Abstract
Mechanical and thermal properties of SiC-porcelain ceramics were studied in the wide SiC content range of 0-95%. Microstructure evolution, shrinkage at sintering, porosity, mechanical strength, elastic modulus, coefficient of thermal expansion (CTE) and thermal conductivity were studied depending on SiC content. The optimal sintering temperature was 1200 ℃, and the maximum mechanical strength corresponded to SiC content of 90%. Parametric evaluation of the ceramic thermal shock resistance revealed its great potential for thermal cycling applications. It was demonstrated that the open-cell foam catalyst supports can be manufactured from SiC-porcelain ceramics by the polyurethane foam replication process.
Highlights
Efficiency of catalytic process with strong heat flux is strongly dependent on the catalyst thermal conductivity
The sintering regimes of SiC–porcelain ceramics are pre-defined by interactions that occur at temperatures of above 1000 °C; major interactions and the accompanying microstructure changes in this system were described before in Refs. [21,22,23]
Different authors who studied SiC interaction with the alkali silicate melt sintering aids stated rather close optimal sintering temperatures; some non-principal deviations can be referred to differences in the sintering aid compositions and different targeted SiC content ranges in the ceramics
Summary
Efficiency of catalytic process with strong heat flux (e.g., hydrocarbon steam reforming) is strongly dependent on the catalyst thermal conductivity. Low robustness of metallic catalyst supports due to corrosive degradation in the reaction media (600–900 °C, water vapor, decomposition products of hydrocarbon, aggressive admixtures) limits their practical application [1,4] This problem does not arise when the catalyst supports are made from various oxide ceramics exhibiting excellent corrosive resistance [5,6,7]. If a reasonable combination of mechanical and thermal properties can be attained, this type of ceramics can have a great commercial potential as the material for monolithic catalyst supports: its low manufacturing cost is predetermined by cheap initial materials and low sintering temperature without special protective atmosphere. It was demonstrated that open-cell ceramic foam catalyst supports can be manufactured from this type of ceramics by the polyurethane foam replication process
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