Open-cell mullite ceramic foams derived from porous geopolymer precursors with tailored porosity

Porous geopolymer precursors were firstly prepared by the direct foaming method using bauxite, fly ash (FA), and metakaolin (MK) as raw materials, and porous mullite ceramics were prepared after ammonium ion exchange and then high-temperature sintering. The effects of chemical foaming agent concentration, ion-exchange time, and sintering temperature on porous geopolymerderived mullite ceramics were studied, and the optimal preparation parameters were found. Studies have shown that the concentration of blowing agent had great influence on open porosity (q) and porosity and cell size distributions of geopolymer samples, which in turn affected their compressive strength (sigma). Duration of the ion exchange had no obvious effect on the sintered samples, and the amount of mullite phase increased with the increase in the sintering temperature. Mullite foams, possessing an open-celled porous structure, closely resembling that of the starting porous geopolymers produced by directly foaming, were obtained by firing at high temperatures. Stable mullite (3Al(2)O(3)center dot 2SiO(2)) ceramic foams with total porosity (epsilon) of 83.52 vol%, high open porosity of 83.23 vol%, and compressive strength of 1.72 MPa were produced after sintering at 1400 degrees C for 2 h in air without adding any sintering additives using commercial MK, bauxite, and FA as raw materials.

Automated summary

Porous geopolymer precursors were prepared using bauxite, fly ash, and metakaolin as raw materials, and porous mullite ceramics were obtained after ion exchange and high-temperature sintering. The concentration of blowing agent, ion-exchange time, and sintering temperature were found to have significant effects on the properties of the mullite ceramics. The resulting mullite foams exhibited a similar open-celled porous structure to the starting geopolymer precursors and had high porosity and compressive strength.