Rapid fabrication of porous metakaolin-based geopolymer via microwave foaming

Microwave foaming was used for the first time to rapidly fabricate the metakaolin-based porous geopolymers. Mechanical, thermal, and microstructural (optical and scanning electron microscope) investigations coupled with X-ray diffraction, Fourier-transform infrared spectroscopy, and nuclear magnetic resonance techniques were conducted to characterize the obtained foams. High porosity metakaolin-based porous geopolymers could be obtained at 4 min of foaming/curing. The effect of the sodium silicate solution content on the total porosity as well as the mechanical and thermal properties was investigated. The total porosity decreased firstly and then increased in the range of ∼74 to ∼84 vol% with the increase of Na2SiO3 content. The foams with 47.7 wt% Na2SiO3 exhibited the lowest thermal conductivity (0.104 W/mK) and the highest total porosity (83.2 vol%). The fabrication time, mechanical, and thermal properties were compared with those of foams obtained by the conventional direct foaming method. With this approach, the preparation time can be greatly reduced, and the compressive strength (1.89–2.04 MPa) and thermal conductivity (0.104–0.155 W/mK) of the materials obtained were not inferior to similar components obtained by other foaming routes. The rapidly obtained porous geopolymers with high porosity and high strength as well as low thermal conductivity can be employed as thermal insulation materials and ceramic precursors.