Fabrication of Alumina-Zirconia Foam Using Foam Replication Method

Abstract

Phase-stabilized zirconia (ZrO₂) and aluminium oxide (Al₂O₃) are popular structural materials due to their high wear resistance, biocompatibility, and corrosion resistance. This thesis explores the fabrication of Alumina Zirconia foam through the foam replication method. The study investigates the effects of different compositions of alumina (Al₂O₃), zirconia (ZrO₂), and kaolinite on the properties of alumina-zirconia composite foam. The objectives of this research are to fabricate alumina-zirconia (Al₂O₃+ZrO₂) composite foam with open and interconnected pores, investigate the physical and mechanical properties of Al₂O₃+ZrO₂ composite foam with different compositions of Al₂O₃, ZrO₂, and kaolinite, and observe the microstructure of Al₂O₃+ZrO₂ composite foam with different compositions of Al₂O₃, ZrO₂, and kaolinite. Five different compositions (C1 to C5) were prepared and analysed. The methodology involves a series of steps including slurry mixing, PU foam dipping and squeezing, drying, sintering, and testing including microstructure analysis, density and porosity test, compression tests and followed by data analysis. Microstructure analysis was done to analyse the size and shape of pores, struts and pores distribution. The results showed that composition C2 with 22.5wt% alumina powder, 22.5wt% kaolin powder, 5 wt% zirconia powder, 2.5 wt% PEG powder, 2.5 wt% CMC powder, and 45 wt% distilled water had a strong structure with minimal shrinkage but showed significant compression strength compared to other compositions.