A Novel Method of Forming Open Cell Ceramic Foam

An alumina slurry containing 21 vol% solids was subjected to electrostatic atomization in the cone-jet mode producing droplets in the size range 0.5–53 m. Polyurethane foam was exposed to this electrospray and pyrolyzed to prepare open-cell alumina foam. Scanning electron microscopy showed that the struts of the ceramic foam produced did not contain holes or cracks and the total porosity of the foam was 96%. A hollow porous house and a twisted artefact was produced using the electrosprayed foam.