Intrinsic microstructural anisotropy in tape cast ceramics by ice templating

Abstract

Ice templating concepts based on tape cast processing technology are capable of creating continuous columnar‐graded pore structures using a wide variety of ceramic oxides with thicknesses from 100 µm up to 1 cm for applications including fuel cells, compositional grading templates, filtration/separation membranes, and catalyst supports. The merging of the tape casting process allows for the preparation of large area flexible green tapes as well as the long‐range alignment of the acicular ice crystals transverse to the cross‐section, yielding an additional degree of microstructure control beyond traditional freeze cast processing. Moreover, optimization of the freeze tape casting processing parameters has proven effective in tailoring porosity in aqueous cast ceramics. Magnetic resonance microscopy (MRM) combined with scanning electron microscopy (SEM) has revealed inherent microstructural anisotropy in the morphology of pores related to the direction of the cast tape. Due to the ability of MRM to image noninvasively with volume averaging over a range of slice thicknesses, the MRM images provide complementary information to the higher resolution single plane SEM images. Morphological variance as observed at different orientations through the cross‐sections of cast yttria stabilized zirconia is reported.