Fabrication and Properties of Alumina-based Reticulated Porous Ceramics

doi:10.19691/j.cnki.1004-4493.2020.02.006

China's Refractories ›› 2020, Vol. 29 ›› Issue (2): 31-36.DOI: 10.19691/j.cnki.1004-4493.2020.02.006

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Fabrication and Properties of Alumina-based Reticulated Porous Ceramics

LAO Dong¹, JIA Wenbao¹, WANG Yufan¹, CHEN Ruoyu¹, LI Shujing², HEI Daqian¹, WANG Zhonghua³, DING Yue¹, ZHANG Wenhao¹, LIU Meiqi¹

1 Institute of Nuclear Analysis Technology, Nanjing University of Aeronautics and Astronautics,Nanjing 211106, China
2 College of Materials and Metallurgy, Wuhan University of Science and Technology, Wuhan 430081, China
3 Wuxi Chenguang Refractories Co., Ltd., Yixing 214221, China

Revised:2021-05-13 Online:2020-06-15 Published:2020-06-15
About author:Lao Dong, obtained his bachelor's degree from Nanjing University of Aeronautics and Astronautics in 2014. Now he is a PhD student in the College of Materials Science and Technology in the same university. He majors in materials science and engineering, and his main research direction is porous structural ceramic materials.

Abstract

Abstract:

The primary impregnation slurry was prepared using active alumina (56.25 mass%), kaolin (15 mass%), zirconia (3.75 mass%), deionized water (25 mass%), and extra adding FS (0.2 mass%) and CMC (0.4 mass%). The effects of the active alumina particle size (d₅₀=5.043, 2.934, and 1.629 μm) on the rheology and the thixotropy of the slurry were researched. It was found that the bimodal active α-Al₂O₃ (AMA-10) with d₅₀=1.629 μm was optimum. The secondary impregnation slurry was prepared using AMA-10, kaolin and zirconia as the main raw materials. Then the alumina-based reticulated porous ceramics were fabricated by the organic foam impregnation method combined with a secondary vacuum impregnation process. The influence of the AMA-10 content on the properties of the ceramics was studied. The residual stress of the specimens was analyzed by finite element analysis. The results show that the smaller alumina particle size and multimodal distribution are beneficial to the thixotropy of the primary impregnation slurry. The secondary vacuum impregnation technique can significantly improve the mechanical properties, the thermal shock resistance and the residual strength of the alumina-based reticulated porous ceramics. With the decrease of alumina content in the secondary impregnation slurry, the residual stress of the external layer of ceramic reinforcement gradually changes from tensile stress to compressive stress, which effectively inhibits the expansion of the surface crack, and remarkably improves the crushing strength retention ratio of alumina reticulated porous ceramics.

Key words: alumina, reticulated porous ceramics, organic foam impregnation method, vacuum impregnation technique, crushing strength, residual stress, thermal shock resistance

LAO Dong, JIA Wenbao, WANG Yufan, CHEN Ruoyu, LI Shujing, HEI Daqian, WANG Zhonghua, DING Yue, ZHANG Wenhao, LIU Meiqi. Fabrication and Properties of Alumina-based Reticulated Porous Ceramics[J]. China's Refractories, 2020, 29(2): 31-36.

Figures/Tables 10

Table 1 Chemical composition of starting materials /mass%

Starting materials	Al₂O₃	Fe₂O₃	SiO₂	R₂O	CaO	MgO	TiO₂	LOI
AMA-40	99.6	0.05	0.09	0.25
Almatis alumina	99.0	0.02	0.02	0.25
AMA-10	99.8	0.04	0.06	0.05
Kaolin	33.09	0.76	45.65	1.15	0.04	0.12	0.33	17.89

Table 2 Formulations of secondary impregnation slurry /mass%

Slurry No.	C1	C2	C3
AMA-10	39	45	51
Kaolin	18	12	6
Zirconia	3	3	3
Deionized water	40	40	40
FS (extra adding)	0.2	0.2	0.2

Fig. 1 Apparent viscosity of slurries with alumina of different particle sizes at different rotational speeds

Fig. 2 Physical properties of reticulated porous ceramics fired at 1 550 ℃

Fig. 3 Cold crushing strength and its retention ratio of specimens before and after thermal shock test

Fig. 4 XRD patterns of specimens after secondary impregnation fired at 1 550 ℃

Fig. 5 SEM micrographs of reticulated porous ceramic specimens before and after thermal shock test

Fig. 6 Schematic graphs of multi-layered structure

Table 3 Performance parameters of secondary impregnation slurries

Items	C1	C2	C3	Inner layer
Modulus of elasticity / MPa	212.03	230.57	258.58	230.57
Poisson ratio	0.32	0.32	0.32	0.32
Thermal expansion coefficient×10⁶/K^-1	7.5	8.1	8.6	8.1

Fig. 7 Residual stress distribution of multi-layered ceramic reinforcement

References 13

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Fabrication and Properties of Alumina-based Reticulated Porous Ceramics

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