Investigations on porous silicon nitride ceramics prepared by the gel-casting method

Due to their special structure and many excellent properties, porous Si3N4 ceramics have a wide range of potential applications as a new structural and functional integrated material. In the present study, porous Si3N4 ceramics with excellent bending properties and satisfactory porosity were prepared by the gel-casting method. The variations in porosity, bending strength, fracture morphology and phase composition of the porous Si3N4 ceramics with different weight fractions of La2O3-MgO sintering additive were investigated. The results showed that the density of porous Si3N4 ceramics increased linearly with the increase of sintering additive content. When the content of sintering additive increased from 2.5 wt.% to 10 wt.%, the porosity of porous ceramics decreased from 30 % to 10 %. With the increase of sintering additive content, the bending strength of the samples first increased and then decreased. When the sintering additive content was 5.0 wt.%, the average bending strength of the samples reached a maximum of 240.88 MPa, and scanning electron microscopy and X-ray diffractometry results showed that beta-Si3N4 particles with well-developed pores and a maximum aspect ratio of 5.8 were formed in the porous silicon nitride ceramics. This study provides a reference for the preparation of porous Si3N4 ceramics with good bending properties and porosity.