Skip to main content
×
×
Home

Lightweight and stiff cellular ceramic structures by ice templating

  • Florian Bouville (a1), Eric Maire (a2) and Sylvain Deville (a3)
Abstract

Porous, strong, and stiff ceramic materials are required for a range of technical applications, involving for instance, liquid or gas flow. Natural materials such as wood can provide useful structural guidelines for the optimal microstructural design, although only few processing routes are able to turn these guidelines into actual materials. We illustrate here, how ice templating of anisotropic particle suspensions can be modified to obtain a honeycomb structure with pores of 30 µm diameter. The growth of ice crystals in the slurry induces self-assembly of the anisotropic particles, leading to relatively thin walls (10 µm). Because large anisotropic particles are difficult to sinter, a glassy phase was introduced to facilitate this densification step and then to further reduce the walls' porosity. Young's modulus and compressive strength were both improved by the addition of a glassy phase by an order of magnitude due to the denser walls. These macroporous materials are more robust and stiff than materials with an equivalent morphology, while offering a simple alternative to the current wood replica processing routes.

Copyright
Corresponding author
a)Address all correspondence to this author. e-mail: florian.bouville@saint-gobain.com
References
Hide All
1.Gibson, L.J. and Ashby, M.F.: Cellular Solids: Structure and Properties (Cambridge University Press, 1999), p. 532.
2.Da Silva, A. and Kyriakides, S.: Compressive response and failure of balsa wood. Int. J. Solids Struct. 44, 86858717 (2007).
3.Scheffler, M. and Colombo, P.: Cellular Ceramics: Structure, Manufacturing, Properties and Applications (Wiley-VCH, Weinheim, 2005), p. 670.
4.Isobe, T., Kameshima, Y., Nakajima, A., Okada, K., and Hotta, Y.: Gas permeability and mechanical properties of porous alumina ceramics with unidirectionally aligned pores. J. Eur. Ceram. Soc. 27, 5359 (2007).
5.Greil, P., Lifka, T., and Kaindl, A.: Biomorphic cellular silicon carbide ceramics from wood: II. Mechanical properties. J. Eur. Ceram. Soc. 18, 19751983 (1998).
6.Vogli, E., Sieber, H., and Greil, P.: Biomorphic SiC-ceramic prepared by Si-vapor phase infiltration of wood. J. Eur. Ceram. Soc. 22, 26632668 (2002).
7.Rambo, C.R.: Microcellular Al2O3 ceramics from wood for filter applications. J. Am. Ceram. Soc. 91, 852859 (2008).
8.Studart, A.R., Gonzenbach, U.T., Tervoort, E., and Gauckler, L.J.: Processing routes to macroporous ceramics: A review. J. Am. Ceram. Soc. 89, 17711789 (2006).
9.Deville, S.: Ice templating, freeze casting: Beyond materials processing. J. Mater. Res. 28, 118 (2013).
10.Hong, C., Zhang, X., Han, J., Du, J., and Han, W.: Ultra-high-porosity zirconia ceramics fabricated by novel room-temperature freeze-casting. Scr. Mater. 60, 563566 (2009).
11.Moon, Y-W., Shin, K-H., Koh, Y-H., Choi, W-Y., and Kim, H-E.: Porous alumina ceramics with highly aligned pores by heat-treating extruded alumina/camphene body at temperature near its solidification point. J. Eur. Ceram. Soc. 32, 10291034 (2012).
12.Fukushima, M., Nakata, M., and Yoshizawa, Y.: Fabrication and properties of ultra highly porous cordierite with oriented micrometer-sized cylindrical pores by gelation and freezing method. J. Ceram. Soc. Jpn. 116, 13221325 (2008).
13.Fukushima, M., Nakata, M., Zhou, Y., Ohji, T., and Yoshizawa, Y.: Fabrication and properties of ultra highly porous silicon carbide by the gelation–freezing method. J. Eur. Ceram. Soc. 30, 28892896 (2010).
14.Deville, S., Saiz, E., Nalla, R.K., and Tomsia, A.P.: Freezing as a path to build complex composites. Science 311, 515518 (2006).
15.Qiu, L., Liu, J.Z., Chang, S.L.Y., Wu, Y., and Li, D.: Biomimetic superelastic graphene-based cellular monoliths. Nat. Commun. 3, 1241 (2012).
16.Hunger, P.M., Donius, A.E., and Wegst, U.G.K.K.: Platelets self-assemble into porous nacre during freeze casting. J. Mech. Behav. Biomed. Mater. 19, 8793 (2013).
17.Lee, J. and Deng, Y.: The morphology and mechanical properties of layer structured cellulose microfibril foams from ice-templating method. Biomacromolecules 7, 6034 (2011).
18.Deville, S.: Ice shaping properties, similar to that of antifreeze proteins, of a zirconium acetate complex. PLoS One 6, e26474 (2011).
19.Deville, S., Viazzi, C., and Guizard, C.: Ice-structuring mechanism for zirconium acetate. Langmuir 28, 1489214898 (2012).
20.Sekhar, J.A. and Trivedi, R.: Solidification microstructure evolution in the presence of inert particles. Mater. Sci. Eng., A 147, 921 (1991).
21.Vural, M. and Ravichandran, G.: Microstructural aspects and modeling of failure in naturally occurring porous composites. Mech. Mater. 35, 523536 (2003).
22.Shanti, N.O., Araki, K., and Halloran, J.W.Particle redistribution during dendritic solidification of particle suspensions. J. Am. Ceram. Soc. 89, 24442447 (2006).
23.Seabaugh, M.M., Kerscht, I.H., and Messing, G.L.: Texture development by templated grain growth in liquid phase sintered alpha-alumina. J. Am. Ceram. Soc. 80, 11811188 (1997).
24.Pavlacka, R.J. and Messing, G.L.: Processing and mechanical response of highly textured Al2O3. J. Eur. Ceram. Soc. 30, 29172925 (2010).
25.Peppin, S.S.L., Elliott, J.A.W., and Worster, M.G.: Solidification of colloidal suspensions. J. Fluid Mech. 554, 147 (2006).
26.Gonzenbach, U.T., Studart, A.R., Tervoort, E., and Gauckler, L.J.: Macroporous ceramics from particle-stabilized wet foams. J. Am. Ceram. Soc. 90, 1622 (2007).
27.Hunger, P.M., Donius, A.E., and Wegst, U.G.K.: Structure-property-processing correlations in freeze-cast composite scaffolds. Acta Biomater. 9, 63386348 (2013).
28.Yoon, H-J.: Macroporous alumina ceramics with aligned microporous walls by unidirectionally freezing foamed aqueous ceramic suspensions. J. Am. Ceram. Soc. 1582, 20092011 (2010).
29.Han, J., Hong, C., Zhang, X., Du, J., and Zhang, W.: Highly porous ZrO2 ceramics fabricated by a camphene-based freeze-casting route: Microstructure and properties. J. Eur. Ceram. Soc. 30, 5360 (2010).
Recommend this journal

Email your librarian or administrator to recommend adding this journal to your organisation's collection.

Journal of Materials Research
  • ISSN: 0884-2914
  • EISSN: 2044-5326
  • URL: /core/journals/journal-of-materials-research
Please enter your name
Please enter a valid email address
Who would you like to send this to? *
×

Metrics

Altmetric attention score

Full text views

Total number of HTML views: 0
Total number of PDF views: 0 *
Loading metrics...

Abstract views

Total abstract views: 0 *
Loading metrics...

* Views captured on Cambridge Core between <date>. This data will be updated every 24 hours.

Usage data cannot currently be displayed