The Modulation of the Pore Structure in Porous Carbon by Metal Salts and Its Application for Joining Silicon Carbide Ceramics

In this work, the metal salts were introduced into the resin-solvent gel system to leverage their ortho-substitution effect, thereby accelerating the polymerization-induced phase separation process. Subsequent in-situ carbonization resulted in the preparation of porous carbon materials with three-dimensional interconnected pores. By precisely tuning the parameters of the resin-solvent-metal ion system, control over the pore structure of the porous carbon was achieved, with a porosity range of 16.5% to 66.5% and a pore diameter range of 8 to 248 nm. The addition of metallic salts can simply and effectively increase the pore structure after carbonization, making the infiltration of molten silicon easier. This is beneficial to the joining process of silicon carbide ceramics. Based on these findings, a high-reliability joining technique for large-sized (135 mm × 205 mm) silicon carbide ceramics was developed. The resulting interlayer was dense and defect-free, exhibiting a joining strength of 309 ± 33 MPa and a Weibull modulus of 10.67. These results highlight the critical role of structured porous media in advancing the field of large-sized ceramic joining.