Preparation of nasal cavity-like SiC-Si3N4 foams with a hierarchical pore architecture

Rigid SiC-Si3N4 foams with hierarchical porosity were prepared through protein-based gel-casting followed by radiant sintering in a modified spark plasma sintering (SPS) set-up. The porous bodies sintered at 1500-1700 degrees C for only 10 minutes achieved a compressive strength of 15-21 MPa while keeping a porosity of 60-70 vol%. Gradient porous structures, with pore sizes ranging between 1 to 100 mm, were intersected by the growth of hybrid SiC and Si3N4 nanowires inside the pores resulting in a nasal cavity-like appearance. Gas permeability at room temperature (25 degrees C) and 600 degrees C was evaluated. Darcian permeabilities and non-Darcian permeabilities of all the prepared foams at room temperature fell within (0.354-1.55) x 10(-12) m(2) and (1.60-6.33) x 10(-8) m, respectively. Measurement of the Darcian and non-Darcian permeabilities at 600 degrees C were much higher, at 1.71 x 10(-11) m(2) and 2.68 x 10(-7) m, respectively. The microstructure, stability, gas flow properties and the green synthesis route reveal the potential of these ceramic foams to be used as industrial PM filters for airborne pollutions.