One-step Sintering Research Articles

In-Situ Constructing N,S-Codoped Carbon Heterointerface for High-Rate Cathode of Sodium-Ion Batteries.

Na3V2(PO4)3 (NVP) is considered one of the promising choices for cathodes of sodium-ion batteries, but the poor conductivity resulted inferior rate performance limited the practical development of NVP cathodes. In this study, we successfully synthesized N/S dual-atom doped carbon coatings in situ through a simple one-step solid-state sintering method. The uniformly coated carbon layer can inhibit the agglomeration and growth of active materials during the sintering process, shorten the Na+ migration path, and increase the contact area with the electrolyte, thus facilitating rapid Na+ migration. Notably, the doping of N elements can alter the electron distribution of carbon coating, enhancing electron conductivity. Furthermore, the introduction of S elements in the carbon layer can induce the formation of stable C-S-C bonds in the molecular layer, expanding the interlayer spacing, which is beneficial for Na+ transport and storage. Therefore, the modified NVP@NSC composite provides a high specific capacity of 90.3 mAh g-1 at a rate of 20 C, with a capacity retention rate of 94.4% after 8000 cycles, demonstrating excellent stability at high current densities. Moreover, the full cell exhibits remarkable electrochemical performance at 5 C. This research contributes to the practical development of NVP cathodes.

Carbon Dots Prepared by One-step Sintering Method and their Application for pH Detection

Introduction: In recent years carbon dots (CDs) have attracted researchers due to their unique physicochemical and fluorescent (FL) features, which can be applied in many fields such as battery materials, fluorescence sensing, display, biological imaging and photocatalysis. Method: We prepared CDs by using a facile one-step sintering method. The fluorescent properties and the application of pH detection were measured and analyzed. Results: The results show that CDs emit bright purplish-blue light centred at 425 nm excited by 355 nm UV light. FL intensity shows a linear relationship with pH values at 1~4 and 7~11, respectively. The reasonable mechanism of the tested effective pH sensitivity is discussed. Conclusion: Our study shows that the CDs prepared by the one-step sintering method have great potential to be used as pH sensors for physiochemical measurements.

Enhanced Critical Current Density in the Garnet Oxide Electrolyte by a Silver Interlayer.

Ta-doped Li6.4La3Zr1.4Ta0.6O12 (LLZTO) for solid-state lithium batteries demonstrates encouraging performance; however, they encounter issues with lithium dendrite formation that impede their widespread use. Herein, we design a LLZTO ceramic with an interlayer containing a mixed dense layer of Ag and LLZTO, prepared by one-step sintering. The Ag-rich interlayer in LLZTO can hinder the growth and the penetration of lithium dendrites though the reaction between Ag and lithium metal. Compared with the Ag-free counterpart, a higher critical current density of 0.6 mA cm-2, in addition to a longer life span under a current density of 0.2 mA cm-2, is achieved by adopting the interlayer in LLZTO. This research offers novel insights into the engineering of garnet-based solid electrolytes, tailored for the advancement of high-rate lithium metal batteries.

Mechanical and electrical properties of α-MoO3 belts under strain for flexible electronics applications

This study investigated a straightforward and cost-effective method for synthesizing α-MoO3 belts and evaluated their potential as substrates for flexible electronic devices. Transparent α-MoO3 belts, featuring millimeter-scale side lengths and micrometer-scale thicknesses, were produced through a one-step sintering process using metallic molybdenum powder. When affixed to stretchable substrates, the α-MoO3 belts demonstrated robust mechanical stability under continuous and sustained tensile strain in the longitudinal direction. The belts exhibited a transmittance exceeding 68 % in the visible and near-infrared light regions. The current between gold dots on belts fixed to a stretchable polydimethylsiloxane substrate increased with the application of tensile strain. Furthermore, a CoFe2O4 thin film deposited at elevated temperature onto an α-MoO3 belt exhibited significant magnetic anisotropy. These findings introduce a novel and efficient approach for fabricating highly crystalline thin films on stretchable and bendable substrates using α-MoO3 belts.

