Rapid manufacture of net-shape SiC components

Stereolithography was introduced into the net-shape SiC components fabrication process to produce the molds for the preparation of porous carbon preforms. The mixed resin was cast into the molds and then pyrolyzed to produce the porous carbon preforms which had a high porosity of 40.93% and were infiltrated and reacted with molten silicon to get reaction-formed silicon carbide (RFSC) components. To realize the complete infiltration of the thick wall parts, pipelines as the channels for the molten silicon were added into the components. The hierarchical structures of the porous carbon had been attained to realize the controllability of the microstructure and properties of RFSC. The samples had a high linear and volume shrinkage, 24.7% and 57.3%, respectively, during the pyrolysis process. Phase composition had been investigated by optical microscopy and X-ray diffraction analysis. The results indicate that no residual carbon was available in the final RFSC. The net-shape fabrication process for the RFSC components could promote the industry applications where SiC components with complex surface and inner structure were needed.