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Silicon-bonded silicon carbide (SBSC) porous ceramics had been prepared by mixing two different particle size of SiC powder (coarse and fine) as aggregates for silicon carbide porous ceramics, adding metallic Si as the binder phase and firing at 1450 °C under argon atmosphere. Various combinations of SiC mixtures consisting of two different particle size and packing density were prepared, and the samples were investigated to understand apparent porosity, bending strength, pore size distribution, and microstructure. The result showed that mixing an appropriate proportion of SiC coarse and fine powders could not only improve the pore size distribution of SBSC porous ceramics but also significantly increase the bending strength compared with the single-particle size sample. The system had the highest free packing density when the ratio of coarse to fine SiC size was &gt;2 and the coarse powder content was 60–70 wt%. The optimal bending strength, and apparent porosity were 37.53 MPa and 37.11% respectively when mixing 70 wt% of coarse powder (50.8  μ m) and 30 wt% of fine powder (9.5  μ m) and sintered at 1450 °C in an argon atmosphere. The material created had 100.3% increased bending strength, and 0.99% decreased porosity compared with the single-particle size sample (50.8  μ m).

Effects of particle grading composition of SiC on properties of silicon-bonded SiC porous ceramics