Preparation of complex-shape SiC ceramic composites parts derived from phenolic resin template

Using phenolic resin as the raw material, complex-shaped components, which were composed of SiC, C and Si, were formed by stereolithography technology. X-ray diffraction was employed to analyze the phase of carbon templates and ceramic components. The pyrolysis behaviors and the forming mechanism of the porous system were studied with thermo-gravimetric analysis. The microstructures of the ceramic components were observed with scanning electron microscope. A model of the mechanism of reactive infiltration of Si into the carbon template was built. The carbon templates obtained by the pyrolysis of phenolic resin precursor possess amorphous stale structures, and the residual carbon is 65 wt%. The ceramic components obtained at 1500°C by reactive infiltration of Si are dense ceramics containing SiC, C and Si. At 1650°C the ceramics are porous ceramics. The porous system formed by photocurable resin structures and starch powders could effectively prevent the carbon templates from breaking and cracking and facilitate penetrating Si to the carbon templates to form SiC. The thickness of SiC obtained at 1500°C for 30 min is 20 μum.