Porous Alumina-Bentonite Ceramics: Effects of Fillers and Molding Technique

Abstract

In porous ceramics processing, the green body shaping technique largely determines the control of the final porous structure and material properties. The study is aimed at finding affordable approaches for the shaping of two different narrow-fraction fillers: F240 electro-corundum and hollow alumina microspheres. The results revealed the influence of accessible shaping techniques (semi-dry pressing, direct casting, and slip casting) on the structural and mechanical properties of porous alumina ceramics. The starting materials were characterized by XRD, SEM, EDX, and BET. The manufactured ceramics were studied in terms of microstructure, density, porosity, and flexural strength. Free stacking of the fillers’ particles during the direct and slip casting resulted in a higher porosity of ceramics compared with that of semi-dry pressing, while reducing its mechanical strength. Direct casting appeared preferable for ceramics with hollow microspheres because it maintained the integrity of the filler particles and preserved their inherent porosity in the ceramics. The optimal parameters for porous ceramics processing were determined as follows: pressing at 30 MPa and sintering at 1280–1320 °C with a bentonite content of 15 wt.%. In this case, the average density and open porosity of F240 samples reached 2.22 g cm−3 and 40.4%, while samples containing hollow microspheres reached 2.20 g cm−3 and 36.7%, respectively.