Porous alumina/zirconia layered composites with unidirectional pore channels processed using a tertiary-butyl alcohol-based freeze casting

Symmetric three-layer porous alumina/zirconia composites with controlled “designer” pore structure have been prepared by a tertiary-butyl alcohol-based freeze casting and sintering at 1400–1500 °C in air. Unidirectional aligned macropore channels were developed over a long range by controlling the solidification direction of tertiary-butyl alcohol solvent; in this case, they were surrounded by more dense structured walls. In layered composite, the bottom layer consisted of small sized pore channels (∼11 μm in diameter) compared with the middle and the top layer, due to the comparatively rapid velocity of the TBA crystal growth during solidification. The compressive strength (63–376 MPa) of the sintered porous layered composite remarkably increased as the porosity decreased (64–32%).

► Alumina/zirconia layered composite with controlled “designer” pore structure was fabricated by tertiary-butyl alcohol (TBA)-based freeze casting. ► The microstructure of sintered body was characterized by unidirectional, large pore channels over a long range and a few isolated, small sized pores. ► In general, the layered specimens (32–64% in porosity) exhibited improved compressive strength (378–63 MPa) when compared with monolithic blocks of each layer material.