Supercritical CO2-assisted extrusion foaming: A suitable process to produce very lightweight acrylic polymer micro foams

A strategy of CO₂-assisted extrusion foaming of PMMA-based materials was established to minimize both foam density and porosities dimension. First a highly CO₂-philic block copolymer (MAM: PMMA-PBA-PMMA) was added in PMMA in order to improve CO₂ saturation before foaming. Then the extruding conditions were optimized to maximize CO₂ uptake and prevent coalescence. The extruding temperature reduction led to an increase of pressure in the barrel, favorable to cell size reduction. With the combination of material formulation and extruding strategy, very lightweight homogeneous foams with small porosities have been produced. Lightest PMMA micro foams (ρ = 0.06 g cm⁻³) are demonstrated with 7 wt% CO₂ at 130°C and lightest blend micro foams (ρ = 0.04 g cm⁻³) are obtained at lower temperature (110°C, 7.7 wt% CO₂). If MAM allows a reduction of T^foaming, it also allows a much better cell homogeneity, an increase in cell density (e.g., from 3.6 10⁷ cells cm⁻³ to 2 to 6 10⁸ cells cm⁻³) and an overall decrease in cell size (from 100 to 40 μm). These acrylic foams produced through scCO₂-assisted extrusion has a much lower density than those ever produced in batch (ρ ≥ 0.2 g cm⁻³).     

Batch foaming of SAN/clay nanocomposites with scCO2: A very tunable way of controlling the cellular morphology

This paper aims at elucidating some important parameters affecting the cellular morphology of poly(styrene-co-acrylonitrile) (SAN)/clay nanocomposite foams prepared with the supercritical CO₂ technology. Prior to foaming experiments, the SAN/CO₂ system has first been studied. The effect of nanoclay on CO₂ sorption/desorption rate into/from SAN is assessed with a gravimetric method. Ideal saturation conditions are then deduced in view of the foaming process. Nanocomposites foaming has first been performed with the one-step foaming process, also called depressurization foaming. Foams with different cellular morphology have been obtained depending on nanoclay dispersion level and foaming conditions. While foaming at low temperature (40 °C) leads to foams with the highest cell density (∼10¹²-10¹⁴ cells/cm³), the foam expansion is restricted (d∼0.7-0.8 g/cm³). This drawback has been overcome with the use of the two-step foaming process, also called solid-state foaming, where foam expansion occurs during sample dipping in a hot oil bath (d∼0.1-0.5 g/cm³). Different foaming parameters have been varied, and some schemes have been drawn to summarize the characteristics of the foams prepared - cell size, cell density, foam density - depending on both the foaming conditions and nanoclay addition. This result thus illustrates the huge flexibility of the supercritical CO₂ batch foaming process for tuning the foam cellular morphology.     

Stabilization of natural gas foams using different surfactants at high pressure and high temperature conditions

Natural gas foam can be used for mobility control and channel blocking during natural gas injection for enhanced oil recovery, in which stable foams need to be used at high reservoir temperature, high pressure and high water salinity conditions in field applications. In this study, the performance of methane (CH₄) foams stabilized by different types of surfactants was tested using a high pressure and high temperature foam meter for surfactant screening and selection, including anionic surfactant (sodium dodecyl sulfate), non-anionic surfactant (alkyl polyglycoside), zwitterionic surfactant (dodecyl dimethyl betaine) and cationic surfactant (dodecyl trimethyl ammonium chloride), and the results show that CH₄-SDS foam has much better performance than that of the other three surfactants. The influences of gas types (CH₄, N₂, and CO₂), surfactant concentration, temperature (up to 110°C), pressure (up to 12.0 MPa), and the presence of polymers as foam stabilizer on foam performance was also evaluated using SDS surfactant. The experimental results show that the stability of CH₄ foam is better than that of CO₂ foam, while N₂ foam is the most stable, and CO₂ foam has the largest foam volume, which can be attributed to the strong interactions between CO₂ molecules with H₂O. The foaming ability and foam stability increase with the increase of the SDS concentration up to 1.0 wt% (0.035 mol/L), but a further increase of the surfactant concentration has a negative effect. The high temperature can greatly reduce the stability of CH₄-SDS foam, while the foaming ability and foam stability can be significantly enhanced at high pressure. The addition of a small amount of polyacrylamide as a foam stabilizer can significantly increase the viscosity of the bulk solution and improve the foam stability, and the higher the molecular weight of the polymer, the higher viscosity of the foam liquid film, the better foam performance.     

