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.     

Foaming strategies for bioabsorbable polymers in supercritical fluid mixtures. Part II. Foaming of poly(?-caprolactone-co-lactide) in carbon dioxide and carbon dioxide + acetone fluid mixtures and formation of tubular foams via solution extrusion

This paper reports on the foaming of poly(?-caprolactone-co-lactide) in carbon dioxide and carbon dioxide + acetone mixtures. Experiments were carried out in specially designed molds with porous metal surfaces and fluid circulation features to generate foams with uniform dimensions at 60, 70 and 80 °C at pressures in the range 7-28 MPa. Depending upon the conditions, foams with pores in the range from 5 to 200 μm were generated. Adding acetone to carbon dioxide improved the uniformity of the pores compared to foams formed by carbon dioxide alone. In addition, a unique high-pressure solution extrusion system was designed and used to form porous tubular constructs by piston-extrusion of a solution from a high-pressure dissolution chamber through an annular die into a second chamber maintained at controlled pressure/temperature and fluid conditions. Long uniform porous tubular constructs with 6 mm ID and 1 mm wall thickness were generated with glassy polymers like poly(methyl methacrylate) by extruding solutions composed of 50 wt% polymer + 50 wt% acetone, or 25 wt% polymer + 10% acetone + 65% carbon dioxide at 70 °C and 28 MPa. Pores were in the 50 μm range. The feasibility of forming similar tubular constructs were demonstrated with poly(?-caprolactone-co-lactide) as well. Tubular foams of the copolymer with interconnected pores with pore sizes in the 50 μm range were generated by extrusion of the copolymer solution composed of 25 wt% polymer + 10 wt% acetone + 65 wt% carbon dioxide at 70 °C and 28 MPa. Reducing the acetone content in the solution led to a reduction of pore sizes. Comparisons with the foaming behavior of the homopolymer poly(?-caprolactone) that were carried out in the molds with porous metal plates show that the foaming behavior of the copolymer is more akin to the foaming behavior of the caprolactone homopolymer component.     

Formation and characterization of porous spherical biphasic calcium phosphate (BCP) granules using PCL

We developed a process to fabricate porous spherical BCP granules using different volumetric ratios of polycaprolactone (PCL). This technique takes advantage of the formation of spherical drop shapes that occur for any liquid. The method to produce porous granules is based on the liquid immiscibility effect of a PCL solution and distilled water. Granules were sintered at 1300 °C and 1400 °C using conventional and microwave sintering techniques. Using this approach, the granules showed a good pore-interconnected relation and granules with a porosity that ranged from 36.12% to 59.8%, inner pore sizes that ranged from 30 μm to 250 μm, and a granular size of about 1.5 mm could be obtained. Granules were characterized for microstructure, phase composition and porosity. Using this novel approach, we were able to achieve desirable porous characteristics that simulate natural bone structure.     

Fabrication of porous SiC ceramics having pores shaped with Si grain templates

SiC porous ceramics were prepared by heating mixtures of Si powder and carbon black at 900 °C for 24 h in Na vapor. The grains of the Si powder were not only the source of Si for SiC but also served as templates for the pores in the SiC porous ceramics. Angular-shaped pores with sizes of 2-10, 10-150 and 50-150 μm were formed by angular Si grains with sizes of ≤10, ≤50 and ≤150 μm, respectively. The porosity of the SiC porous ceramics was around 55-59%. Spherical pores were also formed when spherical Si grains were used. A bending strength of 14 MPa was measured for the SiC porous ceramics prepared with the Si grains (≤50 μm).     

Silicon carbide-based foams from direct blowing of polycarbosilane

Macro-cellular porous silicon carbide foams were produced using a polycarbosilane preceramic polymer and a chemical blowing agent (azodicarbonamide). Polycarbosilane (PCS) was mixed with a blowing agent and the mixture was foamed close to the melting point of PCS at 250-260 °C, under nitrogen in order to avoid cross-linking by oxidation. The foamed PCS was then cured under air at 200 °C and pyrolyzed at 1000 °C, leading to the formation of open macro-cellular ceramic components. Porosity ranged from 59 to 85 vol%, and the cell size ranged from 416 to 1455 μm; these values could be modulated by changing the content of blowing agent and foaming temperature. This process is a simple and efficient way to produce silicon carbide-based foam with tailored pore architecture and porosity.     

