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Research Article | Open Access

Open-cell mullite ceramic foams derived from porous geopolymer precursors with tailored porosity

Jiahuan Shaoa, Chengying Baia( ), Xinyu Lia( ), Kun Yanga, Ting Zhenga, Yingjie Qiaoa, Lili Zhanga, Hongqiang Lib, Paolo Colomboc,d
Key Laboratory of Superlight Materials and Surface Technology, Ministry of Education, College of Materials Science and Chemical Engineering, Harbin Engineering University, Harbin 150001, China
College of Civil Engineering, Hunan University, Changsha 410082, China
Department of Industrial Engineering, University of Padova, via Marzolo, Padova 35131, Italy
Department of Materials Science and Engineering, The Pennsylvania State University, State College 16802, USA
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Graphical Abstract

Abstract

Porous geopolymer precursors were firstly prepared by the direct foaming method using bauxite, fly ash (FA), and metakaolin (MK) as raw materials, and porous mullite ceramics were prepared after ammonium ion exchange and then high-temperature sintering. The effects of chemical foaming agent concentration, ion-exchange time, and sintering temperature on porous geopolymer-derived mullite ceramics were studied, and the optimal preparation parameters were found. Studies have shown that the concentration of blowing agent had great influence on open porosity (q) and porosity and cell size distributions of geopolymer samples, which in turn affected their compressive strength (σ). Duration of the ion exchange had no obvious effect on the sintered samples, and the amount of mullite phase increased with the increase in the sintering temperature. Mullite foams, possessing an open-celled porous structure, closely resembling that of the starting porous geopolymers produced by directly foaming, were obtained by firing at high temperatures. Stable mullite (3Al2O3·2SiO2) ceramic foams with total porosity (ε) of 83.52 vol%, high open porosity of 83.23 vol%, and compressive strength of 1.72 MPa were produced after sintering at 1400 ℃ for 2 h in air without adding any sintering additives using commercial MK, bauxite, and FA as raw materials.

Keywords

porous mullite ceramicporosityporous geopolymer precursordirect foamingnanophase strengthening

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Journal of Advanced Ceramics
Volume 12 Issue 2,
February 2023
Pages 279-295
DOI: 10.26599/JAC.2023.9220682
Cite this article:
Shao J, Bai C, Li X, et al. Open-cell mullite ceramic foams derived from porous geopolymer precursors with tailored porosity. Journal of Advanced Ceramics, 2023, 12(2): 279-295. https://doi.org/10.26599/JAC.2023.9220682

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Received: 14 July 2022
Revised: 23 September 2022
Accepted: 18 October 2022
Published: 10 January 2023
© The Author(s) 2022.

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