The network structure and properties of a unique mining solid waste-based glass-ceramics

To alleviate the environmental pollution caused by the stockpile of mining-based, such as coal-based solid waste, mining solid waste-based CaO-MgO-Al2O3-SiO2 (CMAS) glass-ceramics with a diopside phase as the main crystalline phase was developed by one-step sintering method, and the effect of different solid waste content on the network structure and properties were investigated. The results show that, with the diversification of solid waste content, the crystallization temperature (Tp), the amount of Fe3+ concentration, and diopside crystalline, the main structure of glass Q2 changed also. Accordingly, significant changes have occurred in properties such as the bending strength, Vickers hardness, and density. Optimizing the raw material ratio, crystallization mechanism, a mining solid waste-based glass-ceramic with unique network structure is well developed and the bending strength, Vickers hardness, fracture toughness, and density reaches maximum values of 175.19 MPa, 10.47 GPa, 2.03 MPa⋅m1/2, and 3.00 g/cm3, respectively. The findings contribute significantly to the development of durable and reliable materials for the utilization of mining solid waste resources.

Fabrication and application of highly permeable ceramic membranes: Membrane-forming mechanism, pore structure, separation performance and fouling mechanism analyses

High separation efficiency and satisfactory economic benefits are of great importance for ceramic membranes in the field of water treatment. Herein, microfiltration ceramic membrane with high permeability and selectivity was prepared in one-step (dip-coating and sintering) by sacrificial-interlayer method. The membrane-forming mechanism, effect of temperature on the morphology and pore structure, separation performance, fouling mechanism, and regeneration performance of the ceramic membranes were systematically investigated. The results show that membrane-forming mechanism of the membranes largely depends on film-coating filtration. The membrane with a mixture of nanocellulose crystals and graphene oxide as sacrificial interlayer (C1G1) and sintered at 1100–1300 °C possessed smooth surface. The open porosity and average pore size increased, and the pore size distribution became broader as the temperature increased. Moreover, the sacrificial-interlayer membrane sintered at 1300 °C (mA4S-C1G1) possessed suitable porosity (53.4%) and average pore size (200 nm), high permeance (4828 L·m−2·h−1·bar−1), which was larger than that of the membrane without sacrificial interlayer, manifesting that C1G1 could prevent the penetration of membrane-forming particles into support. The final fouling mechanism of mA4S-C1G1 was cake filtration, although complete pore blocking, standard pore blocking, intermediate pore blocking also involved in the initial stage. In addition, the oil rejection rate (∼97%) and steady-state feed flux (810–1154 L·m−2·h−1) of mA4S-C1G1 was high, and it also possessed good regeneration performance.

A general methodology for the in situ construction of MxSy@N,S-C composites from L-cysteine for sodium-ion battery applications

High-capacity metal sulfides have been extensively investigated as cathode materials for secondary batteries. Despite their high capacity, the redox potential of metal sulfides is limited to 2.7 V. Therefore, researchers explored its application as a negative electrode material and discovered its exceptional electrochemical performance. However, the conventional methods for synthesizing transition metal sulfides (TMS) inevitably require an external source of sulfur for secondary sulfidation, resulting in energy dissipation. In this study, L-cystine was adopted as a polydentate ligand for the synthesis of MxSy@N, SC metal-organic frameworks, which can confine the desired carbon, nitrogen, and sulfur sources within the framework. This approach facilitates one-step sintering to obtain nitrogen-doped transition metal sulfides. The structure composition and electrochemical reaction mechanism of FeS@N,S-C as the negative electrode in Na-ion batteries were studied through scanning electron microscopy (SEM)/transmission electron microscopy (TEM) and X-ray diffraction (XRD)/X-ray photoelectron spectroscopy (XPS) analysis. The electrochemical properties of FeS@N,S-C materials were test as an example. The FeS@N, SC composite exhibited a reversible Na+ storage capacity of 724.4 mAh g−1 at a current density of 200 mA g−1, and still maintained a reversible capacity of 600.7 mAh g−1 at a current density of 2000 mA g−1, demonstrating excellent rate performance. After 200 cycles, the material was still able to retain 97.3 % of the discharge specific capacity, demonstrating fine cycle performance. It shows that the FeS@N, SC composite has rapid electron conduction ability and high sodium ion diffusion coefficient. At the same time, a rapidly charge-discharge process can be achieved with a large capacitive contribution, indicating the great potential of this material as a sodium-ion battery.

