refinement and the larger ceramic particles. High-temperature grain stability was obtained, with minimal loss to mechanical properties, up to 500 °C due to the Zenner pinning effect of the nano-sized ceramic particles at the grain boundaries. Fractures took place throughout the matrix up to 300 °C. Above 300 °C, the interfacial bonding between the particle and matrix became weak, and fractures took place at the particle-matrix interface.

Mechanism of bonding, surface property, electrical behaviour, and environmental friendliness of carbon/ceramic composites produced via the pyrolysis of coal waste with polysiloxane polymer

A simple mixing-pressing followed by thermal curing and pyrolysis process was used to upcycle coal waste into high-value composites. Three coal wastes of different physicochemical properties were investigated. The hypothetical mechanisms of bonding between the coal particles and the preceramic polymer are presented. The textural properties of the coals indicated that the lowest volatile coal waste (PCD) had a dense structure. This limited the diffusion and reaction of the preceramic polymer with the coal waste during pyrolysis, thereby leading to low-quality composites. The water contact angles of the composites up to 104° imply hydrophobic surfaces, hence, no external coating might be required. Analysis of the carbon phase confirmed that the amorphous carbon structure is prevalent in the composites compared to the coal wastes. The dc volume resistivity of the composites in the range of 22 to 82 Ω-cm infers that the composites are unlikely to suffer electrostatic discharge, which makes them useful in creating self-heating building parts. The leached concentrations of heavy metal elements from the composites based on the end-of-life scenario were below the Toxicity Characteristic Leaching Procedure regulatory limits. Additionally, the release potential or mobility of the metals from the composites was not influenced by the pH of the eluants used. On the basis of the reported results, these carbon/ceramic composites show tremendous prospects as building materials due to these properties.

Additive Manufacturing of Advanced Ceramics Using Preceramic Polymers

Ceramic materials are used in various industrial applications, as they possess exceptional physical, chemical, thermal, mechanical, electrical, magnetic, and optical properties. Ceramic structural components, especially those with highly complex structures and shapes, are difficult to fabricate with conventional methods, such as sintering and hot isostatic pressing (HIP). The use of preceramic polymers has many advantages, such as excellent processibility, easy shape change, and tailorable composition for fabricating high-performance ceramic components. Additive manufacturing (AM) is an evolving manufacturing technique that can be used to construct complex and intricate structural components. Integrating polymer-derived ceramics and AM techniques has drawn significant attention, as it overcomes the limitations and challenges of conventional fabrication approaches. This review discusses the current research that used AM technologies to fabricate ceramic articles from preceramic feedstock materials, and it demonstrates that AM processes are effective and versatile approaches for fabricating ceramic components. The future of producing ceramics using preceramic feedstock materials for AM processes is also discussed at the end.

SiCNFe Ceramics as Soft Magnetic Material for MEMS Magnetic Devices: A Mössbauer Study

Polymer-derived SiCNFe ceramics is a prospective material that can be used as soft magnets in MEMS magnetic applications. The optimal synthesis process and low-cost appropriate microfabrication should be developed for best result. Homogeneous and uniform magnetic material is required for developing such MEMS devices. Therefore, the knowledge of exact composition of SiCNFe ceramics is very important for the microfabrication of magnetic MEMS devices. The Mössbauer spectrum of SiCN ceramics, doped with Fe (III) ions, and annealed at 1100 °C, was investigated at room temperature to accurately establish the phase composition of Fe-containing magnetic nanoparticles, which were formed in this material at pyrolysis and which determine their magnetic properties. The analysis of Mössbauer data shows the formation of several Fe-containing magnetic nanoparticles in SiCN/Fe ceramics, such as α-Fe, Fe_xSi_yC_z, traces of Fe-N and paramagnetic Fe³⁺ with octahedral oxygen environment. The presence of iron nitride and paramagnetic Fe³⁺ ions shows that the pyrolysis process was not completed in SiCNFe ceramics annealed at 1100 °C. These new observations confirm the formation of different Fe-containing nanoparticles with complex composition in SiCNFe ceramic composite.

Recent advances in precursor-derived ceramics integrated with two-dimensional materials

This review focused on the recent advances in precursor-derived ceramics integrated with two-dimensional materials. Their fabrication methods, structures and applications were discussed in detail and the perspectives in this field were presented.

Polymer-Derived Lightweight SiBCN Ceramic Nanofibers with High Microwave Absorption Performance

Lightweight SiBCN ceramic nanofibers were prepared by a combination of electrostatic spinning and high-temperature annealing techniques, showing tunable electromagnetic wave absorption. By controlling the annealing temperature, the nanoscale architectures and atomic bonding structures of as-prepared nanofibers could be well regulated. The resulting SiBCN nanofibers ∼300 nm in diameter, which were composed of an amorphous matrix, β-SiC, and free carbon nanocrystals, were defect-free after annealing at 1600 °C. SiBCN nanofibers annealed at 1600 °C exhibited good microwave absorption, obtaining a minimum reflection coefficient of -56.9 dB at 10.56 GHz, a sample thickness of 2.6 mm with a maximum effective absorption bandwidth of 3.45 GHz, and a maximum dielectric constant of 0.44. Owing to the optimized A + B + C microstructure, SiBCN ceramic nanofibers with satisfying microwave absorption properties endowed the nanofibers with the potential to be used as lightweight, ultrastrong radar wave absorbers applied in military and the commercial market.

Fabrication of (SiC-AlN)/ZrB2 Composite with Nano-Micron Hybrid Microstructure via PCS-Derived Ceramics Route

In this work, a (SiC-AlN)/ZrB₂ composite with outstanding mechanical properties was prepared by using polymer-derived ceramics (PDCs) and hot-pressing technique. Flexural strength reached up to 460 ± 41 MPa, while AlN and ZrB₂ contents were 10 wt%, and 15 wt%, respectively, under a hot-pressing temperature of 2000 °C. XRD pattern-evidenced SiC generated by pyrolysis of polycarbosilane (PCS) was mainly composed by 2H-SiC and 4H-SiC, both belonging to α-SiC. Micron-level ZrB₂ secondary phase was observed inside the (SiC-AlN)/ZrB₂ composite, while the mean grain size (MGS) of SiC-AlN matrix was approximately 97 nm. This unique nano-micron hybrid microstructure enhanced the mechanical properties. The present investigation provided a feasible tactic for strengthening ceramics from PDCs raw materials.