Novel mullite ceramic foams with high porosity and strength using only fly ash hollow spheres as raw material

Huo, Wenlong; Zhang, Xiaoyan; Chen, Yugu; Lu, Yuju; Liu, Jingjing; Yan, Shu; Wu, Jia‐Min

doi:10.1016/j.jeurceramsoc.2017.11.002

Cited by 93 publications

(29 citation statements)

References 33 publications

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“…According to the essence of generating pore structure, replication of the sacrificial template, foaming of slurry or ceramic precursor solution and removal of pore‐formers are mainly used methods to fabricate ceramic foam materials . In order to meet the diversified structure and performance, more fabrication methods including freeze casting, hollow spheres, capillary suspension, 3D printing, etc. have been developed to impart ceramic foam material new pore structure and properties.…”

Section: Introductionmentioning

confidence: 99%

Aerogel‐like ceramic foams with super‐high porosity and nanoscale cell wall from sol nanoparticles stabilized foams

et al. 2018

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Ultralight ceramic foam materials with high porosity play an important role in increasingly hi‐tech areas due to the combinative merit of ceramic material and highly porous structure. So far, it remains challenging to fabricate alumina ceramic foams with extremely high porosity and high specific surface area that are comparable to aerogel materials by employing a low cost, eco‐friendly and convenient approach. For the first time, we propose the preparation of aerogel‐like ceramic foams with nanoscale cell wall and unprecedentedly high porosity using boehmite sol as both ceramic source and bubble interface stabilizer, based on sol nanoparticles stabilized foams using sodium lauryl sulfate (SDS) as modifier. The obtained ultra‐stable sol foams allow for the achievement of bulk foams with ultrathin cell wall with thickness in the range of 30‐90 nm, super‐high porosity up to 99%, and large specific surface area of 280 m2/g, which is attributed to the well‐organized assembly of nanoparticles at the liquid/air interfaces. This novel foam material demonstrates excellent adsorption ability for polar volatile organic gases (VOCs) due to its extremely high porosity and large specific surface area.

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Section: Introductionmentioning

confidence: 99%

Aerogel‐like ceramic foams with super‐high porosity and nanoscale cell wall from sol nanoparticles stabilized foams

et al. 2018

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“…Ceramic materials with porous structure are playing indispensable role in hi‐tech fields, including adsorption, filters, carrier for catalysts, bioreactors, thermal insulations and the beyond, depending on their unique pore structure . Nowadays, various methods have be developed for the fabrication of porous ceramics, for instance, direct foaming, particle stacking, polymeric sponge, sacrificial template, burn‐out of pore‐formers, freezing casting, capillary suspension, hollow spheres, and 3D printing, etc . The performances of porous ceramics basically depend on the fabrication approach and starting materials …”

Section: Introductionmentioning

confidence: 99%

Silica foams with ultra‐large specific surface area structured by hollow mesoporous silica spheres

Huo

Zhang

et al. 2018

J Am Ceram Soc

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Ceramic foams with multi‐scale pores and large specific surface area have received extensive attention due to their unique structure and superior properties. Considering that there are still challenges to synthesize porous ceramics with large specific surface area, a novel ceramic foam material with ultra‐large specific surface area has been prepared using hollow silica mesoporous spheres (HMSSs) as building block in this work. These building blocks were made weakly hydrophobic in order to produce HMSS particle stabilized foams. The foams exhibit a uniform primary macropore structure, which is composed of a three dimensional HMSS‐assembled network, via HMSS‐stabilized foams. The influence of sintering temperature on the microstructure and properties of HMSS foams is investigated. The HMSS foams exhibit highest specific surface area of 1733 m2/g, attributed to the radial mesopores in HMSS shell, when sintered at between 500°C and 800°C. This specific surface area is much higher than that of existing ceramic materials. The uniform pore structure and ultra‐large specific surface area make it a promising lightweight material in potential application fields, including catalyst, adsorption, fire‐resistant thermal insulation, and load and control release system.

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“…Moreover, plenty of globular grains with 2-40 μm were obvious observed in fly ash. Combining with the Huo et al research, 26 the globular grains was identified as mullite and its inside were hollow. The hollow structure was beneficial to endow the ceramic materials with high porosity.…”

Section: Resultsmentioning

confidence: 62%

Preparation and characterization of porous anorthite ceramics from red mud and fly ash

Xiang

Ding

Zhang

2019

Int J Applied Ceramic Tech

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The porous anorthite ceramics with high porosity, good mechanical strength and low heat conductivity were prepared using red mud and fly ash as raw materials via the pore forming method. The effects of sintering temperature and fly ash on phase evolution, densification, compressive strength, thermal conductivity and microstructure of the ceramic materials were investigated. The results showed that the compressive strength of the porous ceramics had an obvious improvement with the increase in fly ash, and the densification and heat conductivity decreased firstly and then increased. In particular, specimen S2 containing 30 wt% red mud and 40 wt% fly ash sintered at 1150°C had the better performances. It had the water absorption of 18.18%, open porosity of 38.52%, bulk density of 1.29 g/cm 3 , compressive strength of 42.46 MPa, and heat conductivity of 1.24 W/m·K. X-ray diffraction analysis indicated that mullite, anorthite, α-quartz, and diopside ferrian were the dominant phases in the specimens. Scanning electron microscopy micrographs illustrated that plenty of open pores with strip shape and closed pores with axiolitic shape existed in the specimens. Furthermore, the existence of mullite could prevent crack propagation to enhance the energy of inter-granular fracture.It endowed the porous anorthite ceramics with high porosity, good compressive strength, and low heat conductivity. K E Y W O R D Scompressive strength, densification, fly ash, porous ceramics, red mud, thermal conductivity

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Novel mullite ceramic foams with high porosity and strength using only fly ash hollow spheres as raw material

Cited by 93 publications

References 33 publications

Aerogel‐like ceramic foams with super‐high porosity and nanoscale cell wall from sol nanoparticles stabilized foams

Aerogel‐like ceramic foams with super‐high porosity and nanoscale cell wall from sol nanoparticles stabilized foams

Silica foams with ultra‐large specific surface area structured by hollow mesoporous silica spheres

Preparation and characterization of porous anorthite ceramics from red mud and fly ash

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