High depolarization temperature and low dielectric loss in high-temperature fine-grain composite piezoceramics

High depolarization temperature (Td) and low dielectric loss (tanδ) were obtained in Sc2O3/BiScO3-PbTiO3-Bi(Zn1/2Hf1/2)O3 (Sc2O3/BS-PT-BZH) high-temperature fine-grained composite piezoceramics prepared by high-energy ball milling and one-step pressureless sintering. The heterogeneous interfacial polarization effect and thermal stress between the Sc2O3 semiconductor secondary phase and the BS-PT-BZH perovskite piezoelectric matrix phase contribute to the polarization orientation of the ferroelectric domain in the electric field and the maintenance of the poled ferroelectric domain state under temperature excitation, respectively. Benefiting from the above two heterogeneous interfacial effects, the Sc2O3/BS-PT-BZH fine-grained (∼0.4 μm) ceramic exhibits a high Td of 349 °C, a low tanδ of 5.1 % and a moderate piezoelectric constant d33 of 495 pC/N, which are comparable to those of many BS-PT-based coarse-grained (>2 μm) ceramics. The advent of Sc2O3/BS-PT-BZH fine-grained piezoceramic is helpful to promote the development of high-performance miniaturized high-temperature piezoelectric devices.

Temperature dependences of phase composition, densification, and thermal/chemical stability of Sr0.5Zr2(PO4)3-Nd0.5Sm0.5PO4 composite ceramics for nuclear waste form

A kind of Sr0.5Zr2(PO4)3-Nd0.5Sm0.5PO4 (hereinafter SrZP-Nd0.5Sm0.5PO4) composite ceramics was prepared through a one-step microwave sintering technique, where Sr, Nd, Sm were simulated for fission products and minor actinides (MA). The crystal structure and morphology of constituent phases were systematically characterized by XRD, TEM, and SEM techniques. The temperature dependent phase analysis results of SrZP-Nd0.5Sm0.5PO4 composite ceramics illustrate that with evaluating temperature monazite structure formed primarily, and the SrZP phase formed subsequently. With the temperature rising further, the monazite phase finally transformed into Nd0.5Sm0.5PO4 monazite solid solution. XRD refinement and TEM measurements are used to verify the crystal structures of the as-prepared SrZP and Nd0.5Sm0.5PO4 phases in the composite ceramics. The dependence of densification behaviors on temperature shows that the distinct densification of the SrZP-Nd0.5Sm0.5PO4 composite ceramics occurs in the temperature range of 950 °C to 1000 °C, and the relative density reaches 97.7 % at 1050 °C. TG-DSC tests show that the SrZP-Nd0.5Sm0.5PO4 composite ceramics exhibit excellent thermal stability at high temperatures. And SrZP-Nd0.5Sm0.5PO4 composite ceramics possess outstanding chemical stability, whose normalized leaching rate of Sr, Nd, and Sm is 10−4 g·m−2·d−1, 10−7 g·m−2·d−1, and 10−7 g·m−2·d−1 order of magnitude, respectively.