Synergistic Effects between Anionic and Sulfobetaine Surfactants for Stabilization of Foams Tolerant to Crude Oil in Foam Flooding

In foam flooding, foams stabilized by conventional surfactants are usually unstable in contacting with crude oil, which behaves as a strong defoaming agent. In this article, synergistic effects between different surfactants were utilized to improve foam stability against crude oil. Targeted to reservoir conditions of Daqing crude oil field, China (45 °C, salinity of 6778 mg L⁻¹, pH = 8–9), foams stabilized by typical anionic surfactants fatty alcohol polyoxyethylene ether sulfate (AES) and sodium dodecyl sulfate (SDS) show low composite foam index (200–500 L s) and low oil tolerance index (0.1–0.2). However, the foam stability can be significantly improved by mixing the anionic surfactant with a sulfobetaine surfactant, which behaves as a foam stabilizer increasing the half-life of foams, and those with longer alkyl chain behave better. As an example, by mixing AES and SDS with hexadecyl dimethyl hydroxypropyl sulfobetaine (C₁₆HSB) at a molar fraction of 0.2 (referring to total surfactant, not including water), the maximum composite foaming index and oil tolerance index can be increased to 3000/5000 L s and 1.0/4.0, respectively, at a total concentration between 3 and 5 mM. The attractive interaction between the different surfactants in a mixed monolayer as reflected by the negative β^s parameter is responsible for the enhancement of the foam stabilization, which resulted in lower interfacial tensions and therefore negative enter (E), spreading (S), and bridging (B) coefficients of the oil. The oil is then emulsified as tiny droplets dispersed in lamellae, giving very stable pseudoemulsion films inhibiting rupture of the bubble films. This made it possible to utilize typical conventional anionic surfactants as foaming agents in foam flooding.     

Aqueous Foam Stabilized by Hydrophobic SiO2 Nanoparticles using Mixed Anionic Surfactant Systems under High-Salinity Brine Condition

A primary concern of surfactant-assisted foams in enhanced oil recovery (EOR) is the stability of the foams. In recent studies, foam stability has been successfully improved by the use of nanoparticles (NP). The adhesion energy of the NP is larger than the adsorbed surfactant molecules at the air–water interface, leading to a steric barrier to mitigate foam-film ruptures and liquid-foam coalescence. In this study, the partially hydrophobic SiO₂ nanoparticles (SiO₂-NP) were introduced to anionic mixed-surfactant systems to investigate their potential for improving the foamability and stability. An appropriate ratio of internal olefin sulfonate (C_15-18 IOS) and sodium polyethylene glycol monohexadecyl ether sulfate (C₃₂H₆₆Na₂O₅S) was selected to avoid the formation of undesirable effects such as precipitation and phase separation under high-salt conditions. The effects of the NP-stabilized foams were investigated through a static foam column experiment. The surface tension, zeta potential, bubble size, and bubble size distribution were observed. The stability of the static foam in a column test was evaluated by co-injecting the NP-surfactant mixture with air gas. The results indicate that the foam stability depends on the dispersion of NP in the bulk phase and at the water–air interface. A correlation was observed in the NP-stabilized foam that stability increased with increasing negative zeta potential values (−54.2 mv). This result also corresponds to the smallest bubble size (214 μm in diameter) and uniform size distribution pattern. The findings from this study provide insights into the viability of creating NP-surfactant interactions in surfactant-stabilized foams for oil field applications.     

