Preparation of high open porosity ceramic foams via direct foaming molded and dried at room temperature

Herein an alternative approach was considered for addressing one difficulty of ceramic foams that the foam slurry with a high content of bubbles which were obtained via direct foaming, cannot maintain well for a long time at room temperature. It is fascinating that the foam slurry mentioned above could stably mold and dry at room temperature, based on an animal protein as foaming agent, kaolin, talc powder and alumina as raw materials, alpha-tricalcium phosphate prepared via co-precipitation as curing agent, and hydrophobic activated carbon powders as stabilizing agent. Effects of the calcination temperatures, the contents of alpha-tricalcium phosphate and activated carbon powder on microstructures, crystal phases, compressive strength and open porosities of ceramic foams were studied systematically. The results indicated that ceramic foams with a high open porosity and uniform pore distribution and sizes sought for application in catalysts supports, could be produced by adjusting these parameters.