On the development of ice-templated silicon carbide scaffolds for nature-inspired structural materials

The processing of ceramic scaffolds using the ice-templating, or freeze casting, technique provides a relatively simple means to mimic the hierarchical design of natural materials such as nacre. In the present study, we investigated the architecture of silicon carbide (SiC) scaffolds produced by this technique over a range of cooling rates and suspension characteristics to demonstrate its versatility and effectiveness for fabricating unidirectional porous bodies with controlled lamella thickness, porosity fraction and morphology. An array of microstructures was generated specifically to examine the role of the suspension solid load and cooling rate on the pore morphology and final ceramic fraction. With respect to the morphology of the pores, a transition from lamellar to dendritic structure was found to be triggered by an increase in cooling rate or in suspension concentration. Similarly, the freezing condition and suspension characteristics were seen to influence the transition between particle rejection and entrapment by the ice. Based on this study, the specific processing parameters that result in distinct scaffold morphologies, namely lamellar, dendritic or isotropic morphology (the latter corresponding to particle entrapment), are identified and presented in the form of a “morphology map” to establish the regions of the different architectures of freeze-cast SiC scaffolds.