Freeze-casting of porous ceramics has seen significant research efforts in recent years. This review provides an overview of the current understanding and challenges of the process, highlighting the unique structure and properties of freeze-cast ceramics, which have opened new opportunities in cellular ceramics. The process involves freezing a liquid suspension, followed by sublimation of the solidified phase and sintering to form a porous structure. The technique is versatile, with the use of a liquid solvent (often water) as a pore-forming agent. Freeze-casting has also been developed as a near-net shape forming technique, yielding dense ceramics.
The process consists of four steps: slurry preparation, controlled solidification, sublimation of the solvent, and sintering. The structure of the final product is influenced by the choice of solvent, slurry formulation, and solidification conditions. A wide variety of ceramic materials have been tested using this technique, including alumina, hydroxyapatite, silicon nitride, and others. The porosity of the sintered materials is a replica of the original solvent crystals, and the morphology of the pores can vary depending on the solvent used.
The structure of freeze-cast ceramics can be controlled by adjusting the solidification conditions, leading to different orientations of the porosity. The properties of the materials, such as compressive strength, are influenced by the porosity and morphology of the structure. Freeze-cast ceramics have shown promising potential in various applications, including biomaterials, chemical processes, energy sources, and photocatalysis. However, challenges remain in controlling the structure, achieving uniform porosity, and scaling up the process for industrial applications. Future perspectives include improving the control of the structure, developing functional structures, and exploring new applications for freeze-cast ceramics.Freeze-casting of porous ceramics has seen significant research efforts in recent years. This review provides an overview of the current understanding and challenges of the process, highlighting the unique structure and properties of freeze-cast ceramics, which have opened new opportunities in cellular ceramics. The process involves freezing a liquid suspension, followed by sublimation of the solidified phase and sintering to form a porous structure. The technique is versatile, with the use of a liquid solvent (often water) as a pore-forming agent. Freeze-casting has also been developed as a near-net shape forming technique, yielding dense ceramics.
The process consists of four steps: slurry preparation, controlled solidification, sublimation of the solvent, and sintering. The structure of the final product is influenced by the choice of solvent, slurry formulation, and solidification conditions. A wide variety of ceramic materials have been tested using this technique, including alumina, hydroxyapatite, silicon nitride, and others. The porosity of the sintered materials is a replica of the original solvent crystals, and the morphology of the pores can vary depending on the solvent used.
The structure of freeze-cast ceramics can be controlled by adjusting the solidification conditions, leading to different orientations of the porosity. The properties of the materials, such as compressive strength, are influenced by the porosity and morphology of the structure. Freeze-cast ceramics have shown promising potential in various applications, including biomaterials, chemical processes, energy sources, and photocatalysis. However, challenges remain in controlling the structure, achieving uniform porosity, and scaling up the process for industrial applications. Future perspectives include improving the control of the structure, developing functional structures, and exploring new applications for freeze-cast ceramics.