Fabrication of porous Al2O3-based ceramics using combustion synthesized powders

Porous Al2O3-based ceramics were fabricated from powders synthesized via a solution combustion process using starch and urea as fuels. Effects of the relative fuel-to-oxidant ratio (φe = 1.4, 1.6, 1.8 and 2.0, respectively) on open porosity, pore size distribution and flexural strength of the as-prepared porous Al2O3-based ceramics were investigated. Experimental results revealed that the densification ability of the as-synthesized powders increased significantly as φe increased, and open porosity, pore size distribution and flexural strength of the porous ceramics exhibited remarkable dependence on the densification ability of the powders instead of the weight fraction of the charred organic residuals in the powders. SEM micrographs disclosed that the porous ceramics from the precursors with φe = 1.8 or 2.0 exhibited significantly homogenous microstructures including pore size and pore distribution.