Enhanced mechanical strength of talc-containing porous kaolin prepared by a replica method
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ORIGINAL ARTICLE
Enhanced mechanical strength of talc‑containing porous kaolin prepared by a replica method Lee Sujin1 · Ha Jang‑Hoon1 · Lee Jongman1 · Song In‑Hyuck1 Received: 1 April 2020 / Revised: 13 July 2020 / Accepted: 10 August 2020 © The Korean Ceramic Society 2020
Abstract Recently, porous ceramics have received much interest in various applications, finding use in membranes, thermal insulation, catalytic substrates, and gas burner media owing to their outstanding thermal stability and chemical stability. To fabricate porous ceramics, many processing methods can be used. Particularly, reticulated porous ceramics prepared by the replica method are worthy of attention given their interconnected open pores with high porosity and a low pressure drop. Therefore, many researchers have studied reticulated porous ceramics using various raw materials, such as alumina, mullite, silicon carbide, cordierite and partially stabilized zirconia. However, there are few reports about reticulated porous ceramic based on kaolin, which is a low-cost raw material that can be sintered at low temperature. In this study, reticulated porous kaolin is fabricated via the replica method. To tailor the mechanical properties of the reticulated porous kaolin, the pore density of polyurethane foam (10–80 PPI (Pores Per Inch)) and the sintering temperature (1000–1300 ℃) of the kaolin slurry-coated polyurethane foams are controlled. To characterize the kaolin, scanning electron microscopy (SEM), mercury porosimetry, high-resolution micro-computed tomography (µCT), and a universal testing machine were used. When the reticulated porous kaolin with a pore density of 60 PPI was sintered at 1300 ℃, it showed compressive strength of 1.23 MPa. Keywords Porous kaolin · Compressive strength · Pore structure
1 Introduction Porous ceramic is lightweight materials [1] with low density [2], chemical stability and thermal durability [3]. Especially, under severe operating conditions, these excellent features of porous ceramics make it possible to employ them instead of porous metals and porous polymers. There are many processing methods investigated to fabricate porous ceramics, such as replica methods [4], sacrificial template methods or direct foaming methods. Among these methods, the replica method has attracted much attention as it offers unique properties such as an interconnected open pore structure and high porosity (above 90%). Accordingly, reticulated porous ceramics using replica methods possess a great potential in a variety of applications, such as in thermal
* Ha Jang‑Hoon [email protected] 1
Powder and Ceramics Division, Korea Institute of Materials Science, 797 Changwondaero, Seongsan‑gu, Changwon, Gyeongsangnam‑do 51508, Republic of Korea
energy storage [5], molten metal filtration devices [6], and catalyst carriers [7]. Recently, with the rapid development of the industry, energy and environmental issues have been attracted attention, but many studies with regard to the reticulated porous ceramics have been conducted on high
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