Synthesis, characterization, and wear and friction properties of variably structured SiC/Si elements made from wood by molten Si impregnation

We have synthesized pre-shaped SiC/Si ceramic material elements from charcoal (obtained from wood) by impregnation with molten silicon, which takes place in a two-stage process. In the first process, a porous structure of connected micro-crystals of beta-SiC is formed, while, in the second process, molten Si totally or partly infiltrates the remaining open regions. This process forms a dense material with cubic (beta-)SiC crystallites, of which the majority is imbedded in amorphous Si. The synthesis of preshaped "sprocket" elements demonstrates that desired shapes of such a dense SiC/Si composite ceramic material can be achieved, thus suggesting new industrial applications. The structure and composition of numerous as-synthesized samples were characterized in detail by using a wide range of techniques. Wear and friction properties were also investigated, with polished samples. The properties found for the present samples are very promising for abrasive applications and for new generation brake systems. (C) 2011 Elsevier Ltd. All rights reserved.