Advanced Hierarchical Biomorphous Silicon Carbide Monoliths

Porous silicon carbide (SiC) has attracted considerable attention in the field of cellular ceramics for a variety of applications such as catalyst supports, filters, or in the biomedical field due to its excellent structural properties, mechanical strength, and chemical stability. However, SiC has certain limitations due to high‐temperature profiles and costly manufacturing methods. Therefore, it is investigated that porous biomorphic silicon carbide monoliths using a powder blend of paper‐derived carbon fibers, phenolic resin, and silicon, resulting in comparatively low sintering temperatures ( T = 1300 to 1550 °C) and good mechanical strength. This near‐net‐shape process uses low‐cost raw materials and enables the production of silicon carbides with high open porosity ( P = 51.48% to 68.28%) and low shrinkage. The influence of different amounts of carbon sources (C fibers and C resin ) on the mechanical (4‐point bending) and thermal properties (laser flash method) is investigated. In addition, to improve the pressure gradients, macrochannels with multiple layers of sacrificial polymer lattices are incorporated, resulting in hierarchical structures with high permeability. Thus, this advanced biomimetic approach offers great potential for structured cellular ceramics with tailored properties for biomedical, catalyst support, or nuclear fuel cladding materials.