Highly wear resistant metal bond for diamond tool based on two-step reactive sintered Fe3Al

Metal bond diamond tools are regularly used in the machining of various hard and brittle materials. The mechanical properties and wear resistance of the metal bond are very important for the tool's life and machining performance. Herein, a low-cost and highly wear resistant Fe3Al bonded material for diamond tool was proposed. A novel two-step reactive sintering method, integrating short-term high-temperature reactive sintering and long-term low-temperature densification sintering, was proposed to prepare Fe3Al bond diamond tools. The effect of sintering temperature on the microstructure and mechanical properties of the Fe3Al bond was examined during one-step reactive sintering. The mechanical properties and tribological characteristics of the one-step and two-step reactive sintered Fe3Al and commercial Fe alloy bond were compared. The machining performance of the two-step reactive sintered Fe3Al bond diamond tool on sapphire was also examined and compared to that of a commercial Fe alloy bond diamond tool. The results showed that the relative density and mechanical properties of the Fe3Al bonded material were enhanced by increasing the sintering temperature during one-step reactive sintering. Moreover, the sample sintered at 1150-850 °C exhibited better mechanical properties and wear resistance compared to the one-step reactive sintered Fe3Al and commercial bond. The grinding ratio of the two-step reactive sintered Fe3Al bond diamond tool was 157 % higher than that of the commercial Fe alloy bond diamond tool.

A novel coaxial heat pipe with an inner vapor tube for cooling high power electronic devices

Improving heat transfer limit of heat pipe is important for their application in high-power equipment system. Shear stress at the liquid–vapor interface affects the heat transfer capacity of heat pipe. In this study, a novel coaxial heat pipe is designed to eliminate vapor entrainment from interfacial shear stress for the first time. An inner thin-walled tube is sintered with the powder wick in the adiabatic section by one-step sintering process. The effects of filling ratio and powder size of sintered wick on the thermal performance of coaxial heat pipe are investigated experimentally. The results indicate that the optimal powder size range for the sintered wick of coaxial heat pipe is 106–125 μm, while the optimal filling ratio is about 125 %. It means that the sintered wick with 106–125 μm powder can achieve better trade-off between capillary performance and permeability. The coaxial heat pipe can operate at heat loads of 70 ∼ 140 W with the total thermal resistance less than 0.06 °C /W. Moreover, compared with the normal heat pipe, the heat transfer capacity of coaxial heat pipe is increased by 57 %, while the evaporation temperature is decreased by 9.6 ∼ 19.1 °C and the total thermal resistance is decreased by 41 %∼320 %. The inner tube can improve the replenishment efficiency of working liquid by eliminating interfacial shear stress, resulting in the significant heat transfer improvement. The design of coaxial heat pipe is an effective and low-cost solution to improve the thermal performance of heat pipe.

Crystal Structure, Infrared Reflection Spectrum, and Improved Microwave Dielectric Characteristics of Ba4Sm28/3Ti18O54 Ceramics via One-Step Reaction Sintering.

High-k Ba4Sm28/3Ti18O54 ceramics with improved microwave dielectric characteristics were successfully fabricated using the one-step reaction sintering (RS) route. The sintering characteristics, microstructure, crystal structure, infrared reflection spectrum, and microwave dielectric characteristics of Ba4Sm28/3Ti18O54 ceramics prepared by the RS route were systematically investigated. Samples prepared by the RS route exhibited single-phase orthorhombic tungsten-bronze structure and dense microstructure at optimum sintering temperature. Compared with the conventional solid-state (CS) process, the Ba4Sm28/3Ti18O54 ceramics fabricated by the RS route presented a smaller temperature coefficient (TCF), a higher quality factor (Q × f), and a higher permittivity (εr). The improved microwave dielectric characteristics were highly dependent on the theoretical permittivity, atomic packing fraction, suppression of Ti3+, and Ti-site bond valence. Excellent combined microwave dielectric characteristics (TCF = -7.9 ppm/°C, Q × f = 9519 GHz, εr = 80.26) were achieved for Ba4Sm28/3Ti18O54 ceramics prepared by RS route sintered at 1400 °C, suggesting the RS route was a straightforward, economical and effective route to prepare high-performance Ba4Sm28/3Ti18O54 ceramics with promising application potential.

