Feasibility study of producing alumina foam by plasma spraying

Abstract

Plasma spraying was utilized as a tool to produce alumina (AI₂ O₃) foam based on a new methodology. Blended powder of A1₂ O₃ and calcium oxide (CaO) of different composition was plasma sprayed on predesigned moulds. The sprayed specimens were subsequently treated in water and glycerol in an ultrasonic cleaner at 80°C selectively to dissolve CaO and retain the A1₂ O₃ matrix. Microstructural investigation showed a slight porosity similar to that observed in the plasma-sprayed coatings in the assprayed untreated specimens, which after treatment in water and glycerol exhibited a considerable increase in the extent of porosity. X-ray diffractometry (XRD) studies confirmed the dissolution of CaO, giving rise to porosity, as exhibited by the presence of peaks corresponding to CaO in the as-sprayed material and its absence after water and glycerol treatments.

Keywords

alumina plasma spraying ceramic foam microstructure porosity

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