Professional Documents
Culture Documents
多孔氧化铝陶瓷材料的制备工艺研究进展_和祥
多孔氧化铝陶瓷材料的制备工艺研究进展_和祥
Vol.26 No.6 Materials Science and Engineering of Powder Metallurgy Dec. 2021
DOI:10.19976/j.cnki.43-1448/TF.2021064
多孔氧化铝陶瓷材料的制备工艺研究进展
和祥 1,黄千里 1,陈煜辉 2,刘伯威 1,刘咏 1
摘 要:多孔氧化铝陶瓷具有力学性能好、耐腐蚀、比表面积大以及化学性质稳定等优点,在耐火材料、电绝缘
体、耐磨机械部件、过滤材料、催化支撑体等领域得到广泛应用。常见多孔氧化铝陶瓷的造孔方法主要有部分烧
结法、复刻模板法、牺牲模板法与直接发泡法,合理的造孔方法有利于获得特定孔隙结构与孔隙率。氧化铝陶瓷
的常规烧结工艺通常温度高、时间长、易形成粗化晶粒与残留气孔,先进烧结技术如振荡压力烧结、放电等离子
烧结、微波烧结等可有效克服上述缺点,综合提升材料的各项性能。本文从造孔方法与烧结技术两个方面综述多
孔氧化铝陶瓷的研究进展,期望为新型多孔氧化铝陶瓷的研究、开发与应用提供参考。
关键词:多孔陶瓷;氧化铝;粉体原料;造孔方法;烧结技术
中图分类号:TF841.8 文献标志码:A 文章编号:1673-0224(2021)06-483-09
(1. State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China;
2. Shenzhen Changlong Technology Co., Ltd., Shenzhen 518100, China)
Abstract: Porous alumina ceramics are widely used as refractory materials, electrical insulators, wear-resistant
mechanical parts, filtering materials and catalytic support due to their excellent mechanical properties, corrosion
resistance, large specific surface area and stable chemical properties. The pores in porous alumina ceramics are
commonly created by partial sintering, replica, sacrificial template or direct foaming method. Specific porous structure
and porosity can be obtained by employing appropriate pore-creating method. Conventional sintering of alumina
ceramics is usually characterized by high temperature, long duration, easy formation of coarse grains and residual pores.
The application of advanced sintering technologies such as oscillatory pressure sintering, spark plasma sintering and
microwave sintering can effectively overcome these shortcomings and comprehensively improve material properties. In
order to provide references for the investigation, development and application of novel porous alumina ceramics, we
reviewed the research progress on two aspects including pore-creating method and sintering technology involved in the
fabrication process of porous alumina ceramics.
Keywords: porous ceramics; alumina; powder raw material; pore-creating method; sintering technology
基金项目:中国博士后科学基金特别资助项目(2019T120711)
收稿日期:2021−08−02;修订日期:2021−09−30
通信作者:黄千里,副教授,博士。电话:18600648872;E-mail: hql1990@163.com
484 粉末冶金材料科学与工程 2021 年 12 月
[1] MARTIENSSEN W, WARLIMONT H. Springer Handbook of of the American Ceramic Society, 2006, 89(6): 1771−1789.
Condensed Matter and Materials Data[M]. NewYork, USA: [16] LEE C Y, LEE S, HA J H, et al. Effect of the processing
Springer Science & Business Media, 2005. conditions of reticulated porous alumina on the compressive
第 26 卷第 6 期 和祥,等:多孔氧化铝陶瓷材料的制备工艺研究进展 489
strength[J]. Journal of the Korean Ceramic Society, 2021, 58(4): ceramics under dual temperature gradients[J]. Journal of the
495−506. European Ceramic Society, 2018, 38(6): 2605−2611.
[17] BROWN D D, GREEN D J. Investigation of strut crack [30] FUKASAWA T, ANDO M, OHJI T, et al. Synthesis of porous
formation in open cell alumina ceramics[J]. Journal of the ceramics with complex pore structure by freeze-dry processing
American Ceramic Society, 1994, 77(6): 1467−1472. [J]. Journal of the American Ceramic Society, 2001, 84(1): 230−
[18] LYCKFELDT O, FERREIRA J. Processing of porous ceramics 232.
by ‘starch consolidation’[J]. Journal of the European Ceramic [31] FUKASAWA T, DENG Z Y, ANDO M, et al. Pore structure of
Society, 1998, 18(2): 131−140. porous ceramics synthesized from water-based slurry by
[19] KIM J, HA J H, LEE J, et al. Effect of pore structure on gas freeze-dry process[J]. Journal of Materials Science, 2001, 36(10):
permeability constants of porous alumina[J]. Ceramics 2523−2527.
