Processing of porous zirconia by direct foaming of emulsified ceramic powder suspensions was examined. Surfactant stabilized heptane droplets were homogeneously dispersed in the aqueous suspension with maximum solids loading of zirconia powder. The porosity of the sintered porous parts increased with the amount of heptane in the emulsified suspensions. On the other hand, the bending strength increased with the decreasing heptane content. Porous zirconia samples were used as a dielectric barrier in an atmospheric pressure plasma system. The plasma system was powered by different applied voltages at 50 Hz using air as a working gas. Filamentary discharge mode was observed in all samples at a limit value of the applied voltage (breakdown voltage). Samples with high concentration of pores and suitable pore size exhibited a glow discharge mode beside the filamentary discharge mode. The effect of the porosity of zirconia on the formation of the glow discharge mode was discussed.
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