Fabrication of porous alumina green bodies from suspension emulsions by gelcasting

Porous alumina green bodies with controlled porosity and pore size were prepared from suspension emulsions of oil-in-water type by gelcasting technique. The basic idea of this novel method was elaborated, and the whole preparation process was analyzed. The results showed that the microstructure was influenced by the addition of oil and emulsifier. Low water/oil ratio led to a high porosity and open-cell, while low oil/emulsifier ratio caused a small pore size. The bulk density varied from 0.7 to 1.6 g/cm3 according to the addition of oil. The compressive strength was affected by the apparent density and the thickness of the pore walls and it varied from 3.5 to 29.4 MPa.

► Porous alumina green bodies with controlled porosity and pore size were prepared.
► Low water/oil led to a high porosity, low oil/emulsifier caused a small pore size.
► The basic idea of this new method was elaborated.
► The microstructure and properties of the green bodies were studied.