A study of the sintering of diatomaceous earth to produce porous ceramic monoliths with bimodal porosity and high strength

Diatomite powder, a naturally occurring porous raw material, was used to fabricate ceramic materials with bimodal porosity and high strength. The effect of the sintering temperature on the density and porosity of dry pressed diatomite green bodies was evaluated using mercury porosimetry and water immersion measurements. It was found that the intrinsic porosity of the diatomite particles with a pore size around 0.2 µm was lost at sintering temperatures above 1200 °C. Maintaining the sintering temperature at around 1000 °C resulted in highly porous materials that also displayed a high compressive strength. Microstructural studies by scanning electron microscopy and energy-dispersive X-ray analysis suggested that the pore collapse was facilitated by the presence of low melting impurities like Na₂O and K₂O.     

Manufacture and characterization of ultra and microfiltration ceramic membranes by isostatic pressing

This paper describes the manufacture of tubular UF and MF porous and supported ceramic membranes to oil/water emulsions demulsification. For such a purpose, a rigorous control was realized over the distribution and size of pores. Suspensions at 30 vol.% of solids (zirconia or alumina powder and sucrose) and 70 vol.% of liquids (isopropyl alcohol and PVB) were prepared in a jar mill varying the milling time of the sucrose particles, according to the pores size expected. The membranes were prepared by isostatic pressing method and structurally characterized by SEM, porosimetry by mercury intrusion and measurements of weight by immersion. The morphological characterization of the membranes identified the formation of porous zirconia and alumina membranes and supported membranes. The results of porosimetry analysis by mercury intrusion presented an average pore size of 1.8 μm for the microfiltration porous membranes and for the ultrafiltration supported membranes, pores with average size of 0.01-0.03 μm in the top-layer and 1.8 μm in the support. By means of the manufacture method applied, it was possible to produce ultra and microfiltration membranes with high potential to be applied to the separation of oil/water emulsions.     

In vitro biodegradable and mechanical performance of biphasic calcium phosphate porous scaffolds with unidirectional macro-pore structure

In this study, porous biphasic calcium phosphate (BCP) scaffolds were fabricated by a freeze–gel casting technique using a tertiary-butyl alcohol (TBA) based slurry. After sintering, unidirectional macropore channels of scaffolds aligned regularly along the TBA ice growth direction were tailored simultaneously with micropores formed in the outer wall of the pore channels. The synthesized porous BCP scaffolds (two different sintering temperatures) exhibit compressive strength of 46.8 MPa for 43.0% porosity and 33.1 MPa for 45.9% porosity, respectively. After immersion in Hank's balanced salt solution (HBSS) for 1, 2, 4, 8 weeks, a precipitation started to be formed with individual small granules on the scaffolds surface. In the case of BCP scaffolds sintered at 1200 °C, β-TCP were slowly degraded with increasing the immersing time; on the other hand, α-TCP (from BCP scaffolds sintered at 1300 °C) was extremely degraded within 1 week of immersing. This behavior could be due to a fast hydrolysis (dissolution–reprecipitation) as a phase transformation from α-TCP to brushite or apatite compared to the β-TCP. After immersion in HBSS, overall the compressive strength of the scaffolds reduced by the gradual degradation in biological environment solution. This behavior is consistent with the degradation behavior of scaffolds after immersion in HBSS.     

Mechanical activation of fly ash: Effect on reaction, structure and properties of resulting geopolymer

Geopolymerisation of mechanically activated fly ash was studied at ambient (27 °C) and elevated (60 °C) temperatures by isothermal conduction calorimeter. Under both the conditions, mechanical activation enhanced the rate and decreased time of reaction. It was interesting to observe that in the samples milled for 45 min (median size ∼5 μm), a broad peak corresponding to geopolymerisation initiated at 27 °C after 32 h. The rate maxima at 60 °C, a measure of fly ash reactivity, showed a non-linear dependence on particle size and increased rapidly when the median size was reduced to less than 5-7 μm. Improvement in strength properties is correlated with median particle size, and reactivity of fly ash. The characterisation of the geopolymer samples by SEM-EDS, XRD and FTIR revealed that mechanical activation leads to microstructure and structural variations which can be invoked to explain the variation in the properties.     

