A Simple Direct Casting Route to Ceramic Foams

A simple direct foaming and casting process using ovalbumin-based aqueous slurries for fabricating ceramic and metal foams is demonstrated. Foaming of aqueous ceramic slurries and the foam microstructure were seen to be a strong function of slurry rheology. Setting of foams with ceramic solids loading above 20 vol% was achieved by addition of acid, which also prevented binder migration. Acid addition resulted in excessive shrinkage, causing cracking of foams with ceramic loading below 20 vol%. Addition of sucrose to the slurries suppressed shrinkage leading to defect-free foams with porosity exceeding 95%. Overall porosity and foam microstructure could be controlled through ceramic solids loading, ovalbumin–water ratio, foaming time and sucrose amount, and sintering temperature. The ceramic foams fabricated by the process were strong enough to be green machined to different shapes.     

Preparation and properties of alumina foams via thermally induced foaming of molten <Emphasis Type="SmallCaps">d</Emphasis>-glucose monohydrate

Alumina foams with porosity of 92.6–94.4 % were obtained by thermally induced foaming of powder dispersions in molten d-glucose monohydrate. Effects of alumina to d-glucose monohydrate weight ratio on the preparation and properties of the alumina foams were investigated. The bubbles generated in molten d-glucose monohydrate were stabilized by alumina particles adsorbed at the gas–liquid interface and the increase in viscosity of the dispersions. The foam rise decreased with the increase in alumina to d-glucose monohydrate weight ratio up to 1.2 and then slightly increased. The alumina foams showed cellular microstructure and the cells had a near spherical morphology. Increasing alumina to d-glucose monohydrate weight ratio widened the cell and window size distribution. The density and compressive strength of the alumina foam showed a maximum at alumina to d-glucose monohydrate weight ratio of 1.2. The corresponding maximum density and compressive strength were 0.293 g/cc and 1.14 MPa, respectively.     

Gelcasting of alumina foams using agarose solutions

Aqueous gelcasting of dense or cellular ceramics by using biopolymers as gel-formers, instead of monomers, is a promising technology mainly in terms of environmental aspects. The main difficulty of using biopolymer solutions in processing of cellular ceramics by foaming method is their high viscosity, which prevents the foaming capacity of the ceramic suspension. In this work, the procedure for preparing concentrated agarose solutions (4 wt.%) by dissolving under overpressure conditions was evaluated for the gelcasting of alumina foams, and the rheological behaviour of alumina suspensions containing agarose was studied. The viscosity of the gelling solution obtained under overpressure conditions was lower than that prepared by simply heating at 90 °C, thus providing high foaming capacity of the alumina suspensions and consequently manufacturing of highly porous ceramics (86–90%). The microstructure of alumina foams was typically composed of approximately spherical cells interconnected by circular windows. The use of different agarose concentrations in alumina suspensions effected the rheological conditions, which resulted in changes in the pore and window sizes of the resulting ceramics. Depending on agarose concentration (0.50–1.0 wt.% on a dry solids basis) in the starting (35 vol.%) alumina slurry, the mean pore size ranged from 529 to 375 μm, while the mean window size varied from 113 to 77 μm.     

Processing of Particle-Stabilized Wet Foams Into Porous Ceramics

Direct foaming of colloidal suspensions is a simple and versatile approach for the fabrication of macroporous ceramic materials. Wet foams produced by this method can be stabilized by long-chain surfactants or by colloidal particles. In this work, we investigate the processing of particle-stabilized wet foams into crack-free macroporous ceramics. The processing steps are discussed with particular emphasis on the consolidation and drying process of wet foams. Macroporous alumina ceramics prepared using different consolidation and drying methods are compared in terms of their final microstructure, porosity, and compressive strength. Consolidation of the wet foam by particle coagulation before drying resulted in porous alumina with a closed-cell structure, a porosity of 86.5%, an average cell size of 35 μm, and a remarkable compressive strength of 16.3 MPa. On the other hand, wet foams consolidated via gelation of the liquid within the foam lamella led to porous structures with interconnected cells in the size range from 100 to 150 μm. The tailored microstructure and high mechanical strength of the macroporous ceramics can be of interest for the manufacture of bio-scaffolds, thermal insulators, impact absorbers, separation membranes, and light weight ceramics.     

