Abstract
Increased processing pressure has resulted in need for the industry to optimize mechanical properties of ceramic foam filters used for molten metal processing. This paper will summarize the effect of ceramic slurry formulation on mechanical properties of reticulated porous ceramics processed by replica method. Commercial polyurethane sponge materials were chosen as a template to produce the RPC (reticulated porous ceramic) from a shear thinning multi component aqueous slurry composed of alumina, SiC, colloidal silica and some different additives. Thermal transformation sequence of the mixtures, resultant macrostructure and microstructure, relative density, grain morphology, phase composition, and mechanical strength of the sintered porous ceramics were investigated. Mechanical properties of struts were investigated by a theoretical model. The RPC had its maximum strength when Alumina/SiC weight ratio was 4.4. Such materials sintered at 1650° C in air, due to their excellent functional properties, are suitable for application as molten metal filter.
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