A new method of preparing highly porous SiC (silicon carbide) ceramics using polysiloxane, PEOc (Poly(etherco-octene)) and hollow microsphere templates was studied. Commercially available polysiloxane, carbon black, α-SiC, hollow poly(methyl methacrylate) microspheres, PEOc, AlN, and Y 2O3were used as starting materials. Three batches of powders were prepared with 30 wt% PEOc, 14 wt% SiC, and 3.5 wt% sintering additives. Cylindrical specimens with a thickness of 3 mm and a diameter of 50 mm were prepared by compression molding at 80°C. The compacts were cross-linked by heating them to 200°C in the air. The cross-linked samples were pyrolyzed at 1100°C for 1 h at a heating rate of 1°C/min in argon, allowing the polysiloxane to convert to silicon oxycarbide (SiOC) in the specimens. The results show that homogeneous distribution of large interconnected pores forms the uniform dispersion of the PEOc melt with the polysiloxane hollow microspheres inorganic powders blend during molding.
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