A simple direct casting route to ceramic foams

A simple direct foaming and casting process using ovalbumin-based aqueous slurries for fabricating ceramic and metal foams is demonstrated. Foaming of aqueous ceramic slurries and the foam microstructure were seen to be a strong function of slurry rheology. Setting of foams with ceramic solids loading above 20 vol% was achieved by addition of acid, which also prevented binder migration. Acid addition resulted in excessive shrinkage, causing cracking of foams with ceramic loading below 20 vol%. Addition of sucrose to the slurries suppressed shrinkage leading to defect-free foams with porosity exceeding 95%. Overall porosity and foam microstructure could be controlled through ceramic solids loading, ovalbumin-water ratio, foaming time and sucrose amount, and sintering temperature. The ceramic foams fabricated by the process were strong enough to be green machined to different shapes.