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Fabrication of large alumina foams by pyrolysis of thermo-foamed alumina–sucrose

Published online by Cambridge University Press:  12 January 2016

Sujith Vijayan ,
Rajaram Narasimman Open the ORCID record for Rajaram Narasimman [Opens in a new window]  and
Kuttan Prabhakaran Open the ORCID record for Kuttan Prabhakaran [Opens in a new window]
Sujith Vijayan
Affiliation:
Department of Chemistry, Indian Institute of Space Science and Technology, Thiruvananthapuram, Kerala 695 547, India
Rajaram Narasimman
Affiliation:
Department of Chemistry, Indian Institute of Space Science and Technology, Thiruvananthapuram, Kerala 695 547, India
Kuttan Prabhakaran*
Affiliation:
Department of Chemistry, Indian Institute of Space Science and Technology, Thiruvananthapuram, Kerala 695 547, India
*
a)Address all correspondence to this author. e-mail: kp2952002@gmail.com
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Abstract

The aim of this study is to prevent cracks in large foam bodies prepared by thermo-foaming of alumina powder dispersions in molten sucrose. Cracks initiate in the binder burnout stage during which the bodies undergo shrinkage in the range of 32–49 vol% depending on sucrose content. Intermediate pyrolysis of the sucrose polymer binder prevents the cracking of large foam bodies as the carbon produced by pyrolysis binds the alumina particles during the initial stage of shrinkage and provides adequate strength to withstand the internal stresses produced during the pyrolysis and subsequent carbon burnout. The carbon bonded alumina foam bodies obtained after pyrolysis do not show any visible cracks during subsequent carbon burnout and sintering because the alumina particles establish a firm network with each other due to particle drag and rearrangement during pyrolysis of the sucrose polymer binder as evidenced from microstructure analysis. The carbon bonded alumina foam bodies show high compressive strength (2–1.3 MPa) and are amenable to machining operations such as milling and drilling without cracking.

Keywords

machiningfoamsintering
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 2 , 28 January 2016 , pp. 302 - 309
Copyright
Copyright © Materials Research Society 2016 

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References

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