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Open-cell silicon carbide foams were fabricated from a blend of carbon-filled polysiloxane using three different plastic forming methods: compression molding, injection molding, and extrusion. Compression molding process led to more homogeneous microstructure than the other forming methods, resulting in superior compressive strength (20.6MPa at 72.4% porosity). In contrast, extrusion molding led to higher porosity (384%) than the other forming methods (72­74%) as a result of a higher level of expansion of expandable microspheres. Injection molding process led to a partial segregation of expanded microspheres and resulted in moderate compressive strength (9.1MPa at 74.1% porosity).

Effect of forming methods on porosity and compressive strength of polysiloxane-derived porous silicon carbide ceramics