Development of Cordierite Based Reticulated Foams with Improved Mechanical Properties for Porous Burner Applications

Abstract

ABSTRACTCordierite is a ternary oxide of silica, magnesia and alumina and one of the interesting ceramic materials and a potential material for various thermo-structural applications. The present study is to explore the possibility of enhancing the mechanical properties of cordierite using zirconia as an additive in the range of 0-10 wt% followed by comparative evaluation of properties. Cordierite precursor mix was subjected to calcination to ensure the partial formation of cordierite. A part of calcined cordierite and another two parts were blended with 5 and 10 wt% of zirconia and were planetary ball milled to ensure homogeneity in compositions. The formulations were compacted after granulation. The green compacts were subjected to TG-DSC and XRD investigations were carried out on sintered samples. Mechanical properties such as flexural strength at room and elevated temperatures and thermal expansion behaviour were analyzed for all the samples. Zirconia addition was found to enhance the mechanical properties; however, at higher concentration (10 wt%) segregation of zirconium silicate resulted in the reduction in flexural strength. Reticulated foams of cordierite and cordierite+5 wt% zirconia were fabricated by polymeric sponge replication process and evaluated for their properties. Further, initial trials as a porous combustion media demonstrated the feasibility for burner applications.