Low temperature preparation and machinability of porous ceramics from talc and foamed glass particles

Porous ceramics were prepared by firing mixtures of talc (Mg3Si4O10(OH)2) and foamed glass particles (ceramic balloons, CB) with and without LiCl as a sintering acid. The mixing ratios of the starting materials were talc:CB = 7:3, 8:2, 9:1 and 10:0, with additions of LiCl of 0, 2 and 5 mass%. The mixtures were formed into pellets and fired at 600–1000 °C. The pellets without LiCl showed very poor strength even when fired at 1000 °C but those containing LiCl were much stronger, even when fired at only 600 °C. The crystalline phases in these samples changed to enstatite (MgSiO3) at ≥ 700 °C by decomposition of the talc under the fluxing action of the LiCl. The resulting samples were machinable and easily cut and drilled. The cutting rate decreased with increasing bending strength, for example, from 105 mm2/s and 6.3 MPa to 50 mm2/s and 16.3 MPa, respectively. The drilling rate of the present sample was found to be only slightly less than Teflon (polytetrafluoroethylene, PTFE) but much faster than graphite, glass ceramics, etc.