Synthesis of Porous Silicon Nitride with Unidirectionally Aligned Channels Using Freeze‐Drying Process

Porous silicon nitride with macroscopically aligned channels was synthesized using a freeze-drying process. Freezing of a water-based slurry of silicon nitride was done while unidirectionally controlling the growth direction of the ice. Pores were generated subsequently by sublimation of the columnar ice during freeze-drying. By sintering this green body, a porous silicon nitride with high porosity (over 50%) was obtained and its porosity was controllable by the slurry concentration. The porous Si 3 N 4 had a unique microstructure, where macroscopically aligned open pores contained fibrous grains protruding from the internal walls of the Si 3 N 4 matrix. It is hypothesized that vapor/solid phase reactions were important to the formation mechanism of the fibrous grains.