Carbon dioxide‐in‐water foams stabilized with nanoparticles and surfactant acting in synergy

Synergistic interactions at the interface of nanoparticles (bare colloidal silica) and surfactant (caprylamidopropyl betaine) led to the generation of viscous and stable CO₂‐in‐water (C/W) foams with fine texture at 19.4 MPa and 50°C. Interestingly, neither species generated C/W foams alone. The surfactant became cationic in the presence of CO₂ and adsorbed on the hydrophilic silica nanoparticle surfaces resulting in an increase in the carbon dioxide/water/nanoparticle contact angle. The surfactant also adsorbed at the CO₂–water interface, reducing interfacial tension to allow formation of finer bubbles. The foams were generated in a beadpack and characterized by apparent viscosity measurements both in the beadpack and in a capillary tube viscometer. In addition, the macroscopic foam stability was observed visually. The foam texture and viscosity were tunable by controlling the aqueous phase composition. Foam stability is discussed in terms of lamella drainage, disjoining pressure, interfacial viscosity, and hole formation. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3490–3501, 2013     

Fabrication of PEI-grafted porous polymer foam for CO2 capture

A polymer foam material with both the open-cell porous structure and the polyethylenemine (PEI)-grafted inner face was constructed for CO₂ capture. The porous poly(tert-butyl acrylate) foam was first prepared via a concentrated emulsion polymerization, and then the carboxyl groups were introduced on the interface of porous polymer after the hydrolysis reaction. Subsequently, the surface of the foam was grafted with PEI, and finally the PEI-grafted porous polymer foam designed as a CO₂ capture material was obtained. The structures of the foams were characterized by infrared spectroscopy, EDS, and SEM. The CO₂ adsorption properties were measured by adsorption/desorption cycles. As a result, the polymer foam contained a large number of amine groups (13.9 wt % N), and therefore possessed a high CO₂ adsorption capacity (5.91 mmol g⁻¹ at 40°C and 100 kPa). In addition, they also exhibited high CO₂ adsorption rate, good selectivity for CO₂-N₂ separation, and good stability according to CO₂ cyclic adsorption/desorption test. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47844.     

Preparation of open‐cell foams from polymer blends by supercritical CO2 and their efficient oil‐absorbing performance

This letter reports on the hydrophobicity and oleophilicity of open‐cell foams from polymer blends prepared by supercritical CO₂. A typical bulk density of the foam is measured to be 0.05 g/cm³. The contact angle of the foam with water is determined to be 139.2°. The foam can selectively absorb the diesel from water with the uptake capacity of 17.0 g/g. The foams are technologically promising for application of oil spill cleanup. © 2016 American Institute of Chemical Engineers AIChE J, 62: 4182–4185, 2016     

Porosity effect on microstructure,mechanical, and fluid dynamic properties of Ti2AlC by direct foaming and gel‐casting

In this study, Ti₂AlC foams were fabricated by direct foaming and gel‐casting using agarose as gelling agent. Slurry viscosity, determined by the agarose content (at a fixed solids loading), as well as surfactant concentration and foaming time were the key parameters employed for controlling the foaming yield, and hence the foam porosity after sintering process. Fabricated foams having total porosity in the 62.5‐84.4 vol% range were systematically characterized to determine their pore size and morphology. The effect of the foam porosity on the room‐temperature compression strength and elastic modulus was also determined. Depending on the amount of porosity, the compression strength and Young's modulus were found to be in the range of 9‐91 MPa and 7‐52 GPa, respectively. Permeability to air flow at temperatures up to 700°C was investigated. Darcian (k₁) and non‐Darcian (k₂) permeability coefficients displayed values in the range 0.30‐93.44 × 10^?11 m² and 0.39‐345.54 × 10^?7 m, respectively. The amount of porosity is therefore a very useful microstructural parameter for tuning the mechanical and fluid dynamic properties of Ti₂AlC foams.     

Open-cell reaction bonded silicon nitride foams: Fabrication and characterization

In this study, a newly designed fabrication procedure was utilized to produce silicon nitride foams. The main goal of the present study was to obtain Si₃N₄ foams with high levels of porosity and pore interconnectivity via an economical fabrication procedure including sacrificial template technique, gel-casting and reaction bonding processes. The fabrication procedure was studied and optimized in terms of suspension preparation and rheology, gel-casting parameters, and reaction bonding conditions. The produced foams have a precisely controlled level of porosity which can be varied up to 87 vol%. BET analysis showed that the surface area of the foam is of the order of 2.01 m²/g. The pore interconnectivity of the foam was investigated via polyester resin infiltration. Based on XRD and SEM analysis, the dominant nitriding reactions are the gas-phase reactions which lead to α-Si₃N₄ in the form of whiskers.     

