In situ synthesis of three‐dimensional nanofiber‐knitted ceramic foams via reactive sintering silicon foams

Abstract

AbstractThree‐dimensional ceramic nanofiber‐assembled materials with large specific surface area and excellent thermal insulation properties are attracting increasing interests for their unique structure and promising applications. In this paper, we propose a facile methodology to fabricate three‐dimensional silicon nitride nanofiber‐knitted ceramic foams via in situ reactive synthesis from silicon foams. Silicon particle‐stabilized foams are fabricated for the first time using long‐chain surfactant cetyltrimethyl ammonium bromide as a hydrophobic modifier. First, the fabrication and stability of silicon foams are investigated. Based on the stable silicon foams, silicon nitride‐based nanofiber‐knitted ceramic foams are synthesized via in situ reactive sintering in nitrogen atmosphere. The novel ceramic foam materials consist of three‐dimensional nanofiber‐assembled strut wall and nanofiber‐spheres in the pores. The diameter of obtained silicon nitride nanofibers ranges from 15 to 100 nm. The unique nanofiber‐knitted foams may have potential applications in specific fields, including catalysis, adsorption, separation, and thermal insulation.