International, 2019, 45(5): 5231−5239. [32] AKARTUNA I, STUDARTA R, TERVOORT E, et al.
[20] SEGADA A M. Microstructure, permeability and mechanical Macroporous ceramics from particle-stabilized emulsions
behaviour of ceramic foams[J]. Materials Science and [J].Advanced Materials, 2008, 20(24): 4714−4718.
Engineering A, 1996, 209(1/2): 149−155. [33] BEPPU Y, ANDO M, OHJI T. Control of porosity and pore size
[21] PARKHOMCHUK E V, FEDOTOV K V, SEMEYKINA V S, for porous alumina prepared from alpha-alumina, BaSO4 and/or
et al. Polystyrene microsphere-template method for textural SrSO4[J]. International Journal of Materials & Product
design of alumina-an effective catalyst support for Technology, 2001, 1: 209−214.
macromolecule conversion[J]. Catalysis Today, 2020, 353(SI): [34] KIM H, DA ROSA C, BOARO M, et al. Fabrication of highly
180−186. porous yttria-stabilized zirconia by acid leaching nickel from a
[22] LUYTEN J, MULLENS S, COOYMANS J, et al. New nickel-yttria-stabilized zirconia cermet[J]. Journal of the
processing techniques of ceramic foams[J]. Advanced American Ceramic Society, 2002, 85(6): 1473−1476.
Engineering Materials, 2003, 5(10): 715−718. [35] POKHREL A, SEO D N, LEE S T, et al. Processing of porous
[23] THIJS I, LUYTEN J, MULLENS S. Producing ceramic foams ceramics by direct foaming: A review[J]. Journal of the Korean
with hollow spheres[J]. Journal of the American Ceramic Ceramic Society, 2013, 50(2): 93−102.
Society, 2004, 87(1): 170−172. [36] ZHAO J, YANG C, SHIMAI S, et al. The effect of wet foam
[24] ZHANG G J, YANG J F, OHJI T. Fabrication of porous stability on the microstructure and strength of porous ceramics
ceramics with unidirectionally aligned continuous pores[J]. [J]. Ceramics International, 2018, 44(1): 269−274.
Journal of the American Ceramic Society, 2001, 84(6): 1395− [37] DU Z P, YAO D X, XIA Y E, et al. Highly porous silica foams
1397. prepared via direct foaming with mixed surfactants and their
[25] KATSUKI H, KAWAHARA A, ICHINOSE H. Preparation and sound absorption characteristics[J]. Ceramics International, 2020,
some properties of porous alumina ceramics obtained by the 46(9): 12942−12747.
gelatination of ammonium alginate[J]. Journal of Materials [38] RAO P R, MURALIDHARAN K, MOMAYEZ M, et al. Direct
Science, 1992, 27(22): 6067−6070. foaming driven synthesis and thermophysical characterization of
[26] CHEN Z W, XU G G, CUI H Z, et al. Preparation of porous silica-alumina foams: Applications for thermal insulation[J].
Al2O3 ceramics by starch consolidation casting method[J]. Ceramics International, 2020, 46(8): 10431−10441.
International Journal of Applied Ceramic Technology, 2018, [39] SCHEITHAUER U, KERBER F, FüSSEL A, et al. Alternative
15(6): 1550− 1558. process routes to manufacture porous ceramics—opportunities
[27] BOWDEN M, RIPPEY M. Porous ceramics formed using starch and challenges[J]. Materials, 2019, 12(4): 663.
consolidation[J]. Key Engineering Materials, 2002, 206/213(3): [40] COLOMBO P, HELLMANN J R. Ceramic foams from
1957−1960 preceramic polymers[J]. Materials Research Innovations, 2002,
[28] LI Y J, YANG X F, LIU D H, et al. Permeability of the porous 6(5): 260−272.
Al2O3 ceramic with bimodal pore size distribution[J]. Ceramics [41] SEPULVEDA P. Gelcasting foams for porous ceramics[J].
International, 2019, 45(5): 5952−5957. American Ceramic Society Bulletin, 1997, 76(10): 61−65.
