The influence of different carbon sources in the carbothermal reduction and nitridation (CRN) synthesis of SiAlON from nanocomposite precursors based on Al–SBA-15

Abstract

Abstract Nanocomposites of Al–SBA-15 with the organic polymers poly-4-vinyl pyridine (P4VP) and polyacrylamide (PAM) were synthesized to produce SiAlON precursors containing various carbon contents. These CRN precursors, and their products after firing under N 2 at 1450 °C for 3 h were investigated by XRD, SEM/EDS and surface area analysis (BET) to compare the influence of the organic polymer carbon source. The results were also compared with those from precursors containing carbon black as the carbon source. XRD and SEM/EDS analysis of the Al–SBA-15 confirmed the formation of mesoporous structures, while BET and pore size distribution measurements indicated that the entry of P4VP into the Al–SBA-15 nanocomposite precursor is significantly more efficient than that of PAM. Firing these precursors in nitrogen produced β-SiAlON and β-cristobalite. At all carbon concentrations the P4VP nanocomposite precursors formed significantly more SiAlON than those of the PAM and carbon black precursors, due to the proximity of a greater amount of the organic carbon source to the silica template in the P4VP composite, and possibly also to the lack of oxygen in the P4VP monomer, in contrast with PAM. At least twice the stoichiometric amount of carbon was required in all cases, with optimal SiAlON formation occurring in the P4VP precursor containing 6 times the stoichiometric amount of carbon. Increasing the carbon content further suppresses SiAlON formation, possibly due to the build-up of back pressure of CO by-products in the pores of the nanocomposite.