直接发泡法制备孔特性可控的氧化铝泡沫陶瓷

综述了近10年氧化铝泡沫陶瓷方面的研究进展,包括表面活性剂稳定泡沫制备的开孔泡沫陶瓷和颗粒稳定泡沫制备的闭孔泡沫陶瓷。对于表面活性剂稳定泡沫,分别采用环氧树脂–多胺和自发凝固2种凝胶体系进行固化成型,制备开孔氧化铝泡沫陶瓷。对于颗粒稳定泡沫,在采用调节浆料pH值或加入分散剂制备陶瓷浆料的基础上,使用长链的表面活性剂对分散的陶瓷颗粒进行疏水修饰,直接发泡后具有自发固化特性,制备出闭孔氧化铝泡沫陶瓷。     

化学发泡法制备稳定胶态泡沫及超轻质Al2O3泡沫陶瓷

利用过氧化氢(H_2O_2)和催化剂二氧化锰(MnO_2)进行化学发泡,基于颗粒稳定泡沫技术,以表面活性剂十二烷基硫酸钠(SDS)为颗粒表面改性剂,用超低固相含量5%～10%(质量分数)的浆料制备了颗粒稳定泡沫。常温常压干燥后在1 430℃烧结2 h制备出闭孔结构的泡沫陶瓷,利用亚微米粉末为原料制备出一种可以与气凝胶相类似的多孔陶瓷材料,其气孔率为98.2%～99.0%。研究了固相含量、H_2O_2和MnO_2加入量对泡沫陶瓷的稳定性影响以及发泡倍率、强度以及孔径与气孔率相互关系。     

颗粒稳定泡沫法制备钢渣泡沫陶瓷

以钢渣为原料,没食子酸正丙酯(PG)为表面活性剂,采用颗粒稳定泡沫法制备钢渣泡沫陶瓷.研究了钢渣含量、表面活性剂的添加量和烧结温度对泡沫陶瓷显微结构和力学性能的影响.结果 表明,采用颗粒稳定泡沫法能够制备出稳定的钢渣陶瓷泡沫,其稳定性与pH值和PG浓度有关.通过调整钢渣含量和烧结温度,可以很好地控制泡沫陶瓷的气孔率和耐压强度.钢渣含量为40％(质量分数),烧结温度为1 200℃时,得到的钢渣泡沫陶瓷气孔率为70.03％,耐压强度为3.08 MPa.     

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.     

聚氨酯泡沫模板法低温制备SiC泡沫陶瓷

利用聚氨酯泡沫浸渍聚碳硅烷(PCS)与SiC微粉制成的有机溶剂浆料,挂浆素坯经热氧化处理后于1000℃下惰性气体中烧结制备SiC泡沫陶瓷。运用X衍射分析、扫描电镜、线收缩率测定和三点弯折强度测试等手段,研究了PCS含量、SiC颗粒粒径对泡沫陶瓷线收缩率、微观形貌、抗弯强度的影响。结果表明:PCS经1000℃热解产物为无定形结构,无定形SiC将SiC颗粒粘结起来,形成泡沫陶瓷的骨架筋结构,泡沫陶瓷孔径介于0.3～0.6mm之间;SiC泡沫陶瓷线收缩率随SiC颗粒尺寸与PCS含量的增大而增加,抗弯强度随颗粒尺寸的增加而减小;在颗粒尺寸为0.3μm时,PCS含量为10%时,抗弯强度最大为2.8MPa,当SiC颗粒尺寸为1μm、5μm、10μm和20μm时,PCS含量为15%时,其抗弯强度最大值分别为2.2 MPa、2.1MPa、1.8 MPa和1.4MPa。     

多孔氮化硅微观组织结构对力学性能的影响

通过添加造孔剂苯甲酸,利用气氛压力烧结技术制备出了不同气孔率(40%～70%)的多孔氮化硅陶瓷,研究了显微结构对材料力学性能的影响;通过分析发现发育较好的长柱状β-氮化硅晶粒保证了材料获得良好的室温力学性能;而材料密度低、晶粒发育不完全是多孔氮化硅陶瓷力学性能下降的主要原因。本文制备的多孔氮化硅断裂形式为沿晶和穿晶断裂模式,当陶瓷气孔率为52%时,弯曲强度为195MPa。     

制备工艺对氮化硅泡沫陶瓷中晶须生长的影响

采用直接起泡法,通过氮化硅颗粒稳定泡沫机制制备氮化硅泡沫陶瓷,研究了烧结温度、保温时间、烧结氮气压、烧结助剂(Al2O3+Y2O3)添加量以及Al2O3与Y2O3质量比对氮化硅泡沫陶瓷中晶须生长的影响,分析了泡沫陶瓷的微观结构。结果表明:通过工艺条件的控制可得到由长柱状β-Si3N4晶粒构成的显微结构;当烧结温度为1750℃、保温时间为4 h、烧结气压为0.9 MPa、烧结助剂添加量为6%(质量分数)、Al2O3与Y2O3质量比为1:1时,β-Si3N4晶粒的长径比达到12以上。     

