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Porous ceramics have been widely used in heat insulation, filtration, and as a catalyst carrier. Ceramics with high porosity and high strength are desired; however, this high porosity commonly results in low strength materials. In this study, porous alumina with high porosity and high strength was prepared by a popular direct foaming method based on particle-stabilized wet foam that used ammonium polyacrylate (PAA) and dodecyl trimethyl ammonium chloride (DTAC) as the dispersant and hydrophobic modifier, respectively. The effects of the dispersant and surfactant contents on the rheological properties of alumina slurries, stability of wet foams, and microstructure and mechanical properties of sintered ceramics were investigated. The microstructure of porous ceramics was regulated using wet foams to achieve high strength. For a given PAA content, the wet foams exhibited increasing stability with increasing DTAC content. The most stable wet foam was successfully obtained with 0.40 wt% PAA and 0.02 wt% DTAC. The corresponding porous alumina ceramics had a porosity of 82%, an average grain size of 0.7 µm, and a compressive strength of 39 MPa. However, for a given DTAC content, the wet foams had decreasing stability with increasing PAA content. A possible mechanism to explain these results is analyzed.


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High-strength porous alumina ceramics prepared from stable wet foams

Show Author's information Linying WANGa,bLiqiong ANa( )Jin ZHAOb,cShunzo SHIMAIbXiaojian MAOb,cJian ZHANGb,cJuan LIUb,cShiwei WANGb,c( )
College of Ocean Science and Engineering, Shanghai Maritime University, Shanghai 201306, China
State Key Laboratory of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
Key Laboratory of Transparent and Opto-functional Advanced Inorganic Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China

Abstract

Porous ceramics have been widely used in heat insulation, filtration, and as a catalyst carrier. Ceramics with high porosity and high strength are desired; however, this high porosity commonly results in low strength materials. In this study, porous alumina with high porosity and high strength was prepared by a popular direct foaming method based on particle-stabilized wet foam that used ammonium polyacrylate (PAA) and dodecyl trimethyl ammonium chloride (DTAC) as the dispersant and hydrophobic modifier, respectively. The effects of the dispersant and surfactant contents on the rheological properties of alumina slurries, stability of wet foams, and microstructure and mechanical properties of sintered ceramics were investigated. The microstructure of porous ceramics was regulated using wet foams to achieve high strength. For a given PAA content, the wet foams exhibited increasing stability with increasing DTAC content. The most stable wet foam was successfully obtained with 0.40 wt% PAA and 0.02 wt% DTAC. The corresponding porous alumina ceramics had a porosity of 82%, an average grain size of 0.7 µm, and a compressive strength of 39 MPa. However, for a given DTAC content, the wet foams had decreasing stability with increasing PAA content. A possible mechanism to explain these results is analyzed.

Keywords:

porous ceramic, alumina, dispersant, hydrophobic modifier, compressive strength
Received: 11 December 2020 Revised: 10 March 2021 Accepted: 29 March 2021 Published: 05 August 2021 Issue date: August 2021
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Publication history
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Publication history

Received: 11 December 2020
Revised: 10 March 2021
Accepted: 29 March 2021
Published: 05 August 2021
Issue date: August 2021

Copyright

© The Author(s) 2021

Acknowledgements

This research was supported by the National Natural Science Foundation of China (51602194 and 51772309), and Science Foundation for Youth Scholar of State Key Laboratory of High Performance Ceramics and Superfine Microstructures (SKL201901).

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