Porous alumina ceramics by spray-pyrolyzed powder from aluminum sulfate and aluminum nitrate solutions

Abstract

Porous α-alumina ceramics were prepared using the spray-pyrolyzed powder from aluminum nitrate solution and aluminum sulfate solution. Porosity and pore size distribution of the samples were examined with respect to the forming pressure and firing temperature. The porosity obtained changed from around 80% in the green compacts to 60–70% in the fired bodies fired at 1500 °C. The porosity of 30–40% remained even by firing at 1700 °C. Although there was no significant difference in the porosity of the fired bodies prepared from the sulfate and nitrate solutions, the fired bodies prepared from the nitrate solution showed apparently larger pore size than those from the sulfate solution. Fired bodies with an average pore radius from 0.2 to 0.8 μm can be prepared by this method. The four-point bending strength of the fired bodies, which had a porosity of 57% and an average pore radius of 0.23 μm, was 35 MPa.