ZrB 2 ‐Based Sponges and Lightweight Devices

This work deals with the production of zirconium diboride (ZrB 2 )‐based ultra‐high‐temperature ceramic porous bodies using different forming techniques with the aim to obtain a reduction in weight of the final components, to balance the high specific mass of ZrB 2 , useful especially in aerospace applications. A feasibility study for the production of ZrB 2 ‐based porous bodies from sponges and foams was carried out. A ZrB 2 composition, containing silicon carbide as the secondary phase and silicon nitride (Si 3 N 4 ) as a sintering aid, has been chosen with the aim to obtain lightweight devices by the replica method through slip casting of ceramic suspensions. Moreover, ZrB 2 macroporous materials have been successfully produced using Si 3 N 4 as a sintering aid and ovalbumin as a foaming agent. Sintering was performed at 2150°C with a dwell time of 120 min after a suitable process to pyrolize the organic templates and additives.