Ceramic foams and micro-beads from emulsions of a preceramic polymer

A commercially available solid silicone resin was dissolved in a solvent and emulsified via stirring in the presence of water and surfactant to form three different types of emulsions, namely water-in-oil (w/o), water-in-oil-in-water (w/o/w) and oil-in-water (o/w), by following different preparation procedures. After curing, thermosets possessing different morphologies, ranging from highly porous (monolithic) foams to porous micro-beads and solid micro-beads, formed. The samples kept their shape upon pyrolysis, and resulted in ceramic foams (via w/o) and porous micron sized (∼200 μm) spherical particles (via w/o/w) having more than 80 vol% of total porosity, while with o/w emulsification solid SiOC ceramic particles with an average diameter of ∼100 μm formed. Both surfactant and water altered the IR spectra for emulsion-derived thermoset samples, in comparison to the pure cured resin, but upon pyrolysis similar amorphous ceramics were obtained from all samples.     

Porous hydroxyapatite ceramics by ice templating: Freezing characteristics and mechanical properties

Ice templating produces porous hydroxyapatite (HA) scaffolds with a lamellar morphology and aligned channels when using aqueous HA slurries. We investigated the freezing characteristics of HA slurries with regard to the pore structures of the porous HA scaffolds. We found that by increasing the cooling rate, the lamellar spacing decreased. The average lamellar spacing is about 785.7 μm at a cooling rate of 1.3 °C/min. The porous geometry changes from lamella and well aligned channels to a partial dendrite and partially aligned cavities with a decrease in the initial nucleation temperature and an increase in the degree of supercooling. Additionally, we determined the relationship between compressive strength and porosity. The compressive strength of the porous HA scaffolds reach 6.7 MPa at a porosity of 64% and the lamellar spacing is about 124 μm.     

Fabrication and characterization of bioactive glass/hydroxyapatite nanocomposite foam by gelcasting method

Bioceramic foams have been applied for drug releasing agents, cell loading, and widely for hard tissue scaffold. The aim of this study was fabrication and characterization of nanostructure bioceramic composite foam (BCF) consisting of hydroxyapatite (HA) and bioactive glass (BG) via gelcasting method for applications in tissue engineering. X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) analysis techniques were utilized in order to evaluate respectively, phase composition, dimension, morphology, and interconnectivity of pores, and particle size of synthesized HA, BG, and BCF. The results showed that fabrication of the BCF with a particle size in the range 20-42 nm and pore size in the range 100-250 μm was successfully performed. The maximum values of compressive strength and elastic modulus of the BCF were found to be about 1.95 MPa and 204 MPa, respectively, related to a sample sintered at 900 °C for 4 h. The mean values of the true (total) and apparent (interconnected) porosity were calculated in the range 86-91% and 60-71%, respectively. It seems that the measured properties make the BCF a good candidate for tissue engineering applications, preferentially in drug delivery, cell loading, and other nonloading applications.     

Development of a new graded-porosity FeAl alloy by elemental reactive synthesis

A new graded-porosity FeAl alloy can be fabricated through Fe and Al elemental reactive synthesis. FeAl alloy with large connecting open pores and permeability were used as porous supports. The coating was obtained by spraying slurries consisting of mixtures of Fe powder and Al powder with 3-5 μm diameter onto porous FeAl support and then sintered at 1100 °C. The performances of the coating were compared in terms of thickness, pore diameter and permeability. With an increase in the coating thickness up to 200 μm, the changes of maximum pore size decreased from 23.6 μm to 5.9 μm and the permeability decreased from 184.2 m³ m^− 2 kPa^− 1 h^− 1 to 76.2 m³ m^− 2 kPa^− 1 h^− 1, respectively, for a sintering temperature equal to 1100 °C. The composite membranes have potential application for excellent filters in severe environments.     