Colloidal co-assembly of dual-phased ceramic/metal particles toward lightweight,hierarchically structured,and mechanically robust alumina foam

Ceramic foams constructed by aqueous-based foam templating have demonstrated great potential in industrial and research applications. However, a multiple-phased suspension with inherently improved complexity inevitably leads to a severe deterioration of foam stability. Herein, we proposed a colloidal co-assembly strategy that introduces Al–Al₂O₃ dual-phased particles for constructing ultralight yet mechanically robust cellular ceramics. Owing to the Al₂O₃ oxidation layer on Al particles, both of Al and Al₂O₃ suspensions demonstrated similar zeta potential and rheological properties, enabling a stable foam structure after colloidal co-assembly. High-temperature oxidation of Al particles contributed to the reinforcement of cell wall and formation of Al₂O₃ whiskers. The calcined products demonstrated a lightweight structure (0.31 g cm⁻³), a robust compressive strength (3.64 MPa) at a porosity level of 88.5%, and a relatively high specific surface area (14.7 m² g⁻¹). The current strategy paves the way for the construction of high-performance ceramic foams for a broad range of applications.     

Comparative Investigation of Dynamic Foam Behavior of Air–Water and CO2–Water Systems

The purpose of this study was to understand and compare the dynamic foam behavior of the surfactant Tween‐20 in air–water and CO₂–water systems. The foam height in the CO₂–water system was less than that in the air–water system, but the foam stability was better in the CO₂–water system. The effect of temperature on axial dye displacement and foam bubble size was studied, where the foam generation ability of the surfactant was directly proportional to the temperature, while the foaminess was inversely proportional. The observed highest foam volume for the air–water system was 3922 ± 181 cm³ and for the CO₂–water system 3195 ± 181 cm³ at 5.0 g L^–1 of surfactant at air flow rate of 1 liter per minute (LPM) at 52 °C. The half‐life for the air–water and the CO₂–water system was 110 and 40 s, respectively, at 5.0 g L^–1 of surfactant at the air flow rate of 1 LPM and 28 °C. In wet foam, the liquid holdup range for the air–water system was 0.38–0.52% and for the CO₂–water system 0.51–0.72% in the concentration range 1.0–5.0 g L^–1 at 1 LPM gas flow rate.     

Stability improvement of CO2 foam for enhanced oil‐recovery applications using polyelectrolytes and polyelectrolyte complex nanoparticles

CO₂ foam for enhanced oil‐recovery applications has been traditionally used in order to address mobility‐control problems that occur during CO₂ flooding. However, the supercritical CO₂ foam generated by surfactant has a few shortcomings, such as loss of surfactant to the formation due to adsorption and lack of a stable front in the presence of crude oil. These problems arise because surfactants dynamically leave and enter the foam interface. We discuss the addition of polyelectrolytes and polyelectrolyte complex nanoparticles (PECNP) to the surfactant solution to stabilize the interface using electrostatic forces to generate stronger and longer‐lasting foams. An optimized ratio and pH of the polyelectrolytes was used to generate the nanoparticles. Thereafter we studied the interaction of the polyelectrolyte–surfactant CO₂ foam and the polyelectrolyte complex nanoparticle–surfactant CO₂ foam with crude oil in a high‐pressure, high‐temperature static view cell. The nanoparticle–surfactant CO₂ foam system was found to be more durable in the presence of crude oil. Understanding the rheology of the foam becomes crucial in determining the effect of shear on the viscosity of the foam. A high‐pressure, high‐temperature rheometer setup was used to shear the CO₂ foam for the three different systems, and the viscosity was measured with time. It was found that the viscosity of the CO₂ foams generated by these new systems of polyelectrolytes was slightly better than the surfactant‐generated CO₂ foams. Core‐flood experiments were conducted in the absence and presence of crude oil to understand the foam mobility and the oil recovered. The core‐flood experiments in the presence of crude oil show promising results for the CO₂ foams generated by nanoparticle–surfactant and polyelectrolyte–surfactant systems. This paper also reviews the extent of damage, if any, that could be caused by the injection of nanoparticles. It was observed that the PECNP–surfactant system produced 58.33% of the residual oil, while the surfactant system itself produced 47.6% of the residual oil in place. Most importantly, the PECNP system produced 9.1% of the oil left after the core was flooded with the surfactant foam system. This proves that the PECNP system was able to extract more oil from the core when the surfactant foam system was already injected. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44491.     

