EFFECT OF SOLID LOADING ON THE POROUS CERAMIC PRODUCED VIA POLYMER FOAM REPLICATION METHOD

M.A.M. Nor*, H.M. Akil, & Z.A. Ahmad

Abstract

EFFECT OF SOLID LOADING ON THE POROUS CERAMIC PRODUCED VIA POLYMER FOAM REPLICATION METHOD

M.A.M. Nor*, H.M. Akil, & Z.A. Ahmad

School of Materials and Mineral Recourses, Engineering Campus, Universiti Sains Malaysia,

14300 Nibong Tebal, Seberang Prai Selatan, Pulau Pinang

Porous ceramic bodies were fabricated via the polymer foam replication method. Polyurethane (PU) template was infiltrated with porcelain slurry, followed by the removal of excess slurry, burning out of the polymer to leave a ceramic replica of the polyurethane and finally sintered at high temperature. The study was based on four batches of porcelain composition with different amount of solid loadings (30, 40, 50 and 60wt %). The structures of the sintered foams at different solid loadings were evaluated through density and porosity measurements, strength and scanning electron microscopy (SEM). Porosity and density was determined by the Archimedes method. Porosity was found to decrease as the amount of solid loading increase and vice versa. Strength determined by flexural-strength test which was increased as the amount of solid loading increases. SEM showed that the porous ceramic produced consist of open cells with spherical and irregular pore shapes.