Mechanical properties and thermal conductivity of porous alumina ceramics obtained from particle stabilized foams

In this work, foams were obtained by direct foaming of aqueous alumina suspensions containing butyric acid. Butyric acid is incorporated in the suspensions in order to hydrophobize alumina particles, leading to their adsorption at the air/water interface. After setting and drying, wet foams were sintered at 1585 °C for 2 h. The resulting porous samples were characterized in terms of microstructure, mechanical properties and thermal conductivity. Microstructures of sintered alumina foams reveal closed pores surrounded by a thin alumina layer. The microstructure of these macroporous ceramics is related to (i) the composition of the initial suspension (alumina and butyric acid contents) and (ii) the stirring velocity during the foaming process. Macroporous ceramics with pore sizes (d50) ranging from 20 µm to 140 µm and porosities between 25% and 89% were obtained. Three-point bending tests were performed on foams with porosities between 65% and 89%. The results of mechanical tests were analyzed with Weibull statistic. The bending strength values are between 5 MPa and 42 MPa. The Young’s modulus, obtained from 3-point bending tests, decreases with the porosity level according to Gibson–Ashby model. Thermal diffusivity measurements were made with the laser flash technique in order to determine the effective thermal conductivity. Experimental values are significantly higher than the predictions with Landauer’s relation and almost close to Maxwell/Hashin–Shtrikman upper bound.