A Highly Selective Acetone Sensor Based on Coal-Based Carbon/MoO2 Nanohybrid Material.

High temperature represents a critical constraint in the development of gas sensors. Therefore, investigating gas sensors operating at room temperature holds significant practical importance. In this study, coal-based porous carbon (C-700) and coal-based C/MoO2 nanohybrid materials were synthesized using a simple one-step vapor deposition and sintering method, and their gas-sensing performance was investigated. The gas-sensing performance for several VOC gases (phenol, ethyl acetate, ethanol, acetone, triethylamine, and toluene) and a 95% RH high-humidity environment were tested. The results indicated that the C/MoO2-450 sample sintered at 450 °C exhibited excellent specific selectivity towards acetone at room temperature, with a response value of 4153.09% and response/recovery times of 10.8 s and 2.9 s, respectively. Furthermore, the C/MoO2-450 sample also demonstrated good repeatability and long-term stability. The sensing mechanism of the synthesized materials was also explored. The superior gas-sensing performance can be attributed to the synergistic effect between the porous carbon and MoO2 nanoparticles. Given the importance of enhancing the high-tech and high-value-added utilization of coal, this study provides a viable approach for utilizing coal-based carbon materials in detecting volatile organic compounds at room temperature.

Distinguishing the effects of lattice Gd3+ and segregated Gd3+ on optical properties of Yb:GdYAG transparent ceramics

Whether adding Gd3+ in Yb:GdYAG broadens absorption and emission peaks for better laser performance is recently under debate. By preparing (Yb0.05Y0.95-xGdx)3Al5O12 (x = 0.2, 0.6, 1, 5, 10, 20 at%) transparent ceramics with one-step solid-state reactive sintering under vacuum, we report a non-monotonic relation between increasing Gd3+ content and micro-structure/properties. Specifically, the grain size decreases till x = 10 at%, but increases at 20 at% with secondary phases formed at grain boundaries by segregated Gd3+. The optimal optical properties are achieved at 10 at%. The in-line transmittance reaches 83.9 % at 1100 nm. Absorption and emission cross-sections are significantly broadened (8.0 × 10−21 cm2 at 940 nm and 26.7 × 10−21 cm2 at 1030 nm, respectively). The FWHM of main emission peak at 1030 nm receives a ∼60 % extension to 15.2±0.4 nm. It indicates lattice Gd3+ broadens peak widths and improves transparency, while segregated Gd3+ diminishes peak broadening and adversely affects transparency.

Functionally graded La0.6Sr0.4Co0.2Fe0.8O3−δ hollow fiber membrane for oxygen separation: fabrication, upscaling, and stability

La0.6Sr0.4Co0.2Fe0.8O3−δ (LSCF) hollow fiber membranes are usually fabricated through slurry spinning process followed by one-step sintering. While high oxygen permeation performance can be obtained, the designs lack sufficient mechanical strength, limiting further upscaling for stack and module development. This research studies a functionally graded hollow fiber LSCF membrane with a three-layer structure, i.e., thick LSCF-ZnO substrate/dense thin film LSCF/porous, thin LSCF catalyst layer. The thick substrate provides sufficient mechanical strength to support the membrane while facilitating facile gas diffusion with embedded open microchannels. The dense thin film LSCF separation layer decreases bulk diffusion resistance. The porous thin LSCF catalyst layer increases the reaction area for surface exchange process. The synergetic combination of the three layers enables to improve both mechanical strength and permeation performance. A stack with three parallelly-connected hollow fibers is assembled to demonstrate its potential capability for upscaling. Permeation performance is systematically measured and accelerated long-term stability is conducted for both the single membrane and the stack. The single membrane and the stack obtain oxygen permeation flux of ∼1.9 and 1.1 ml⋅cm−2⋅min−1 at 900 °C, respectively, and demonstrate excellent stability and robustness during a long-term test of ∼400 h and ∼20 thermal cycles between 600 and 900 °C. Membrane samples are characterized before and after the test. Experimental data are analyzed, and fundamental mechanisms are discussed.