Low‐temperature sintering and enhanced piezoelectric properties of random and textured PIN–PMN–PT ceramics with Li2CO3

Low‐temperature sintered random and textured 36PIN–30PMN–34PT piezoelectric ceramics were successfully synthesized at a temperature as low as 950°C using Li₂CO₃ as sintering aids. The effects of Li₂CO₃ addition on microstructure, dielectric, ferroelectric, and piezoelectric properties in 36PIN–30PMN–34PT ternary system were systematically investigated. The results showed that the grain size of the specimens increased with the addition of sintering aids. The optimum properties for the random samples were obtained at 0.5 wt% Li₂CO₃ addition, with piezoelectric constant d₃₃ of 450 pC/N, planar electromechanical coupling coefficient k_p of 49%, peak permittivity ε_max of 25 612, remanent polarization P_r of 36.3 μC/cm². Moreover, the low‐temperature‐sintered textured samples at 0.5 wt% Li₂CO₃ addition exhibited a higher piezoelectric constant d₃₃ of 560 pC/N. These results indicated that the low‐temperature‐sintered 36PIN–30PMN–34PT piezoelectric ceramics were very promising candidates for the multilayer piezoelectric applications.     

Molecular dynamics simulation of the synergistic effect of a compound surfactant on the stability of CO2 oil-based foam

It is of great significance to study the stability of foams in the petroleum industry. Therefore, the stability mechanism of Span 20, the fluorinated surfactant FCO-80 and their mixture FS in a CO₂ oil-based foam system were studied by molecular simulation. The sandwich model of CO₂ oil-based foam was constructed to reveal the stability of the foam system from the microscopic perspective. The result shows that under the synergistic effect of Span 20 and FCO-80, the oil–CO₂ distance of the FS foam system and the coordination number of oil molecules are larger than those of Span 20 and FCO-80 foam system. In FS foam system, the diffusion coefficients of CO₂ molecules are small, and the surface tension is reduced, which can improve the stability of foam. The results can supplement previous experimental results on the stability of oil-based foam.     

Thermosetting foam with a high bio‐based content from acrylated epoxidized soybean oil and carbon dioxide

A resilient, thermosetting foam system with a bio‐based content of 96 wt % (resulting in 81% of C₁₄) was successfully developed. We implemented a pressurized carbon dioxide foaming process that produces polymeric foams from acrylated epoxidized soybean oil (AESO). A study of the cell dynamics of uncured CO₂/ AESO foams proved useful to optimize cure conditions. During collapse, the foam's bulk density increased linearly with time, and the cell size and cell density exhibited power‐law degradation rates. Also, low temperature foaming and cure (i.e. high viscosity) are desirable to minimize foam cell degradation. The AESO was cured with a free‐radical initiator (tert‐butyl peroxy‐2‐ethyl hexanoate, T_i ～ 60°C). Cobalt naphtenate was used as an accelerator to promote quick foam cure at lower temperature (40–50°C). The foam's density was controlled by the carbon dioxide pressure inside the reactor and by the vacuum applied during cure. The viscosity increased linearly during polymerization. The viscosity was proportional to the extent of reaction before gelation, and the cured foam's structure showed a dependence on the time of vacuum application. The average cell size increased and the cell density decreased with foam expansion at a low extent of cure; however, the foam expansion became limited and unhomogeneous with advanced reaction. When vacuum was applied at an intermediate viscosity, samples with densities ～ 0.25 g/cm³ were obtained with small (<1 mm) homogeneous cells. The mechanical properties were promising, with a compressive strength of ～ 1 MPa and a compressive modulus of ～ 20 MPa. The new foams are biocompatible. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Fabrication and characterization of alumina and zirconia-toughened alumina porous structures