Novel ZrP2O7 ceramic foams with controllable structures and ultra-low thermal conductivity

This study demonstrated the synthesis of novel zirconium pyrophosphate (ZrP₂O₇) ceramic foams via a two-step method using a foam casting technique. The synthesised foams functioned as thermal insulators with a highly controllable performance. We investigated the effects of the addition of foaming and thickening agents as well as the solid content of the slurries on the slurry, mechanical properties, thermal conductivities, and microstructure of ZrP₂O₇ ceramic foams. The ZrP₂O₇ ceramic foams synthesised at 1473 K exhibited a porosity, compressive strength, and thermal conductivity of 75.2–89.1 %, 1.95–0.02 MPa, and 0.144–0.057 W/(m K) (298–573 K), respectively. The increase in the porosity to >60 % will facilitate applications based on the low thermal conductivities of the foams.     

Effect of additives on the microstructure of porous alumina

Protein forming, a direct consolidation technique for shaping of powders into a rigid body, use globular protein as gelling agent, which makes the process environment friendly. The present paper combines foaming and gelling capabilities of globular protein (albumin) along with starch to consolidate the ceramic bodies to develop porous structure based on alumina. The effect of albumin and starch on the gel strength, rheological properties of alumina slurry as well as the microstructure of final structure were studied in detail. It has been observed, that albumin which gels by forming strong polymer network dominates the gel properties, and thereby the strength of the consolidated green bodies, whereas starch, being insoluble in water at room temperature, increases the viscosity of slurry, but increases stability of foamed slurry. Also starch acts as pore former to introduce connectivity between pores and hence increases open porosity. Hence, by controlling albumin and starch ratio in the slurry one can control the microstructural developments in the cast body to obtain the desired micro-structure.     

Preparation of high open porosity ceramic foams via direct foaming molded and dried at room temperature

Herein an alternative approach was considered for addressing one difficulty of ceramic foams that the foam slurry with a high content of bubbles which were obtained via direct foaming, cannot maintain well for a long time at room temperature. It is fascinating that the foam slurry mentioned above could stably mold and dry at room temperature, based on an animal protein as foaming agent, kaolin, talc powder and alumina as raw materials, alpha-tricalcium phosphate prepared via co-precipitation as curing agent, and hydrophobic activated carbon powders as stabilizing agent. Effects of the calcination temperatures, the contents of alpha-tricalcium phosphate and activated carbon powder on microstructures, crystal phases, compressive strength and open porosities of ceramic foams were studied systematically. The results indicated that ceramic foams with a high open porosity and uniform pore distribution and sizes sought for application in catalysts supports, could be produced by adjusting these parameters.     

Bubble behaviors in chemical direct foaming process and effects on pore structures of geopolymer foams

Geopolymer foams (GPFs) are considered potential candidates for the highly porous ceramics owing to their high porosity and simple synthesis. In this study, bubble behaviors during different phases of the foaming process and their effects on the pore structure of molded GPFs were examined. The foaming reaction characteristics in a foaming system containing H₂O₂ were adjusted based on variables, such as catalyst content, temperature, activator-to-precursor ratio, and surfactant content. The viscosity of the slurry was also measured under different experimental conditions. Bubble behaviors were determined by characterizing the change in the gas volume in the slurry and the pore structure of the molded GPFs. Different pore structures will be realized by adjusting the relationship between the extrusion effect and liquid film properties in the various foaming phases.     

Effect of Sucrose on Fabrication of Ceramic Foams from Aqueous Slurries

Ceramic foams with porosity exceeding 90% were prepared by direct foaming and casting of aqueous suspensions containing cetyl trimethyl ammonium bromide (CTAB) as a foaming agent. Foaming of the suspensions, particularly with lower viscosity, was initially non-homogeneous but the foam appeared to homogenize with milling time. Addition of sucrose to ceramic suspensions resulted in lowering of the suspension viscosity, stabilized the foams by reducing drainage of the suspension, and minimized coalescence of bubbles leading to lower cell sizes in sintered foams. Ceramic foams prepared from sucrose based suspensions were strengthened to such an extent that foams with porosity above 90% could be machined in the green state.     

Effect of Viscosity on Preparation of Foamed Silica Ceramics by a Rapid Gelation Foaming Method

An environmentally benign preparation method for silica foam (the rapid gelation foaming method) was developed by combining sol-gel reactions and mechanical foaming without using organic polymers or monomers, in order to generate less CO₂ and harmful gases from the decomposition of organic compounds contained in the raw material. The viscosity of the silica sol during foaming affects the porous properties of the silica foam, i.e. the porosity and average pore size decrease with increasing viscosity. The pore structure of the silica foams depend on the viscosity of silica sol, two types of pore structure being formed. An open-pore structure is obtained by foaming low-viscosity sols, while a closed-pore structure is obtained by foaming high-viscosity sols. Since the viscosity of the silica sol affects the stability and foaming ability of the foam, the porous properties of the product can be controlled by controlling the viscosity of the silica during foaming.     

