Abstract
This chapter discusses the processing of high porosity engineering ceramics. It describes a new method of producing highly porous ceramics. The process employs an organic monomer that is polymerized to cause the in-situ gelation of a foamed ceramic slurry. The essential components of the process are ceramic powder, organic monomers, an initiator for polymerization, a catalyst, dispersing agents, a foaming agent (surfactant), and water. The organic monomer solutions provide a liquid medium that is polymerized to form a strong, cross linked polymer-water gel, thereby entrapping both the ceramic powder and water in the foamed structure. The polymer is then removed as a part of a controlled sintering cycle to leave behind ceramic foam. The resulting foams can have a variable density and pore size depending on the intended application.
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