Aluminum titanate based composite porous ceramics with both high porosity and mechanical strength prepared by a special two-step sintering method

In this work, we develop a two-step sintering technology special for porous ceramics to resolve the contradiction between porosity and mechanical strength. It contains a first long-time sintering at the relatively low temperature (T1) and a second fast sintering at higher temperature (T2). Porous ceramics of aluminum titanate-strontium feldspar-mullite (ASM) ternary composite were prepared by this method, and exhibit both high porosity and high mechanical strength. The effects of T1 and T2 on the phase composition, microstructure, porosity, pore size distribution, mechanical strength and thermal expansion coefficient (TEC) of ASM porous ceramics are systematically studied. The sample sintered at T1 = 1400 °C & T2 = 1500 °C shows optimum performance: the porosity, bulk density, and mean pore diameter (D50) are 63.48%, 1.20 g/cm3 and 15.94 μm, respectively; while the flexural strength reaches 9.22 MPa and the TEC is 2.9 × 10−6/K. The two-step sintering technology provides a powerful tool to develop porous ceramics with excellent comprehensive properties. [Display omitted] •This work develops a special two-step sintering technology for porous ceramics.•Excellent comprehensive properties achieved in aluminum titanate-strontium feldspar-mullite composite porous ceramics.•The sample sintered at T1 = 1400 °C & T2 = 1500 °C shows optimized porous and mechanical performances.