In situ mullite foam fabrication using microwave energy

In situ mullite ceramic foams were fabricated using polymeric sponge replication method from ceramic slurry containing alpha alumina and kaolin mixtures. Ceramic preforms were processed using microwave energy and conventional heating. The sintered foam samples were characterized by SEM and XRD observations, density measurements and compression tests in order to observe the effect of two different sintering techniques on the structure and properties. It was found that the microwave processing was completed in a shorter burning out and sintering cycle and produced structures having higher mullite transformation ratio and fine grains.