Improving the properties of ceramic foams by a vacuum infiltration process

Reticulated ceramic foams are widely used for industrial applications such as metal filtration, exhaust gas and air purification, catalyst support and others. In this work, the compression strength and specific surface area of reticulated foams have been improved, while at the same time maintaining a high level of permeability in the final foam structure. In particular, a vacuum infiltration step by using a suitable slurry, followed by a pre-sintering cycle was adopted for filling up the hollow struts, generated due to the burnout of the PU foam. Furthermore, various mixtures of fine and coarse-grained alumina as well as in combination with zirconia, were utilised with the aim of controlling the foam properties such as compression strength, specific surface area and permeability. The compression strength was improved by a factor of two for alumina foams by infiltrating the hollow struts, and by a factor of four when infiltrating the struts of ZTA foams, with the composition 70 mol% Al2O3 and 30 mol% ZrO2. The weight gain resulting from the vacuum infiltration process was in the order of 10 wt%.