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Porous materials are useful as lightweight structures, bone substitutes, and thermal insulators, but exhibit poor mechanical properties compared to their dense counterparts. Biological materials such as bone and bamboo are able to circumvent this trade‐off between porosity and mechanical performance by combining pores at multiple length scales. Inspired by these biological architectures, a manufacturing platform that allows for the fabrication of Al2O3 foams and Al2O3/Al composites with hierarchical porosity and enhanced mechanical properties is developed. Macroscale pores are formed through the assembly of aluminum particles around templating air bubbles in wet foams, whereas the thermal oxidation of the metal particles above 800 °C generates porosity at the micrometer scale. After elucidating the mechanism of pore formation under different sintering conditions at the microscale, the mechanical performance of the resulting hierarchical foams using compression experiments and finite element simulations is evaluated. Porous materials manufactured via this simple approach are found to reach unparalleled mechanical properties with near‐zero sintering shrinkage and minimum loss in mechanical strength. The ability to produce macroscopic objects with ultrahigh strength at porosities up to 95% makes this an attractive manufacturing technology for the fabrication of high‐performance lightweight structures or advanced thermal and acoustic insulators. [ABSTRACT FROM AUTHOR]

Hierarchical structured porous ceramics have attracted tremendous research interests because of their numerous excellent properties including robust mechanical strength and large surface area. In this work, silicon carbide (SiC)‐based porous ceramics with three levels of pore hierarchy are fabricated from silicon particle‐stabilized foams and a subsequent one‐step calcination after they were embedded with coke. Three‐dimensional (3D) flexible nanofibrous network is adhered and wrapped on cell walls of porous ceramics, which is readily fine‐tuned and tailored by the temperature to provide optimized pore structure. The resultant SiC‐based porous ceramics present a density of 1.03 g/cm3 at a porosity of 72% with a large quantity of hierarchical micro‐ and macropores. This hierarchical structure leads to robust compressive strength (23.52 MPa) and large surface area (64.32 m2/g). The fabrication method is straightforward and sought‐after, providing a facile technical route for advanced hierarchical porous ceramics used in filtration and catalysis fields. [ABSTRACT FROM AUTHOR]

An innovative approach for fabricating porous alumina ceramics (PACs) with improved mechanical and thermal properties using walnut shell powders as pore-forming agent combined with alumina sol impregnation is reported in the present work. It is demonstrated that uniform distribution of spherical pores can be observed in as-prepared PACs by using above technical route. The decrease of walnut shell powder sizes significantly promotes the enhancement of crushing strength and reduction of thermal conductivity of the PACs. Meanwhile, the impregnated alumina sol is favoring for the formation of spherical micro-pores, then further improves their mechanical and thermal insulation performances. The lowest thermal conductivity and highest crushing strength of resulting sample reach 0.16 W/m K and 29.2 MPa, respectively. This novel method offers new possibilities to fabricate high-quality PACs. [ABSTRACT FROM AUTHOR]

Abstract: In order to investigate the relationship between pore structure and thermal conductivity as well as mechanical strength, porous alumina ceramics (PAC) with various pore structures were fabricated, using starch as the pore‐forming agent. Fractal theory was employed to characterize the pore size distribution more accurately than ever used parameters. The results show that the increase in starch content in PAC leads to an enhanced porosity, a higher mean pore size, and reduced fracture dimension, thermal conductivity and strength. The fractal analysis indicated that the fractal dimension decreases gradually and reaches its minimum value with increasing the starch content up to 25 wt%, but the further incorporation results in an opposite trend. It is suggested from micro‐pore fractographic analysis that the optimization of both thermal insulation performance and mechanical strength are positively correlated with the increase in the mean pore size and proportion of 2‐14 μm pores but negatively corrected with the porosity. These results provide a new perspective and a deeper understanding for fabrication of PAC with both excellent thermal insulation and mechanical performance. [ABSTRACT FROM AUTHOR]

In order to reduce thermal conductivity but to exhibit better mechanical properties of porous alumina ceramics (PACs), a novel approach, based on the modification of pore structures (i.e. mean pore size, micro-pore proportions and pore shape factor) by impregnation of alumina sol, is reported in the present work. The properties of as-impregnated samples were compared with commercial alumina hollowsphere bricks. Results show that impregnation of alumina sol in PACs has a positive influence on pore structures, leading to a superior strength and a lower thermal conductivity. In particular, when 8 wt% alumina sol solid content is impregnated, the crushing strength (35.3 MPa) and thermal conductivity (0.15 W/m K at 200 °C) of sample are much better than that of the commercial alumina hollowsphere bricks. This novel method for excellent PACs provides promising applications as insulating lining materials in the fields of industrial furnace. [ABSTRACT FROM AUTHOR]