Solid-state supercritical CO2 foaming of PCL and PCL-HA nano-composite: Effect of composition, thermal history and foaming process on foam pore structure

In this work we investigated the solid-state supercritical CO₂ (scCO₂) foaming of poly(?-caprolactone) (PCL), a semi-crystalline, biodegradable polyester, and PCL loaded with 5 wt% of hydroxyapatite (HA) nano-particles.In order to investigate the effect of the thermal history and eventual residue of the crystalline phase on the pore structure of the foams, samples were subjected to three different cooling protocols from the melt, and subsequently foamed by using scCO₂ as blowing agent. The foaming process was performed in the 37-40 °C temperature range, melting point of PCL being 60 °C. The saturation pressure, in the range from 10 to 20 MPa, and the foaming time, from 2 to 900 s, were modulated in order to control the final morphology, porosity and pore structure of the foams and, possibly, to amplify the original differences among the different samples.The results of this study demonstrated that by the scCO₂ foaming it was possible to produce PCL and PCL-HA foams with homogeneous morphologies at relatively low temperatures. Furthermore, by the appropriate combination of materials properties and foaming parameters, we prepared foams with porosities in the 55-85% range, mean pore size from 40 to 250 μm and pore density from 10⁵ to 10⁸ pore/cm³. Finally, we also proposed a two-step depressurization foaming process for the design of bi-modal and highly interconnected foams suitable as scaffolds for tissue engineering.     

Processing and microstructure characterization of porous corundum–spinel ceramics prepared by in situ decomposition pore-forming technique

Porous corundum–spinel ceramics were prepared from Al(OH)₃ and basic magnesium carbonate by an in situ decomposition pore-forming technique. Apparent porosity was detected by Archimedes’ Principle with water as medium. Pore size distribution and the volume percentage of micropores were measured by mercury intrusion porosimetry, and the microstructure was analyzed by SEM. The apparent porosity of the sintered sample decreased with increasing the Al(OH)₃ content in the raw mixture. With increasing temperature from 1200 °C to 1300 °C the porosity of the sample increased rapidly, from 1300 °C to 1500 °C the apparent porosity increased slightly, while it decreased rapidly when the temperature increased from 1500 °C to 1600 °C. The pores in the samples consist of two groups. One group is composed of micropores whose diameter is mostly in the range from 150 nm to 300 nm while the other is composed of bigger pores whose diameter is in the range from 0.5 μm to 1 μm. It was found that the composition of the starting powders and the sintering temperature are responsible for the apparent porosity and the pore size distribution of the samples. However the spinel formation and sintering play a more important role on porosity and pore size distribution.     

The effect of the shape and size of the pores on the mechanical properties of porous HAP-based bioceramics

In this study, the influence of the shape and size of the pores on the mechanical properties of the obtained porous HAP-based bioceramics was investigated. The porous HAP-based bioceramics were obtained starting from spherical calcium hydroxyapatite powder, obtained by hydrothermal syntheses. The number of shapeless inter-agglomerate pores decreased and amount of spherical intra-agglomerate pores increased on increasing the sintering temperature from 1100 °C to 1250 °C. The shape of pores also changed with thermal treatment of specimens; the small pores remained spherical while the larger pores became more spherical in shape, as was proved by image analysis. A three-dimensional, finite element unit cell model was applied to evaluate the influence of pore shape on the mechanical strength of HAP ceramics. By analyzing the effect of the shape of pores to the fracture toughness of sintered porous HAP bioceramics, it was observed that the more spherical the pores were, the tougher became the bioceramics. After sintering at 1250 °C for 2 h, measured toughness was 1.31 MPa m^1/2, which is a relatively high value for this type of bioceramics.     