Exploring microfine magnesite based on thermal decomposition and sintering kinetics: A new direction in the one-step preparation of high-density sintered magnesia

The thermal decomposition and sintering kinetics of microfine magnesite were investigated to inaugurate a new One-step process for preparing high-density sintered magnesia. The optimal parameters for the discharging particle size of magnesite through ball milling were determined using an orthogonal experiment and Three-Way Measures ANOVA. The model for the thermal decomposition process of microfine magnesite was established through TGA-DSC and nonlinear regression analysis. Meanwhile, by describing the sintering process of microfine magnesite in detail through microstructure and CTE, the kinetic mechanisms of grain growth at different sintering stages were obtained. The results revealed that increasing the ratio of ball to powder can quickly obtain microfine magnesite which the bulk density reaches 3.45 g·cm−3 after One-step sintering. The thermal decomposition process required an activation energy of only 124.98 kJ·mol−1, which is much lower than existing technology and followed the Two-dimensional phase boundary reaction mechanism R2. Additionally, the densification process was dominated alternatively by grain boundary diffusion and volume diffusion. This paper provided a detailed theoretical basis and leads a new direction in the One-step preparation of high-density sintered magnesia.

The preparation and performances of Co-Zn 18H hexagonal ferrite with an ultra-high magnetic resonance frequency and low-loss characteristics

Modern 5G communication technologies require evolution of antennas towards high frequency and miniaturization. The search for magneto-dielectric materials with simultaneous high permeability, matched dielectric constant, and low loss properties for sub-6 GHz band applications has received considerable attention from both academic and industrial circles. Due to the low magnetic resonance frequency and high magnetic loss, traditional spinel and hexagonal ferrites hardly meet these requirements. In this study, polycrystalline Co-Zn 18H ferrites (Ba5Co2-xZnxTi3Fe12O31) were synthesized by co-precipitation method with only one-step sintering process. The polycrystalline Co-Zn 18H hexagonal ferrite possesses an ultra-high natural resonance frequency (14.5 GHz) and low magnetic loss (tanδμ≤0⊡10), which provides a better performance factor (PF= 68.6 GHz) at a higher operating frequency (4.97 GHz) compared to traditional microwave ferrites. The miniaturization rate of the planar inverted F antenna (PIFA) with Co-Zn 18H ferrite working at 4.0 GHz reaches 13.3 %. These results demonstrate the high potential of Co-Zn 18H ferrites for high frequency and low loss applications.

One-step Solid-State Synthesis of V1.13Se2/V2O3 Heterostructure as a High Pseudocapacitance Anode for Fast-Charging Sodium-Ion Batteries.

Sodium-ion batteries (SIBs) offer several benefits, including cost-efficiency and fast-charging characteristics, positioning them as attractive substitutes for lithium-ion batteries in energy storage applications. However, the inferior capacity and cycling stability of electrodes in SIBs necessitate further enhancement due to sluggish reaction kinetics. In this respect, the utilization of heterostructures, which can provide an inherent electric field and abundant active sites on the surface, has emerged as a promising strategy for augmenting the cycling stability and rate features of the electrodes. This work delves into the utilization of V1.13Se2/V2O3 heterostructure materials as anodes, initially fabricated via a simplified one-step solid-state sintering technique. The high pseudocapacitance and low characteristic relaxation time constant give the V1.13Se2/V2O3 heterostructure impressive properties, such as a high capacity of 328.5 mAh g-1 even after 1500 cycles at a high current density of 2 A g-1 and rate capability of 278.9 mAh g-1 at 5 A g-1. Moreover, the assembled sodium-ion full battery delivers a capacity of 118.5 mAh g-1 after 1000 cycles at 1 A g-1. These findings provide novel insight and guidance for the rapid synthesis of heterojunction materials and the advancement of SIBs.