Effects of surfactant and particle size on the microstructure and strength of Si3N4 foams with high porosity

The highly porous Si₃N₄ ceramic foams were prepared by direct foaming with mixed surfactants. The surface tension and viscosity of slurries were tailored by different carbon chain length of surfactants and different mean Si₃N₄ particle size to achieve the pore size controlling. The nearly linear relationship between the pore size and the ratio of surface tension to viscosity was observed, which indicates that the pore size could be precisely tailored by the slurry properties. Si₃N₄ ceramic foams with porosity of nearly 94%, mean pore size of 110–230 µm, and compressive strength of 1.24–3.51 MPa were obtained.     

Direct foaming of macroporous ceramics containing colloidal alumina

Liquid foams containing Al₂O₃ nanoparticles were obtained after direct foaming of a colloidal alumina suspension with ammonium stearate. These systems were stable for at least 24 h and were comprised by small cells (<35 μm). Up to 10 wt% of these foams were added to an ultrastable Al₂O₃-stabilised one and resulted in macroporous samples with high total porosity (>70%). Their green mechanical strength was proportional to the amount of colloidal alumina added, but lower than a composition with calcium aluminate cement. When compared with compositions prepared with colloidal alumina suspension, the colloidal foams resulted in samples with a higher number of small pores (<30 μm) and lower linear shrinkage after firing at 1600 °C for 5 h (~9%). Thus, colloidal alumina foams can be used for processing macroporous refractory ceramics with smaller pores, lower dimensional changes after firing and higher porosity.     

The effect of wet foam stability on the microstructure and strength of porous ceramics

Wet foam stability is of prime importance in fabricating porous ceramics with the desired microstructure and mechanical properties. In this research, wet foams were fabricated via direct foaming after separately adding an anionic surfactant (TLS) and a cationic surfactant (DTAC) into alumina slurries with a copolymer of isobutylene and maleic anhydride (PIBM) as both the dispersant and the gelling agent. The foam stability was evaluated by a stability analyzer. The bubble size rapidly increased in the wet foam with TLS as the foam stabilizer and many large bubbles appeared within 60 min. The wet foam containing DTAC was very stable. Cationic DTAC increased the hydrophobicity of alumina particles by interacting with the anionic PIBM adsorbed on the particles. The hydrophobically modified particles acted as the foam stabilizer and enhanced the wet foam stability. Furthermore, the fast gelling speed of the slurry containing DTAC also enhanced the wet foam stability. The average cell size of the ceramic with 82.9% porosity from the wet foam with TLS was 188 µm and the compressive strength was 9.7 MPa. The counterparts from the wet foam with DTAC were 54 µm of average cell size and 18.1 MPa of compressive strength. The superior stability of wet foam brought about a smaller cell size and higher strength of the resultant ceramic.     

A novel process to high-strength and controlled-shrinkage Al2O3 foams with open-cell by Al powder hollowing technology

Ceramic foams with open-cell structures have attracted extensive attention due to their unique structure and superior properties. But these materials often exhibit the weakness of high sintered shrinkage and low strength at high porosity levels. In this work, novel ceramic foams with open-cell structures have been obtained using Al powder by combining direct foaming and gelation freezing (DF–GF). The foams are assembled by hollow Al₂O₃ particles resulting from the Kirkendall effect, in which expanded particles overcome the shrinkage of sintering. The influence of sintering temperature on the microstructure and properties of foams are investigated. The Al₂O₃ foams show near-zero-shrinkage at 1773 K after undergoing the process of first expansion and then shrinkage. Compared to other conventional open-cell foam, this foam displays relatively high compressive strength of 0.35–2.19 MPa at high porosity levels of 89.45%–94.45%, attributed to hierarchical pore structure and reaction bonding between Al and O₂. This method from pore structure design provides a novel route for the preparation of controlled shrinkage and high-compressive strength alumina foam with open-cell toward potential application.     

High porosity glass foams from waste glass and compound blowing agent

The foaming behavior of waste glass green spheres mixed with carbonate was investigated at the temperatures of 680–800 °C. Effects of carbonate on the foaming process, microstructures and properties of the obtained glass foams were evaluated. Both the organic compounds and carbonate act as blowing agents during the foaming process. The results show that the carbonate effectively promotes the foaming process in the temperature range of 680–800 °C. The obtained glass foams show uniform microstructure, with bulk density, porosity and compressive strength values of 0.117–0.209 g/cm³, 91.7–95.4 % and 0.52–3.93 MPa, respectively. The high porosity glass foams have potential applications in many areas such as thermal insulation materials and sound absorption materials.     

