Additive Manufacturing of Ceramics Enabled by Flash Pyrolysis of Polymer Precursors with Nanoscale Layers

Zoli, Luca; Sciti, Diletta; Liew, Li-Anne; Terauds, Kalvis; Azarnoush, Setareh; Raj, Rishi

doi:10.1111/jace.13946

Cited by 23 publications

(16 citation statements)

References 18 publications

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“…The special feature of this process is the excellent wetting behavior of the polymer which “wicks” into the fiber preform spreading the coating on all the fibers. The process was used to produce minicomposites of carbon fibers embedded in a SiCN matrix . In the present work we show a successful application of the process to SiC fibers.…”

Section: Introductionmentioning

confidence: 63%

“…The samples were invariably entirely free from cracks. It is interesting to compare the present experiments with those carried out with carbon fiber bundles, where cracks were seen at 80 cycles but were then eliminated by reducing the amount of precursor injected per cycle in view of the falling surface to volume ratio of the specimen as the matrix continued to fill. In the present experiments, the end of the fiber tow was dipped, slightly, into the precursor solution, allowing the liquid to wick up to the top of the fiber tow; thus the thickness of the liquid coating was self‐limited, being constant regardless of the surface to volume ratio of the sample.…”

Section: Resultsmentioning

confidence: 93%

“…The additive manufacturing set‐up is described in Ref. and more fully in Supplementary Materials. Samples were prepared with 8, 16, 40 and 80 cycles.…”

Section: Methodsmentioning

confidence: 99%

“…In recent work we have shown that an additive manufacturing method where the matrix is built‐up with nanoscale layers of the PDC can produce a dense matrix . Each layer is typically 10–100 nm thick.…”

Section: Introductionmentioning

confidence: 99%

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Additive Manufacturing of SiCN Ceramic Matrix for SiC Fiber Composites by Flash Pyrolysis of Nanoscale Polymer Films

et al. 2016

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The potential of polymer-derived ceramic matrices for siliconcarbide fiber composites is demonstrated by additive layering of thin films on SiC fiber bundles. The thin liquid films, which naturally wet the fiber surfaces, are cross-linked and pyrolyzed in-situ into the silicon carbonitride ceramic in just a few seconds to yield defect-free layers that are 10 to 100 nm thick. The infiltration is completed by repeating the cycles. A nearly fully dense and defect free SiCN matrix could be obtained. Room-temperature tensile tests show a tensile strength of 1200 MPa. Good matrix-fiber interface behavior is seen with pull-out character which is most likely responsible for the apparent ductility. The SiC fibers were uncoated.

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Section: Introductionmentioning

confidence: 63%

Section: Resultsmentioning

confidence: 93%

“…The additive manufacturing set‐up is described in Ref. and more fully in Supplementary Materials. Samples were prepared with 8, 16, 40 and 80 cycles.…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Additive Manufacturing of SiCN Ceramic Matrix for SiC Fiber Composites by Flash Pyrolysis of Nanoscale Polymer Films

et al. 2016

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“…(Earlier work on thin films deposited on copper substrates did not show an improvement [8].) At the same time a novel processing approach also presented itself where we were able to deposit thin films of SiCO using a flash-pyrolysis method where a small amount of the liquid precursor was sprayed onto a web of carbon fibers and pyrolyzed in just a few seconds at 800 o C [9]. The nearly perfect wetting of all surfaces of the fibers within the fiber-matt allowed all fibers to be immediately covered with thin films of SiCO.…”

Section: Introductionmentioning

confidence: 95%

Three-dimensional architecture of lithium-anodes made from graphite fibers coated with thin-films of silicon oxycarbide: Design, performance and manufacturability

Saleh

Raj

2016

Journal of Power Sources

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Silicon oxycarbide (SiCO) is an amorphous molecular network of Si-CO tetrahedra anchored to graphene-like carbon. The graphene forms a three dimensional cellular network with a domain size of ~5 nm. Therefore nanometer thick films of SiCO grown on graphite may be expected to have unusual behavior. We grow these films on a bed of commercially available graphite fibers that serve the dual function of a current collector. The electrochemical behavior of the composite is measured as a function of the thickness of the SiCO films. Thick films approach the typical behavior of bulk SiCO (which has three times the capacity of graphite, but suffers from poor first cycle efficiency). However, films, approximately 100 nm thick, show high first cycle efficiency as well as high capacity. The composite performs better than the prediction from the rule-of-mixtures, which further substantiates the unusual behavior of the thin-film architecture. The Raman spectra of these thin films also differ from bulk SiCO. The development of thin graphite fibers, with a high surface to volume ratio that have the same capacity as the current graphite-powder technology, coupled with manufacturing of these thin-films by a liquid-polymer precursor based process, can propel these results toward commercialization.

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Polymer‐Derived Ceramics

Mera

Ionescu

2019

Encyclopedia of Inorganic and Bioinorganic Chemistry

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Polymer‐derived ceramics (PDCs) represent a class of ceramics that are preparatively accessible from inorganic polymers (also called preceramic polymers). The synthesis and processing of PDCs from polymeric precursors have been shown within the past four decades to be an excellent way to design ceramics, which provides unique tools to control and tune structural features and consequently properties in PDCs. Thus, the molecular architecture and the chemistry of the preceramic polymers strongly correlate to the polymer‐to‐ceramic transformation characteristics as well as the structural features of the resulting PDC materials. By carefully designing the preceramic polymer, fine‐tuning of the chemical and phase composition of the resulting ceramics is possible, which results in unique microstructures and behavior thereof. The present article aims to give a brief introduction to the field of PDCs. Typically, an introduction of preparative tools to access PDCs from tailored inorganic polymers will be done. In addition, a critical consideration of the main structural features of PDCs will be given, with emphasis on the strong correlation between the nano/microstructure of the PDCs and the molecular architecture of their polymeric precursors. Also, various technologies being used to process PDCs in the form of porous materials, coatings, fibers, complex‐shaped monolithic parts, and so on will be introduced and discussed. Finally, some selected structural and functional properties (e.g., high‐temperature behavior, electrical properties, optical properties, and bioactivity) of PDCs will be highlighted and some emerging application fields in which PDCs may be highly suitable material candidates will be introduced. The present article does not intend to provide an exhaustive review of the activities from the past three to four decades in the field of PDCs, but rather to give a short overview of the particularities and the potential of this technology. The article refers in the section “Related Papers” to some excellent reviews and book chapters from the past 20 years, which address and summarize various aspects related to PDCs.

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Additive Manufacturing of Ceramics Enabled by Flash Pyrolysis of Polymer Precursors with Nanoscale Layers

Cited by 23 publications

References 18 publications

Additive Manufacturing of SiCN Ceramic Matrix for SiC Fiber Composites by Flash Pyrolysis of Nanoscale Polymer Films

Additive Manufacturing of SiCN Ceramic Matrix for SiC Fiber Composites by Flash Pyrolysis of Nanoscale Polymer Films

Three-dimensional architecture of lithium-anodes made from graphite fibers coated with thin-films of silicon oxycarbide: Design, performance and manufacturability

Polymer‐Derived Ceramics

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