[29] GENG S L, SHEN P, HU Z J, et al. Formation mechanism and [42] ROMÁN-MANSO B, MUTH J, GIBSON L J, et al.
control of a large-scale lamellar structure in freeze-cast Al2O3 Hierarchically porous ceramics via direct writing of binary
490 粉末冶金材料科学与工程 2021 年 12 月
colloidal gel foams[J]. ACS Applied Materials & Interfaces, [57] YANG Y, MA M S, ZHANG F Q, et al. Low-temperature
2021, 13(7): 8976−8984. sintering of Al2O3 ceramics doped with 4CuO-TiO2-2Nb2O5
[43] CELANI A, BLACKBURN S, SIMMONS M J, et al. composite oxide sintering aid[J]. Journal of the European
Formulation of ceramic foams: A new class of amphiphiles[J]. Ceramic Society, 2020, 40(15): 5504−5510.
Colloids and Surfaces A, 2018, 536(SI): 104−112. [58] WATARI K J, HWANG H J, TORIYAMA M, et al. Effective
[44] REN B, LIU J J, WANG Y L, et al. Hierarchical cellular sintering aids for low-temperature sintering of AlN ceramics[J].
scaffolds fabricated via direct foam writing using gelled colloidal Journal of Materials Research, 1999,14(4): 1409−1417.
particle-stabilized foams as the ink[J]. Journal of the American [59] ZHOU Y, HIRAO K, TORIYAMA M, et al. Effects of
Ceramic Society, 2019, 102(11): 6498−6506. intergranular phase chemistry on the microstructure and
[45] REN J T, YING W, ZHAO J, et al. High-strength porous mullite mechanical properties of silicon carbide ceramics densified with
ceramics fabricated from particle-stabilized foams via oppositely rare-earth oxide and alumina additions[J]. Journal of the
charged dispersants and surfactants[J]. Ceramics International, American Ceramic Society, 2001, 84(7): 1642−1644.
2019, 45(5): 6385−6391. [60] KUMAR R, CHAUBEY A K, MAITY T, et al. Mechanical and
[46] HAN Y, YANG J W, JUNG M, et al. Controlling the pore size tribological properties of Al2O3-TiC composite fabricated by
and connectivity of alumina-particle-stabilized foams using spark plasma sintering process with metallic (Ni,Nb) binders[J].
sodium dodecyl sulfate: Role of surfactant concentration[J]. Metals, 2018, 8(1): 50−58.
Langmuir, 2020, 36(35): 10331−10340. [61] TELLE R. Analysis of pressureless sintering of titanium diboride
[47] LIU J J, REN B, RONG Y D, et al. Highly porous alumina ceramics with nickel, cobalt, and tungsten carbide additives[J].
cellular ceramics bonded by in-situ formed mullite prepared by Journal of the European Ceramic Society, 2019, 39(7): 2266−
gelation-assisted Al2O3-Si particle-stabilized foams[J]. Ceramics 2276.
International, 2020, 46(8): 12282−12287. [62] COBLE R L. Initial sintering of alumina and hematite[J]. Journal
[48] AHMAD R, HA J H, SONG I H. Particle-stabilized ultra-low of the American Ceramic Society, 1958, 41(2): 55−62.
density zirconia toughened alumina foams[J]. Journal of the [63] BASU B, BALANI K. Advanced Structural Ceramics[M]. New
European Ceramic Society, 2013, 33(13/14): 2559−2564. Jersey, USA: John Wiley and Sons, 2011.
[49] GERMAN R M. Sintering Theory and Practice[M]. New York, [64] HAN Y, LI S, ZHU T B, et al. An oscillatory pressure sintering
USA: John Wiley and Sons, 1996. of zirconia powder: Rapid densification with limited grain
[50] RAHAMAN M N. Ceramic Processing and Sintering[M]. Boca growth [J]. Journal of the American Ceramic Society, 2017,
Raton, USA: CRC Press, 2003. 100(7): 2774−2780.
[51] 谢志鹏. 结构陶瓷[M]. 北京: 清华大学出版社, 2011. [65] YUAN Y, FAN J Y, LI J S, et al. Oscillatory pressure sintering
XIE Zhipeng. Structural Ceramics[M], Beijing: Tsinghua of Al2O3 ceramics[J]. Ceramics International, 2020, 46(10):
University Press, 2011. 15670−15673.
[52] GERMAN R M, PAVAN S, SEONG J P. Liquid phase sintering [66] LIU D U, ZHANG X C, FAN J Y, et al. Sintering behavior and
[J]. Journal of Materials Science 2009, 44(1): 1−39. mechanical properties of alumina ceramics exposed to
[53] ĆURKOVIĆ L, VESELI R, GABELICA I, et al. A review of oscillatory pressure at different sintering stages[J]. Ceramics
microwave-assisted sintering technique[J]. Transactions of International, 2021, 47(16): 23682−2365.