Design and formulation of polyurethane foam used for porous alumina ceramics

The present work studied a simple direct foaming method for preparation of porous alumina ceramics by expansion of a ceramic suspension based on polyurethane (PU) foam system. The effects of polyurethane formulas including catalyst composition, blowing agent content, NCO index and solid content on the samples properties were investigated. The results showed that the homogeneity, porosity and mechanical properties are various for different formulas. The dried green bodies showed diametrical compressive strength in the range of 0.39–1.25 MPa and were amenable to machining operations such as milling, drilling and lathing. Meanwhile, PU formulas play an important role in the microstructures and mechanical properties of green bodies and sintered ceramic foams. Pyrolytic removal of polyurethane skeleton followed by sintering at 1550 °C produced alumina bodies with open cell porosity 54–75% and diametrical compressive strength 1.39–28.47 MPa. Microstructure showed both large (200–300 μm) and small (50–100 μm) pores all with various sizes of windows. Based on the optimization of polyurethane formulation, the porous alumina foam with porosity of 64% and compressive strength of 25.26 MPa was prepared. This polyurethane foam system is easily available and low-cost, which could be widely applied in preparation of other porous ceramics, such as ZrO₂, SiO₂, etc.     

粒子稳定型泡沫浆料及多孔氧化铝陶瓷的制备

采用短链两亲分子戊酸修饰氧化铝颗粒,使其部分具有的疏水性,在机械搅拌的作用下,形成了粒子稳定型泡沫(particle-stabilized foam),制备了一种新型的超稳定陶瓷泡沫浆料.研究了这种浆料的pH值对发泡率的影响,发现在pH值为4.8附近,戊酸对氧化铝颗粒的表面修饰作用最好,发泡程度最大;通过改变pH值,能够调整浆料的发泡程度,以满足不同应用领域对发泡率的要求.采用凝胶注模成型工艺,利用粒子稳定型泡沫浆料,成功制备了具有相互连通气孔-窗口(cell-window)结构的多孔陶瓷,由于其致密的支架结构使其具有高抗压强度,对于气孔率为85%的多孔氧化铝,其抗压强度在8MPa以上.     

Preparation of alumina foams by the thermo-foaming of powder dispersions in molten sucrose

The alumina powder disperses in molten sucrose due to the hydrophilic interaction between the particle surface and sucrose hydroxyls. The thermo-foaming of the dispersions is due to the bubbles created by the water vapour produced by the OH condensation at 150 °C which are stabilized by the alumina particles adsorbed on the gas–liquid interface as well as the increase in viscosity. The foaming time, the foam setting time and the foam volume depend on the alumina powder to sucrose weight ratio. The alumina foams have interconnected cellular microstructure and the cells are having a near spherical morphology. The porosity (97.84–93.29 vol.%.) decreased and the average cell size (0.54–1.2 mm) increased with the increase in alumina powder to sucrose weight ratio (0.4–1.4). The alumina foams with density in the range of 0.239–0.267 g/cc showed compressive strength in the range of 1.02–1.47 MPa.     

A Novel Process for Low-Density Alumina Foams

A novel process for low-density alumina foams has been studied. Aqueous acidic sucrose solution containing aluminum nitrate when concentrated by heating formed a viscous resin. The resin mixed well with aqueous alumina slurry and the resulting powder-filled resin underwent foaming on heating in a Teflon mold. The green foams produced had very good handling strength. Binder removal and sintering of the green foam prepared at sucrose to alumina weight ratio in the range 0.69–1.03 produced alumina foam bodies with porosities 93.5%–96.7%. Microstructure of the foams depends on sucrose to alumina weight ratio such that a clear transition from reticulated structure to cellular foam structure took place at sucrose to alumina weight ratio below 0.89. Average pore size depends on sucrose to alumina weight ratio and was observed in the range 0.48–2.69 mm.     

Production of non‐crosslinked thermoplastic foams with a controlled density and a wide range of cellular structures

A novel foaming route, with respect to existing industrial foaming processes, called “Improved Compression Molding” (ICM), which allows producing non‐crosslinked thermoplastic foams in a wide density range, is described in this work. This process is different from others because it is possible to control independently density and cellular structure and therefore, tailored cellular polymers can be produced. To understand the process, a collection of polypropylene foams, with relative densities ranging from 0.3 to 0.6 were produced. The influence of foaming parameters, on foams microstructure and mechanical response was analyzed. Results revealed that for similar densities, foams with different open cell content and cell size can be achieved. In addition, it was proved that mechanical behavior strongly depends on the degree of interconnectivity of the cells. The analysis of the relative mechanical properties allowed determining the influence of microstructure on mechanical behavior as well as quantifying the efficiency of the foaming process to produce light‐weight stiff materials. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42324.