烧结助剂对多孔氮化硅陶瓷的力学性能及介电性能的影响

通过添加烧结助剂,采用常压烧结工艺制备出不同气孔率(19%～54%)的氮化硅陶瓷.采用Archimedes法、三点弯曲法和Vickers硬度测试法测量了材料的密度、气孔率、抗弯强度及硬度.用X射线衍射及扫描电镜检测了相组成和显微结构.用谐振腔法测试了氮化硅陶瓷在10.2 GHz的介电特性.结果表明:材料具有优良的介电性能.随着烧结助剂的减少,样品中气孔率增加,力学性能有所下降,介电常数和介电损耗降低.添加Lu2O3所制备的氮化硅陶瓷的力学性能和介电性能优于添加Eu2O3或Y2O3制备的氮化硅陶瓷.当气孔率高于50%时,多孔氮化硅陶瓷(添加入5%的Y2O3或Lu2O3,或Eu2O3,质量分数)的抗弯强度可达170 MPa,介电常数为3.0～3.2,介电损耗为0.000 6～0.002.     

Effect of Fabrication Process on Whisker Growth in Si3N4 Foam Ceramics

采用直接起泡法,通过氮化硅颗粒稳定泡沫机制制备氮化硅泡沫陶瓷,研究了烧结温度、保温时间、烧结氮气压、烧结助剂（Al2O3＋Y2O3）添加量以及 Al2O3与 Y2O3质量比对氮化硅泡沫陶瓷中晶须生长的影响,分析了泡沫陶瓷的微观结构。结果表明：通过工艺条件的控制可得到由长柱状β-Si3N4晶粒构成的显微结构;当烧结温度为 1750 ℃、保温时间为 4 h、烧结气压为 0.9 MPa、烧结助剂添加量为 6% （质量分数）、Al2O3与 Y2O3质量比为 1：1 时,β-Si3N4晶粒的长径比达到 12 以上     

泡沫浸渍法制备氧化铝多孔陶瓷

采用泡沫浸渍工艺制备出了高孔隙率、高强度的氧化铝多孔陶瓷,研究了泡沫体的预处理方式以及烧成温度对多孔陶瓷性能的影响。扫描电子显微镜（SEM）结果显示：选用聚氨酯泡沫体作为成型骨架,并对其进行酒精浸泡和清水冲洗的预处理过程,最终制备的氧化铝多孔陶瓷具有很高的气孔率,且孔洞分布均匀,孔的连通性好,孔径在0.3-1 mm之间。陶瓷的最佳烧成温度为1600℃,此时陶瓷气孔率保持在67%以上,抗折强度为5.6 MPa。     

Pore structure control of Si3N4 ceramics based on particle-stabilized foams

Porous Si₃N₄ ceramics with open, closed pores and nest-like structures were prepared by direct foaming method, and the stability of bubbles and the microstructures of sintered Si₃N₄ foam ceramics were investigated. The bubbles produced by short-chain amphiphiles have higher stability as compared with that produced by long-chain surfactants. Si₃N₄ ceramic foams using short-chain amphiphiles are particle-stabilized one, porous Si₃N₄ ceramics with open and closed pores can be easily prepared with this method, and the nest-like microstructure in Si₃N₄ foam ceramics is achieved at high gas-pressure sintering conditions. The decrease of flexural strength due to the increase of porosity can be weakened by decreasing pore size.     

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.     

Effect of carboxymethyl cellulose addition on the properties of Si3N4 ceramic foams

The effect of carboxymethyl cellulose (CMC) addition on the preparation of Si₃N₄ ceramic foam by the direct foaming method was investigated. The addition of CMC in the foam slurry can reduce the surface tension, increase the viscoelasticity of foams, and improve their stability and fluidity. The foam ceramics show low shrinkage during drying owing to the CMC and the gelation of acrylamide monomers. The surface structure of dried foam is uniform, and there are no macropores and cracks on the surface. The sintered Si₃N₄ foam ceramics have very uniform pore distribution with average pore size of about 16 μm; the flexure strength is as high as 3.8–77.2 MPa, and the porosity is about 60.6–82.1%.     

Effect of valeric acid on the agglomeration of zirconia particles and effects of the sintering temperature on the strut wall thickness of particle-stabilized foam

Highly porous zirconia ceramics were prepared utilizing a particle-stabilized direct foaming technique in which the hydrophilic characteristic of zirconia particles was altered by the in situ adsorption of valeric acid on its surface. These surface modified zirconia particles are irreversibility adsorbed at the air/water interface and create an armor coating around the bubbles to stabilize them. In this study, the foamability and stability of zirconia foam were investigated by varying the valeric acid concentration, and zirconia foam with a foam volume of approximately four times the colloidal system volume was successfully prepared. The sintered foam has cell size ranging from 50 to 150 μm and the pore structure was characterized by mercury porosimetry. The effects of the sintering temperature on the grain size, strut wall thickness, and tetragonal phase were studied and correlated with an increase in the mechanical strength to 3.5 MPa with porosity of more than 90%.     

