Processing of Polymer-Derived Microcellular Ceramics Containing Reactive Fillers

Processing techniques for producing microcellular silicon carbide, mullite, and cordierite ceramics with cell densities greater than 108 cells/cm3 and cells smaller than 30 μm have been developed by a reaction method that incorporates a polysiloxane and reactive fillers. The techniques developed in this study offer substantial flexibility for producing microcellular ceramics whereby cell size, cell density, degree of interconnectivity, composition, and porosity can all be effectively controlled. It is demonstrated that the adjustment of filler composition enables the possibility of tailoring the composition and properties of the microcellular ceramics. The present results suggest that the proposed novel processing techniques are suitable for the manufacture of microcellular ceramics with high morphological uniformity.