In the present study, alumina (Al₂O₃) and zirconia-toughened alumina (ZTA) porous structures (foams) were manufactured using the space holder technique. Al₂O₃ and ZTA foams with varying porosities from 20% to 69% were fabricated by adding different sizes (10, 20, and 40 μm) and different volume % of polystyrene beads (space holders) to Al₂O₃ and ZTA powders. All the fabricated foams were investigated under static conditions to assess the compressive behavior. It is observed that the compressive strength of these foams strongly depends on porosity, pore size, pore size distribution and pore wall thickness. Among all fabricated foams, Al₂O₃ foams with 20 vol% beads of 10 μm size showed a higher compressive strength of 700 MPa with low porosity (21%) and a higher pore wall thickness (2.8 μm). It is also observed that the pore wall thickness decreased with the increase in beads size and the volume % of the beads, resulting in a low compressive strength value of 8 MPa with a lower pore wall thickness of 1.75 μm at 80 vol% of 40 μm beads. All the foams, irrespective of pore size, showed a typical ceramic failure phenomenon up to 70 vol% of beads; after that, the failure behavior changed to complete open-cell fracture.     

Climate‐friendly polyurethane blowing agent based on a carbon dioxide adduct from palmitic acid grafted polyethyleneimine

To explore a new blowing agent for polyurethanes (PUs), palmitic acid was grafted onto a branched polyethyleneimine (bPEI; weight‐average molecular weight = 25,000 Da) via N,N′‐carbonyldiimidazole condensation to form a hydrophobically modified bPEI [palmitic acid grafted branched polyethyleneimine (C₁₆–bPEI)] with a grafting rate of 12%. A CO₂ adduct of C₁₆–bPEI, which trapped 16.8% CO₂ in it, was synthesized from C₁₆–bPEI. The long alkyl chain grafting improved the dispersibility of the CO₂ adduct in the PU raw materials and favored a homogeneous release of CO₂ to blow PUs during the exothermic foaming process. The preliminary results show that the foams possessed a density of 72.0 kg/m³ and a compressive strength of 246 kPa; this matched the required values of foams for the thermal insulation of underground steel pipes. This new blowing agent emitted nothing but CO₂ to the atmosphere, so it will not promote ozone depletion and will avoid global warming problems that are associated with traditional blowing agents such as chlorofluorocarbons and hydrochloroflourocarbons. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43874.     

Effect of formation of calcium carbonate on foam stability in Neodol 25-3S anionic surfactant systems

The effect of oils and hardness on stability of foams made from solutions containing 0.01 wt% of three EO alcohol ethoxysulfate sodium salt of commercial anionic surfactant Neodol 25-3S was investigated. When dissolved calcium was present under alkaline conditions using Na₂CO₃ instead of NaOH as a pH regulator, solid CaCO₃ precipitated. It was found in the absence of oil that CaCO₃ particles did not destabilize foam, in contrast to those of the more hydrophobic calcium oleate. The rate of collapse of a foam column was also measured for foams generated from alkaline solutions of an anionic surfactant Neodol 25-3S containing dispersed drops of n-hexadecane, triolein, or mixtures of these oils with small amounts of oleic acid. Oils were added in increments up to oil to surfactant ratio of 1 on a weight basis and the hardness and pH of the aqueous solutions were fixed at 300 ppm and 9 respectively. It was found that triolein has almost no defoaming effect, but the defoaming effect of hexadecane was evident. The same trend was found with mixtures of n-hexadecane/triolein with addition of small amounts of oleic acid. The results of foam stability measurement in the presence of oil could be understood in terms of entry, spreading and bridging coefficients, i.e., ESB analysis. Moreover, as the initial concentration of carbonate ions increased, foam stability was greatly improved for both hexadecane/oleic acid and triolein/oleic acid oils. Evidently, CaCO₃ precipitated preferentially, reducing the number of calcium ions available to form calcium oleate.     

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.