Porous Silicon Carbide Ceramics Produced by a Carbon Foam Derived from Mixtures of Mesophase Pitch and Si Particles

Carbon foam templates were prepared from a mixture of mesophase pitch (MP) and Si particles, followed by foaming and carbonization. Subsequent molten Si infiltrated into the carbon foam at 1500°C for 4 h in an inert atmosphere resulted in the formation of porous SiC ceramics. Micrographs were investigated by a scanning electron microscope (SEM), and phase identification of porous SiC ceramics was performed by X-ray diffraction (XRD). The flexural strength and bulk density of porous SiC ceramics were also measured and calculated. The results revealed that the flexural strength of porous SiC ceramics increases with increasing Si content and decreasing porosity. The addition of Si in MP results in an increased densification of porous SiC struts. With 50 wt% Si, porous SiC ceramics with a high flexural strength of 23.9 MPa and a porosity of 55% were obtained.     

烧结助剂含量对多孔Si3N4/BN复合陶瓷力学性能和介电性能的影响

以Si3N4和BN为原料,叔丁醇为溶剂,SiO2、Y2O3和Al2O3为烧结助剂,采用凝胶注模成型工艺制备具有高强度、低介电常数多孔Si3N4/BN复合陶瓷。研究了Y2O3和Al2O3含量对多孔陶瓷气孔率、孔径分布、物相组成、显微结构、抗弯强度和介电常数的影响。结果表明:通过调节Y2O3和Al2O3含量,多孔Si3N4/BN复合陶瓷的气孔率由55%增加到68%,气孔尺寸呈单峰分布,平均孔径为0.89～1.02μm;抗弯强度和相对介电常数随Y2O3和Al2O3含量的增加而单调增大,抗弯强度和相对介电常数的变化范围分别为29.9～60.9 MPa和2.30～2.85;通过调节Y2O3和Al2O3含量调控气孔率,能够获得介电性能和力学性能可调的高性能透波材料。     

Harnessing Ostwald ripening to fabricate hierarchically structured mullite-based cellular architecture via the gelation network-triggered morphology-regulation method

Gas-in-liquid foam templating is considered as a promising method for commercial-scale production of porous materials. However, Ostwald ripening occurs frequently during the preparation, which could bring about inhomogeneous bubbles with large sizes and deteriorate the performance of resultant products. To tackle this challenging task, we report a gelation network-triggered morphology-regulation strategy during the foaming process. As an exemplar, boehmite sol was incorporated into the andalusite suspension to stabilize the foam framework. After casting, the wet foam was able to maintain its overall shape, since andalusite particles were anchored onto the gas-liquid interface by the gelation network during mechanical frothing. The samples calcined at 1400°C feature homogeneous bubble with hierarchical porous architecture, smaller pore size with a mean value of 5.32 μm and robust compressive strength of 11.97MPa at a porosity level of 84 %. Our approach substantially broadens the design philosophy of high performance porous ceramics.     

Performance study of foam ceramics prepared by direct foaming method using red mud and K-feldspar washed waste

In this study, foam ceramics were prepared via a direct foaming method at high temperatures (1080–1120 °C), using red mud (RM) and K-feldspar washed waste (KFW) as the raw materials and SiC as the foaming agent, respectively. The chemical compositions and crystalline phases of the raw materials as well as the structural and mechanical properties of the foam ceramics were investigated. By adjusting the formulation and sintering process parameters, the porous structure of the foam ceramics could be effectively modulated. In addition to some residual crystalline phases in the raw materials, new phases, including rutile (TiO₂) and anorthite (CaAl₂Si₂O₈), were generated in foam ceramics. The compressive strength of the foam ceramics decreased with an increase in the KFW/RM ratio and sintering temperature, which was mainly related to the low density of the foam ceramics and the poor support of the pore walls to the structure. Among all the foam ceramics investigated, the foam ceramic with the KFW/RM ratio of 1:1, SiC content of 1 wt%, sintering temperature of 1100 °C and sintering time of 60 min showed the best overall performance with a bulk density, an apparent porosity, an average pore size and a compressive strength of 0.77 g/cm³, 61.89%, 0.52 mm, and 3.64 MPa, respectively. Its excellent porous structure and mechanical properties rendered it suitable for application as insulation materials or decorative materials for building partition walls.     

Analysis of the Effects of Hydrocarbon Chain on Foam Properties of Alkyl Polyglycosides

The influence of surfactant structure on foam properties of different alkyl polyglycosides (APGs) in aqueous solutions was studied. Foamability, foam stability, and foam morphology were analyzed using the FoamScan method. Results showed that the foamability, foam stability, and the liquid carrying ability of long-chain APGs are higher than those of short-chain APGs. Foam morphology analysis showed that the foam produced by short-chain APGs is more unstable than the foam generated by long-chain APGs. Long-chain APGs have stronger intermolecular cohesion force, stringency, and ductility than short-chain APGs.