SiC retains high mechanical strength and oxidation stability at temperatures above 1500 °C, representing a viable alternative to silica, alumina, and carbon, which have been in use as catalyst supports for more than 60 years. Preparation of monolithic porous SiC is usually elaborate and porosities around 30% v/v are typically considered high. This report describes the synthesis of monolithic highly porous (70% v/v) SiC by carbothermal reduction (1200−1600 °C) of 3D sol−gel silica nanostructures (aerogels) conformally coated and cross-linked with polyacrylonitrile (PAN). Synthesis of PAN-cross-linked silica aerogels is carried out in one pot by simple mixing of the monomers, whereas conversion to SiC is carried out in a tube reactor by programmed heating. Intermediates after aromatization (225 °C in air) and carbonization (800 °C under Ar) were isolated and characterized for their chemical composition and materials properties. Data are interpreted mechanistically and were used iteratively for process optimization. Solids 29Si NMR validates use of skeletal densities (by He pycnometry) for the quantification of the conversion of silica to SiC. Consistent with the topology of the carbothermal process, data support complete conversion of SiO2 to SiC requiring a C:SiO2 ratio higher than the stoichiometric one (=3). The morphology of the SiC network is invariant of the processing temperature between 1300 and 1600 °C, and hence it is advantageous to carry out the carbothemal process at higher temperatures where reactions run faster. Those samples are macroporous and consist of pure polycrystalline β-SiC (skeletal density: 3.20 g cm−3) with surface areas in the range reported previously for biomorphic SiC (∼20 m2 g−1). Although the micromorphology remains constant, the crystallite size of SiC increases with processing temperature (from 7.1 nm at 1300 °C to 16.5 nm at 1600 °C). Samples processed at 1200 °C are mesoporous and amorphous (by XRD), even though they consist of ∼75% mol/mol SiC. The change in the morphology of SiC in the 1200−1300 °C range has been explained by a melting mechanism. This comprises the first report of using a polymer cross-linked aerogel for the synthesis of another porous material.

For many applications ranging from catalysis to sensors to energetic materials, it is desirable to produce intimate mixtures of nanoparticles. For instance, to improve the reaction rates of energetic materials, the oxidizing agent and the fuel need to be mixed as intimately as possible, ideally at the nanoscopic level. In this context, the acidity of a hydrated CuCl(2) solution reacting toward a network of CuO nanoparticles (a good oxidant) is used to induce one-pot cogelation of a nanostructured network of a resorcinol-formaldehyde resin (RF, the fuel). The resulting wet gels are dried to aerogels, and upon pyrolysis under Ar, the interpenetrating CuO/RF network undergoes a smelting reaction toward metallic Cu. Upon ignition in the open air, pure RF aerogels do not burn, while CuO/RF composites, even with substoichiometric CuO, sustain combustion, burning completely leaving only a solid residue of CuO whose role then has been that of a redox mediator through the smelting reaction.

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Porous carbons, including carbon (C-) aerogels, are technologically important materials, while polyacrylonitrile (PAN) is the main industrial source of graphite fiber. Graphite aerogels are synthesized herewith pyrolytically from PAN aerogels, which in turn are prepared first by solution copolymerization in toluene of acrylonitrile (AN) with ethylene glycol dimethacrylate (EGDMA) or 1,6-hexanediol diacrylate (HDDA). Gelation is induced photochemically and involves phase-separation of "live" nanoparticles that get linked covalently into a robust 3D network. The goal of this work was to transfer that process into aqueous systems and obtain similar nanostructures in terms of particle sizes, porosity, and surface areas. That was accomplished by forcing the monomers into (micro)emulsions, in essence inducing phase-separation of virtual primary particles before polymerization. Small angle neutron scattering (SANS) in combination with location-ofinitiator control experiments support that monomer reservoir droplets feed polymerization in ∼3 nm radius micelles yielding eventually large (∼60 nm) primary particles. The latter form gels that are dried into macro-/mesoporous aerogels under ambient pressure from water. PAN aerogels by either solution or emulsion gelation are aromatized (240 °C, air), carbonized (800 °C, Ar), and graphitized (2300 °C, He) into porous structures (49−64% v/v empty space) with electrical conductivities >5× higher than those reported for other C-aerogels at similar densities. Despite a significant pyrolytic loss of matter (up to 50−70% w/w), samples shrink conformally (31−57%) and remain monolithic. Chemical transformations are followed with CHN analysis, 13 C NMR, XRD, Raman, and HRTEM. Materials properties are monitored by SEM and N 2 -sorption. The extent and effectiveness of interparticle connectivity is evaluated by quasi-static compression. Overall, irrespective of the gelation method, PAN aerogels and the resulting carbons are identical materials in terms of their chemical composition and microstructure. Although cross-linkers EGDMA and HDDA decompose completely by 800 °C, surprisingly their signature in terms of different surface areas, crystallinity, and electrical conductivities is traced in all the pyrolytic products.