FAMENA, 2021, 45(1): 1−16. [67] LI J S, FAN J Y, YUAN Y, et al. Effect of oscillatory pressure
[54] SINGH V K. Densification of alumina and silica in the presence on the sintering behavior of ZrO2 ceramic[J]. Ceramics
of a liquid phase[J]. Journal of the American Ceramic Society, International, 2020, 46(9): 13240−13243.
1981, 64(10): 133−136. [68] ZHU T B, XIE Z P, HAN Y, et al. Microstructure and
[55] WANG H P, CHEN J M, YANG W Y, et al. Effects of Al2O3 mechanical properties of ZTA composites fabricated by
addition on the sintering behavior and microwave dielectric oscillatory pressure sintering[J]. Ceramics International, 2018,
properties of CaSiO3 ceramics[J]. Journal of the European 44(1): 505−510.
Ceramic Society, 2012, 32(3): 541−545. [69] GUILLON O, GONZALEZ‐JULIAN J, DARGATZ B, et al.
[56] LU X C, LI G S, KIM J Y, et al. Enhanced sintering of β″- Field-assisted sintering technology/spark plasma sintering:
Al2O3/YSZwith the sintering aids of TiO2 and MnO2[J]. Journal Mechanisms, materials, and technology developments[J].
of Power Sources, 2015, 295:167−174. Advanced Engineering Materials, 2014, 16(7): 830−849.
第 26 卷第 6 期 和祥,等:多孔氧化铝陶瓷材料的制备工艺研究进展 491
[70] SHEN Z J, JOHNSSON M, ZHAO Z, et al. Spark plasma [76] COLOGNA M, RASHKOVA B, RAJ R. Flash sintering of
sintering of alumina[J]. Journal of the American Ceramic nanograin zirconia in < 5 s at 850 ℃ [J]. Journal of the
Society, 2002, 85(8): 1921−1927. American Ceramic Society, 2010, 93(11): 3556−3559.
[71] MUNIR Z A, ANSELMITAMBURINI U, OHYANAGI M. The [77] COLOGNA M, RAJ R. Surface diffusion-controlled neck
effect of electric field and pressure on the synthesis and growth kinetics in early stage sintering of zirconia, with and
consolidation of materials: A review of the spark plasma without applied DC electrical field[J]. Journal of the American
sintering method[J]. Journal of Materials Science, 2006, 41(3): Ceramic Society, 2011, 94(2): 391−395.
763−777. [78] 谢志鹏, 许靖堃, 安迪. 先进陶瓷材料烧结新技术研究进展
[72] LANGER J, HOFFMANN M J, GUILLON O. Direct [J]. 中国材料进展, 2019, 38(9): 821−830, 886.
comparison between hot pressing and electric field-assisted XIE Zhipeng, XU Jingkun, AN Di. Research progress of novel
sintering of submicron alumina[J]. Acta Materialia, 2009, 57(18): sintering technology for advanced ceramic materials[J].
5454−5465. Materials China, 2019, 38(9): 821−830, 886.
[73] LIU Y, MIN F F, ZHU J B, et al. Effect of nanometer Al2O3 [79] BIESUZ M, SGLAVO V M. Flash sintering of alumina: Effect
powder on microstructure and properties of alumina ceramics by of different operating conditions on densification[J]. Journal of
microwave sintering[J]. Materials Science and Engineering A, the European Ceramic Society, 2016, 36(10): 2535−2542.
2012, 546: 328−331. [80] YOON B, YADAV D, GHOSE S, et al. Reactive flash sintering:
[74] YAN S Y, YIN Z B, YUAN J T, et al. Microstructure and MgO and α-Al2O3 transform and sinter into single-phase
properties of submicron grained alumina ceramic tool material polycrystals of MgAl2O4[J]. Journal of the American Ceramic
prepared by two-step microwave sintering[J]. Ceramics Society, 2019, 102(5): 2294−2303.
International, 2018, 44(14): 17479−17485. [81] OJAIMI C L, FERREIRA J A, CHINELATTO A L, et al.
[75] HONG D B, YUAN J T, YIN Z B, et al. Ultrasonic-assisted Microstructural analysis of ZrO2/Al2O3 composite: Flash and
preparation of complex-shaped ceramic cutting tools by conventional sintering[J]. Ceramics International, 2020, 46(2):
microwave sintering [J]. Ceramics International, 2020, 46(12): 2473−2480.
20183−20190. (编辑 汤金芝)