In-situ mullite whisker reinforced SiC porous ceramics with whiskers and bonding layers synchronously growing: Using CaF₂ as a temperature-controlled whisker formation switch

Mullite-bonded SiC porous ceramics are of potential in hot gas infiltration while the insufficient mechanical performance limits its application. In-situ mullite whisker reinforcement is a potential solution but the formation temperature mismatch between mullite whisker and bonding layer is a challenge. In that case, mullite whiskers massively form ahead of the bonding layer excessively consuming alumina leading to poor bonding layers between SiC particles and thus, the mechanical performance. Herein, the mismatch was solved by using CaF₂ as a temperature-controlled reaction switch. As a result, both the bonding layer and whisker synchronously formed. The material showed significant reinforcement effects, and exhibited a flexural strength of 124.8 MPa and a fracture toughness of 1.53 MPa·m^1/2 with an open porosity of 36.6 vol%, realizing a breakthrough in the mechanical performance. Interestingly, an increase in oxygen vacancy concentration with the sintering temperature was first reported, which may benefit the whisker growth.