The cordierite foam ceramics were successfully fabricated using direct foaming and slip casting method with plaster moulds. Kaolin, attapulgite and magnesium oxide were used as starting materials with Arabic gum added as the dispersant. The samples were sintered at 1200°C, and then the microstructure, porosity, bulk density and thermal conductivity were characterised. The results show that the cordierite foam ceramics had a porous structure of open cells and the struts had abundant small pores. The maximum open porosity achieved 87·65% with a bulk density of 329 kg m− 3, and the thermal conductivity was as low as 0·095 W (m K)− 1. Therefore, these cordierite foam ceramics show promise for use as the thermal insulator.
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