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A novel method based on ultrastable foam and improved gelcasting for fabricating porous mullite ceramics with thermal insulation–mechanical property trade-off

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Abstract

Foam instability and long drying cycle limits the widespread use of foaming method. In this paper, a kind of porous mullite ceramic with thermal insulation–mechanical property trade-off were fabricated via novel ultrastable foam and improved gelcasting procedure. The solidification process and stability of foam slurry, as well as the thermal, mechanical property and pore structure of the porous mullite ceramics were investigated. The results showed that porous mullite ceramics with different bulk densities could be prepared via varying volume of foam which was stable enough to be maintained in slurry for a long time. The accelerated gelation rate as well as the gelation degree resulted in the improved gelcasting method led to a shortened period of drying and demould. The obtained pores, which were small, smooth, and unimodal distributed in size in porous mullite ceramics, contributed to achieving the trade-off between thermal insulation and mechanical property.

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Acknowledgments

The work was financially supported by the pre-research project of National Key Basic Research Program (Grant No. 2012CB722702).

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Authors and Affiliations

  1. The State Key Laboratory of Refractories and Metallurgy, Wuhan University of Science and Technology, Wuhan, 430081, People’s Republic of China

    Xing Du, Lei Zhao, Xuan He, Xin Wang, Hui Chen & Huan Chen

  2. Wuhan Iron and Steel (Group) Refractory Materials Limited Liability Company, Wuhan, 430081, People’s Republic of China

    Weimin Qu, Junjie Wang & Zhongxing Lei

Authors
  1. Xing Du
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  2. Lei Zhao
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  3. Xuan He
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  4. Xin Wang
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  5. Weimin Qu
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  6. Hui Chen
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  7. Huan Chen
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  8. Junjie Wang
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  9. Zhongxing Lei
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Correspondence to Lei Zhao.

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Du, X., Zhao, L., He, X. et al. A novel method based on ultrastable foam and improved gelcasting for fabricating porous mullite ceramics with thermal insulation–mechanical property trade-off. J Porous Mater 23, 381–388 (2016). https://doi.org/10.1007/s10934-015-0091-x

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  • DOI: https://doi.org/10.1007/s10934-015-0091-x

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