Enhancing mechanical properties and air permeability of corundum porous materials by in situ formation of LaAl11O18 in bonding phase

Abstract

Corundum porous materials of particle-packing type with different contents of in situ formed LaAl11O18 were prepared using tabular corundum, reactive alumina and La2O3 powder as raw materials. The effects of the introduction of LaAl11O18 on the microstructure, phase composition and properties of the porous materials were investigated. The specimens were characterized by scanning electron microscopy, X-ray diffraction and mercury porosimetry. Results show that platelet-like LaAl11O18 is formed in situ by the reactions of La2O3 and Al2O3. With a certain amount of La2O3 added, the cold crushing strength, cold modulus of rupture and hot modulus of rupture (1400 × 0.5 h) of the specimens are increased, and the air permeability is improved simultaneously. However, upon further increasing the amount of La2O3 added, the mechanical properties and air permeability of the porous materials then decrease gradually owing to the increased numbers of pores and cracks in the bonding phase. The enhanced mechanical properties of the specimens with La2O3 added are attributed to the strengthening effects of plate-like LaAl11O18 in the bonding phase and to the activated sintering of both Al2O3 powder and corundum coarse aggregate for the diffusion of La3+ in Al2O3 lattice. In addition, the improved air permeability of the specimens should be related to the decreased content of pores in the bonding phase and the reduced number of interfacial cracks.