Dissolution properties of different compositions of biphasic calcium phosphate bimodal porous ceramics following immersion in simulated body fluid solution

Biphasic calcium phosphate (BCP) bimodal porous ceramics were prepared from a mixture of fine powders of hydroxyapatite (HAp) and beta-tricalcium phosphate (β-TCP) with varying HAp/β-TCP ratios. Two types of HAp powders and one type of β-TCP powder were used to produce porous BCP bioceramics with HAp/β-TCP weight ratios of 20/80, 40/60, and 80/20. Dissolution tests were performed to compare the dissolution properties of BCP-based bioceramics with different structural properties. Porous ceramic samples of approximately 0.5 g were individually soaked in 30 ml of simulated body fluid (SBF) solution at 36.5 °C for 1, 3, 7 and 10 days, respectively. The calcium content of the SBF solution was analyzed by ICP. The porous bodies were filtered, dried, and characterized using SEM, XRD, and FT-IR. The results indicate that the sample structural properties seem to have a greater effect than the storage environment on the dissolution properties.     

New ceramic microfiltration membranes from Tunisian natural materials: Application for the cuttlefish effluents treatment

New microfiltration membranes from Tunisian natural materials are obtained using ceramic method. Paste from Tunisian silty marls refereed (M₁₁) is extruded to elaborate a porous tubular configuration used as supports. The support heated at 1190 °C, shows an average pore diameters and porosity of about 9.2 μm and 49%, respectively. The properties in term of mechanical and corrosion resistances are very interesting. The elaboration of the layer based on Tunisian clay refereed (JM₁₈) is performed by slip-casting method. The heating treatment at 900 °C leads to an average pore size of 0.18 μm. The water permeability determined of this membrane is 867 l h⁻¹ m⁻² bar⁻¹. This membrane can be used for crossflow microfiltration. The application to the cuttlefish effluent clarification shows an important decrease of turbidity (inferior to 1 NTU) and chemical organic demand (COD) values (retention rate of about 65%). So, it seems that the prepared membrane is suitable for such wastewater treatment.     

Preparation of a new ceramic microfiltration membrane from mineral coal fly ash: Application to the treatment of the textile dying effluents

New microfiltration membranes from mineral coal fly-ash material are obtained using ceramic method. Paste from mineral coal fly ash (obtained by calcinations at 800 °C of non-grinded mineral coal) is extruded to elaborate a porous tubular configuration used as supports. The support heated at 1125 °C, shows an average pore diameter and porosity of about 4.5 μm and 51%, respectively. The properties in terms of mechanical and corrosion resistances are very interesting. The elaboration of the layer based on fly-ash powder (obtained by sintering at 700 °C of a finely grinded mineral coal) is performed by slip-casting method. The heating treatment at 800 °C leads to an average pore size of 0.25 μm. The water permeability determined of this membrane is 475 L/h m² bar. This membrane can be used for crossflow microfiltration. The application to the treatment of the dying effluents generated by the washing baths in the textile industry shows an important decrease of turbidity (inferior to 1 NTU), of chemical oxygen demand (COD) values (retention rate of about 75%) and a total color removal. The performances in term of permeate flux and efficiency were determined and compared to those obtained using a commercial alumina microfiltration membrane. Almost the same stabilised permeate flux was obtained (about 100 L h⁻¹ m⁻²). So, it seems that the prepared membrane is suitable for such wastewater treatment.     

The characteristics of Ni–Co–Mn–O precursor and Li(Ni1/3Co1/3Mn1/3)O2 cathode powders prepared by spray pyrolysis

Ni–Co–Mn–O precursor powders with spherical shape and dense structure were prepared by spray pyrolysis from a spray solution containing a drying control chemical additive (DCCA) and polymeric precursors. In contrast, the Ni–Co–Mn–O precursor powders obtained from a spray solution without additives had a hollow and porous morphology. Ni–Co–Mn–O precursor powders with a spherical shape and dense structure yielded Li(Ni_1/3Co_1/3Mn_1/3)O₂ cathode powders with a spherical shape and fine size by means of a solid-state reaction with lithium hydroxide. The mean size of the spherical cathode powder was 1.1 μm. The discharge capacity of the Li(Ni_1/3Co_1/3Mn_1/3)O₂ powders with spherical shape and filled morphology was 195 mA h g⁻¹ at a current density of 0.1 C. The discharge capacities of the cathode powders with spherical shape and filled morphology at 55 °C decreased from 183 to 154 mA h g⁻¹ by the 30th cycle at a current density of 0.5 C.