Open and partially
closed cell polymer derived ceramic, specifically
silicon oxycarbide, foams were produced from commercially available
polyurethane (PU) foams through the replica technique combined with
the preceramic polymer pyrolysis route. The focus was directed on
the role of PU morphology (cell size and open/partially closed cells),
synthesis parameters (cross-linking temperature and time), and type
of the polysiloxane precursors for fine-tuning the microstructural
features of the resulting ceramic foams and their eventual effect
on the fluid dynamic/mechanical properties. Consequently, ceramic
foams having dense/hollow struts with/without hierarchical porosity
were able to be manufactured and characterized in detail. The average
total porosity including all compositions was above 95%, the maximum
surface area was found to be reaching 79 m2.g–1, and the room temperature permeability measurements indicated a
wide range for k
1 (0.28 × 10–9–11.48 × 10–9 m2) and k
2 (0.34 × 10–5–54.17 × 10–5 m) according to the selected
PU substrate. Hot air permeation tests showed that the foams were
stable up to 700 °C without any loss of functionality. Accordingly,
they are envisioned to be employed as reusable air filtration device
parts for pollutants (viruses, bacteria, dust, etc.), catalytic supports,
and filter components for reactions occurring in aggressive environments.