Isothermal foaming-nucleation-crystallization of glass ceramic foams with hierarchical pore structure: A sustainable approach for disposal of secondary aluminum ash

Secondary aluminum ash (SAA) is a hazardous solid waste generated in the process of recycling aluminum. The preparation of glass ceramic foams from high content of SAA, used as nucleating and foaming agent, was proposed to achieve green and comprehensive utilization of SAA. With the help of thermodynamic phase diagram and viscosity calculation, a mixture of SAA and waste glass (WG) were transformed, at 1200 °C for 30 min, into glass ceramic foams with porosity of 45.49%–59.45%, respectively. The mean pore size of the samples decreased from 2.89 to 1.53 mm with the decrease of SAA addition. Through the adjustment of temperature, it was found that the mixture had a microporous region at 1100 °C. The expansion region was observed at 1180 °C and 1200 °C, because of the oxidation of AlN in SAA. The porosity of the samples could be raised to 64.51%, with 5–9% B2O3 as a supplement, which contributed to the development of the liquid phase and a decrease in the melt's viscosity. The mechanism of in-situ isothermal foaming, nucleation, and crystallization of SAA and WG was clarified. The crystal intensity dropped and the amorphous phase became the primary phase at 800 °C. Al2O3, sodium silicate and sodium aluminum silicate precipitated at 1000 °C. Al2O3 and spinel with high melting point were wrapped by silicate. Silicate turned into the melt again as the temperature continued to rise. With the further reduction of viscosity, the gas diffused in crystalline and amorphous phases, and finally forms glass ceramic foams with hierarchical pore structure.