A New Insight into the Role of Silicate-Type Binders on the Crushing Strength of Alumina Foams

Semi-closed cell macroporous alumina foams with relative densities ranging from 0.26 to 0.35 have been produced by the well-established replication method based on coating of a polyurethane (PU) template foam ceramic slurry, followed burnout PU template, and sintering skeleton. Collapse three-dimensional structure upon volatilisation sponge can only be prevented using appropriate binders. Scarce data are available slurry formulations commercial foams. The aim this study was investigate influence silicate-type binders, namely kaolin bentonite additives, crushing strength highest around 10 MPa observed at porosity 66 ± 2%. open-cell model is inadequate fit such semi-closed type structures. Both microscopic macroscopic flaws resulting processing contribute wide scatter strength, thereby explaining Weibull modulus 4 7. flaw populations require further improvement maximise these high potential for design structured catalyst carriers molten aluminium filters.