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Research Article | Open Access

Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration

Xiao Chena,b, Jie Yina,b( ), Longzhi Huanga,b, Sea-Hoon Leec, Xuejian Liua,b( ), Zhengren Huanga( )
State Key Lab of High Performance Ceramics and Superfine Microstructures, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
College of Materials Science and Opto-Electronic Technology, University of Chinese Academy of Sciences, Beijing 100049, China
Extreme Materials Institute, Korea Institute of Materials Science, Changwon 51508, Republic of Korea
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Graphical Abstract

Abstract

Poor flowability of printable powders and long preparation cycles are the main challenges in the selective laser sintering (SLS) of chopped carbon fiber (Cf) reinforced silicon carbide (SiC) composites with complex structures. In this study, we develop an efficient and novel processing route in the fabrication of lightweight SiC composites via the SLS of phenolic resin (PR) and Cf powders with the addition of α-SiC particles combined with the one-step reactive melt infiltration (RMI). The effects of α-SiC addition on the microstructural evolution of the Cf/SiC/PR printed bodies, Cf/SiC/C green bodies, and derived SiC composites were investigated. The results indicate that the added α-SiC particles play an important role in enhancing the flowability of raw powders, reducing the porosity, increasing the reliability of the Cf/SiC/C green bodies, and contributing to improving the microstructure homogeneity and mechanical properties of the SiC composites. The maximum density, flexural strength, and fracture toughness (KIC) of the SiC composites are 2.749±0.006 g·cm−3, 266±5 MPa, and 3.30±0.06 MPa·m1/2, respectively. The coefficient of thermal expansion (CTE, α) of the SiC composites is approximately 4.29×10−6 K−1 from room temperature (RT) to 900 ℃, and the thermal conductivity (κ) is in the range of 80.15–92.48 W·m−1·K−1 at RT. The high-temperature strength of the SiC composites increase to 287±18 MPa up to 1200 ℃. This study provides a novel as well as feasible tactic for the preparation of high-quality printable powders as well as lightweight, high-strength, and high–κ SiC composites with complex structures by the SLS and RMI.

Keywords

chopped carbon fiber (Cf)microstructural tailoringselective laser sintering (SLS)mechanical propertiesthermal properties

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Journal of Advanced Ceramics
Volume 12 Issue 4,
April 2023
Pages 830-847
DOI: 10.26599/JAC.2023.9220724
Cite this article:
Chen X, Yin J, Huang L, et al. Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration. Journal of Advanced Ceramics, 2023, 12(4): 830-847. https://doi.org/10.26599/JAC.2023.9220724

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Received: 22 October 2022
Revised: 17 January 2023
Accepted: 19 January 2023
Published: 14 March 2023
© The Author(s) 2023.

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