3D printing “wire-on-sphere” hierarchical SiC nanowires / SiC whiskers foam for efficient high-temperature electromagnetic wave absorption

Electromagnetic wave absorption (EWA) materials for use in extreme environments are of great interest. Herein, SiC nanowires / SiC whiskers (SiCnw/SiCw) foam with unique “wire-on-sphere” hierarchical structure was developed for efficient high-temperature EWA. SiCw were assembled to porous SiCw spheres via spray drying and then SiCw spheres were 3D printed to SiCw foam. The catalyst-free precursor infiltration pyrolysis process was first developed to ensure that SiCnw can intentionally grow in situ on the surface of SiCw spheres, thereby achieving “wire-on-sphere” hierarchical structure foam. At room-temperature, the maximum electromagnetic wave effective absorption bandwidth (EABmax) and minimum electromagnetic wave reflection coefficient (RCmin) of SiCnw/SiCw foam can reach 4 GHz and -57 dB, respectively. At 600 °C, the EABmax and RCmin were 3 GHz and -15 dB, respectively. Furthermore, even oxidized at 1000–1500 °C, SiCnw/SiCw foam can still retain EABmax ranging from 2.7 to 3.9 GHz and RCmin ranging from -16 dB to -64 dB, because the formation of SiO2 layer with appropriate thickness can boost interfacial polarization and regulate impedance matching. The SiCnw/SiCw foam also shows the flexural strength as high as 17.05 MPa. All results demonstrate that the SiCnw/SiCw foam is a promising EWA material for applications of harsh environments. And the material-independent “wire-on-sphere” hierarchical structure and its novel preparation process should find the widespread use in the design and fabrication of high-efficiency EWA micro-nano materials.