Abstract
Abstract In this study, a newly designed fabrication procedure was utilized to produce silicon nitride foams. The main goal of the present study was to obtain Si 3 N 4 foams with high levels of porosity and pore interconnectivity via an economical fabrication procedure including sacrificial template technique, gel-casting and reaction bonding processes. The fabrication procedure was studied and optimized in terms of suspension preparation and rheology, gel-casting parameters, and reaction bonding conditions. The produced foams have a precisely controlled level of porosity which can be varied up to 87 vol%. BET analysis showed that the surface area of the foam is of the order of 2.01 m 2 /g. The pore interconnectivity of the foam was investigated via polyester resin infiltration. Based on XRD and SEM analysis, the dominant nitriding reactions are the gas-phase reactions which lead to α-Si 3 N 4 in the form of whiskers.
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