Abstract
Highly porous Si3N4 ceramics were prepared by aqueous gelcasting using Si3N4 poly-hollow microspheres as pore-forming agent and the effect of calcining temperature of Si3N4 poly-hollow microspheres on their properties was investigated. With the increase of the calcining temperature, the surfaces of the Si3N4 poly-hollow microspheres become coarser and coarser due to more rod-like β-Si3N4 grains appearing on their surfaces. Only the β-Si3N4 phase is observed in the porous Si3N4 ceramics regardless of the calcining temperature. The Si3N4 poly-hollow microspheres distribute uniformly in the Si3N4 green samples and porous Si3N4 ceramics, and they contact with each other, which could restrict the shrinkage, warpage and cracking of the final material. With the increase of the calcining temperature, the porosity of the porous Si3N4 ceramics increases, while shrinkage, flexural strength and fracture toughness decrease.
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