Pore structure of porous ceramics synthesized from water-based slurry by freeze-dry process

A unique porous ceramic with complex pore structure was synthesized by the freeze-dry process. A water-based ceramic slurry was frozen while controlling the growth direction of ice, and sublimation of the ice were generated by drying it at a reduced pressure. By sintering this green body, a porous ceramic with complex pore structure was obtained, where macroscopically aligned open pores exceeding 10 μm in size contained minute pores of about 0.1 μm in their internal walls. Wide control of the porosity was possible by changing the concentration of the starting slurry. The pore size distribution as well as the microstructure were substantially affected by the freezing and sintering temperatures. Optimization of the synthesis conditions was investigated in order to obtain the desired pore structure.