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Microstructure and properties of hierarchical porous ZrO2/Al2O3 ceramics prepared by gel-foaming method

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Abstract

Hierarchical porous ZrO2/Al2O3 ceramics with controllable pore structure were fabricated by gel-foaming method using nontoxic sodium alginate as gelling agent. Both the rheological property of ceramic slurry and the curing mechanism of gelatin system were studied. The effects of ZrO2 content and sintering temperature on the pore structure and properties were also investigated. The three-dimensional net structure forms between calcium ion and sodium alginate molecule; then, the ceramic powder can realize in situ solidification. The porosity changes from 33 to 74% with different ZrO2 content and sintering temperature. The macropores can be controlled through adjusting the foaming agent and ZrO2 contents. The mesopores are mainly regulated by sintering temperature. The porosity and pore structure can be tailored through optimizing the gel-foaming and sintering process parameters. The sintering temperature has important influence on the mechanical properties. The porous ceramics with 25% ZrO2 content sintered at 1550°C shows the highest compressive strength of 130MPa. The mechanical properties are improved with the micro-crack toughening and phase transformation mechanisms of ZrO2 phases. Hierarchical porous ceramics with more inter-connective pores, high specific surface area, and suitable strength are promising for filtration and catalyst support applications.

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Funding

This work was supported by the National Natural Science Foundation of China (NO.51302053).

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Authors and Affiliations

  1. Department of Materials Science and Chemical Engineering, Harbin University of Science and Technology, Harbin, 150040, People’s Republic of China

    Xiulan He, Zhaofen Zhang & Shilong Wang

  2. Guangxi Nixing Ceramic Industry Association, Qinzhou, 535011, People’s Republic of China

    Fengchu Su

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  1. Xiulan He
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  2. Zhaofen Zhang
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Correspondence to Xiulan He.

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He, X., Zhang, Z., Wang, S. et al. Microstructure and properties of hierarchical porous ZrO2/Al2O3 ceramics prepared by gel-foaming method. J Aust Ceram Soc 59, 905–914 (2023). https://doi.org/10.1007/s41779-023-00883-x

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