In the last 20 years, tape casting, a standard wet‐shaping process to produce thin ceramics, has been applied to manufacture polymer‐derived ceramics (PDCs). Si‐based polymers, such as polysiloxanes and polysilazanes, also known as preceramic polymers (PCPs), have been used as precursors/binders replacing conventional raw materials and additives for tape casting process. Thermal processing of PCPs is carried out at lower temperatures in comparison with classical ceramic sintering, particularly of carbides and nitrides. Furthermore, polymeric precursors can be converted into hybrid or composite ceramics, when parts of the polymers remain unreacted. Inert or reactive fillers might be used to reduce both shrinkage and porosity inherently caused by the weight loss occurring during polymer pyrolysis while forming new ceramic phases in the final materials. Alternatively, pore formers might also be added to tailor pore shape, connectivity, and volume (macroporosity). Nevertheless, current equipment and process parameters for tape casting‐based products must be eventually adjusted to fit the characteristics of ceramic precursors. Therefore, the aim of this review is focused on listing and discussing the efforts to produce PDCs using tape casting as a shaping technique. Interactions of system components and effects of treatment, particularly thermal stages, on final microstructure and properties are stressed out. Gaps in the literature concerning processing optimization are pointed out, and suggestions are given for further development of PDCs produced by tape casting.
A proposed reaction scheme for in situ controlled low-temperature formation of metallic-Co at the early stage of pyrolysis of perhydropolysilazane (PHPS) coordinated with CoCI2.
Herein, we report the mechanistic investigation of the formation of nickel (Ni) nanocrystallites during the formation of amorphous silicon nitride at a temperature as low as 400 °C, using perhydropolysilazane (PHPS) as a preformed precursor and further coordinated by nickel chloride (NiCl2); thus, forming the non-noble transition metal (TM) as a potential catalyst and the support in an one-step process. It was demonstrated that NiCl2 catalyzed dehydrocoupling reactions between Si-H and N-H bonds in PHPS to afford ternary silylamino groups, which resulted in the formation of a nanocomposite precursor via complex formation: Ni(II) cation of NiCl2 coordinated the ternary silylamino ligands formed in situ. By monitoring intrinsic chemical reactions during the precursor pyrolysis under inert gas atmosphere, it was revealed that the Ni-N bond formed by a nucleophilic attack of the N atom on the Ni(II) cation center, followed by Ni nucleation below 300 °C, which was promoted by the decomposition of Ni nitride species. The latter was facilitated under the hydrogen-containing atmosphere generated by the NiCl2-catalyzed dehydrocoupling reaction. The increase of the temperature to 400 °C led to the formation of a covalently-bonded amorphous Si3N4 matrix surrounding Ni nanocrystallites.
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