Two-stage repeat sintering: A modified method for fabricating hydroxyapatite scaffolds with enhanced mechano-therapeutic properties

A modified two-stage repeat sintering (TSRS) technique has been used to produce hydroxyapatite (HAp) from non-separated animal bones, and the energy consumption per cycle of the proposed TSRS was calculated. The TSRS technique was compared to the conventional one-step sintering method. The energy consumption per cycle of the proposed TSRS was calculated considering economies of scale and typical energy consumption billing in Nigeria. The synthesized powders from both techniques underwent comprehensive characterization through X-ray diffraction (XRD), Fourier transform infrared (FT-IR), and scanning electron microscopy (SEM). The XRD analysis revealed the main reflections of HAp in the (112), (300), and (202) planes. The FT-IR spectra exhibited characteristic bands representative of HAp at all measurement points. Notably, the TSRS-derived sample during the second sintering step showed carbonate bands, suggesting relevance in the bone structure makeup. SEM images unveiled varying crystal morphologies, ranging from irregular shapes in the raw bone (RB) sample to rounded shapes with nucleation in aggregates and agglomerates at micro and macro levels in the TSRS-derived samples. The samples obtained from the TSRS technique demonstrated a high Ca/P ratio that is potentially beneficial for osteoblast adhesion in vivo. The cost analysis of electricity consumption per TSRS cycle, factoring in economies of scale and typical energy consumption billing in Nigeria, amounted to approximately $8 with consideration of the exchange rates at the time of the study. The microhardness measured using the TSRS technique was 0.5 GPa with a 1 MPa compaction pressure, while the samples prepared using the conventional sintering method were too fragile to handle and measure. The obtained microhardness using the modified technique surpassed values reported in various studies. In conclusion, the samples produced using the TSRS technique exhibited promising results regarding energy efficiency, material characteristics, and microhardness compared to the samples produced through conventional sintering. The distinct crystal morphologies observed suggest potential advantages for biomedical applications, particularly in enhancing osteoblast adhesion.

Microstructure, Mechanical Property and Thermal Conductivity of Porous TiCO Ceramic Fabricated by In Situ Carbothermal Reduction of Phenolic Resin and Titania.

The porous TiCO ceramic was synthesized through a one-step sintering method, utilizing phenolic resin, TiO2 powder, and KCl foaming agent as raw materials. Ni(NO3)2·6H2O was incorporated as a catalyst to facilitate the carbothermal reaction between the pyrolytic carbon and TiO2 powder. The influence of Ni(NO3)2·6H2O catalyst content (0, 5, 10 wt.% of the TiO2 powder) on the microstructure, compressive strength, and thermal conductivity of the resultant porous TiCO ceramic was examined. X-ray diffraction and X-ray photoelectron spectroscopy results confirmed the formation of TiC and TiO in all samples, with an increase in the peak of TiC and a decrease in that of TiO as the Ni(NO3)2·6H2O content increased from 0% to 10%. Scanning electron microscopy results demonstrated a morphological change in the pore wall, transforming from a honeycomb-like porous structure composed of well-dispersed carbon and TiC-TiO particles to rod-shaped TiC whiskers, interconnected with each other as the catalyst content increased from 0% to 10%. Mercury intrusion porosimetry results proved a dual modal pore-size distribution of the samples, comprising nano-scale pores and micro-scale pores. The micro-scale pore size of the samples minorly changed, while the nano-scale pore size escalated from 52 nm to 138 nm as the catalyst content increased from 0 to 10%. The morphology of the pore wall and nano-scale pore size primarily influenced the compressive strength and thermal conductivity of the samples by affecting the load-bearing capability and solid heat-transfer conduction path, respectively.