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Fabrication of porous Al2O3 ceramics by rapid gelation and mechanical foaming

Published online by Cambridge University Press:  27 June 2013

Yan Yang ,
Shunzo Shimai ,
Yi Sun ,
Manjiang Dong ,
Hidehiro Kamiya  and
Shiwei Wang
Yan Yang
Affiliation:
R&D Center for Structural Ceramics and Composites, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, People’s Republic of China
Shunzo Shimai
Affiliation:
R&D Center for Structural Ceramics and Composites, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, People’s Republic of China
Yi Sun
Affiliation:
R&D Center for Structural Ceramics and Composites, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, People’s Republic of China
Manjiang Dong
Affiliation:
R&D Center for Structural Ceramics and Composites, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, People’s Republic of China
Hidehiro Kamiya
Affiliation:
Graduate School of Bio-Applications and Systems Engineering, Tokyo University of Agriculture and Technology, Tokyo 183-8538, Japan
Shiwei Wang*
Affiliation:
R&D Center for Structural Ceramics and Composites, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, People’s Republic of China
*
a)Address all correspondence to this author. e-mail: [email protected]
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Abstract

Porous Al2O3 ceramics were fabricated using a rapid gelation to fix the foam structure after mechanical foaming. The slurry was made with deionized water, Al2O3 powder, a water-soluble copolymer of isobutylene and maleic anhydride, and a surfactant. The resultant gel formed at room temperature in air. The influence of the surfactant (EMAL TD) content on gelling behavior, pore structure (porosity, cell size), shrinkage behavior, and compressive strength of the resultant porous Al2O3 ceramics was evaluated. Porous Al2O3 ceramics were sintered in only one step without debinding because of the low concentration of additives (≤0.5 wt%). The porous Al2O3 ceramics had porosities from 20 to 89% and cell sizes from 60 to 220 μm. The compressive strength was 75 MPa when the porosity was 60%.

Type
Articles
Information
Journal of Materials Research , Volume 28 , Issue 15 , 14 August 2013 , pp. 2012 - 2016
Copyright
Copyright © Materials Research Society 2013 

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