Investigation of different phenolic resins and their behavior during pyrolysis to form SiC/C-composites

Abstract

Specific phenolic resin samples have been developed as the carbon precursor for SiC/C composites. Liquid phenolic resins suitable for fiber-infiltration in the resin transfer moulding (RTM) process are synthesized by using versatile combination of the aromatic component (phenol, naphthalen-2-ol) with various formaldehyde equivalents such as methanal, 1,3,5,7-tetraazatricyclo[3.3.1.13,7]decane (urotropine), and 1,3,5-trioxane, under different reaction conditions. Room temperature liquid resoles (RTLR) are obtained by using an excess of the formaldehyde component over phenol (≥2) under basic conditions. Upon heating RTLR can form a crosslinked network even without addition of a hardening reagent. In addition, novolacs are synthesized under acidic conditions using a phenol/formaldehyde ratio ≥1. Nitrogen-containing resins contain nitrogen due to reaction of phenol with urotropine. Novolacs and nitrogen-containing resins are solids at room temperature and not self-curing. To infiltrate these both resins into SiC fibers in the RTM process, they are dissolved in 2-furanmethanol (furfuryl alcohol FA) and urotropine which is added as curing-agent. Both, the molecular weight and the amount of the dissolved phenolic resin have an influence on the viscosity and the carbon yield after pyrolysis which is important for this application. The aim was to create different phenolic resins for the fabrication in the RTM process and to characterize the carbon after pyrolysis with respect to the structure and porosity as these are key parameters to generate a stoichiometric SiC matrix by liquid silicon infiltration (LSI).