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<p>Porous mullite ceramics possess significant application value in the domains of high-temperature heat insulation and catalysis, attributed to their low thermal conductivity, high specific surface area, and exceptional thermal shock stability. However, the intricate pore structure results in a reduction of strength and diminished resistance to alkali corrosion, thereby constraining its industrial applicability. In this study, an innovative approach was employed by utilizing MgO@(C<sub>6</sub>H<sub>10</sub>O<sub>5</sub>)n as a pore-forming agent to induce an in situ reaction. This process facilitated the formation of a magnesium aluminate spinel protective layer (with a thickness ranging from 1 to 10&#xa0;μm) on the pore walls of porous mullite ceramics. The resulting novel porous ceramic achieves a compressive strength of 66.81&#xa0;MPa, demonstrating a significant improvement over ceramics fabricated using corn starch as a pore-forming agent and direct incorporation of MgO into the raw materials via mechanical mixing. Furthermore, after undergoing an alkali corrosion resistance test represented by K<sub>2</sub>CO<sub>3</sub>, the residual strength retention rate is recorded at 66.74%. Additionally, through analyzing both the Kirkendall pore inhibition effect and the protective mechanism provided by magnesium aluminate spinel within these materials, this research offers novel insights for designing high-performance porous ceramics.</p>

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Synergistic enhancement mechanism of mechanical-alkali corrosion resistance of porous mullite ceramics with in situ built spinel layers on inner pore surfaces

  • 期刊论文

  • 发表日期：

    2026年3月15日

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  • Zecheng Yan,
  • Jun Yu,
  • Jingjie Li,
  • Pengda Zhao

摘要

Porous mullite ceramics possess significant application value in the domains of high-temperature heat insulation and catalysis, attributed to their low thermal conductivity, high specific surface area, and exceptional thermal shock stability. However, the intricate pore structure results in a reduction of strength and diminished resistance to alkali corrosion, thereby constraining its industrial applicability. In this study, an innovative approach was employed by utilizing MgO@(C6H10O5)n as a pore-forming agent to induce an in situ reaction. This process facilitated the formation of a magnesium aluminate spinel protective layer (with a thickness ranging from 1 to 10 μm) on the pore walls of porous mullite ceramics. The resulting novel porous ceramic achieves a compressive strength of 66.81 MPa, demonstrating a significant improvement over ceramics fabricated using corn starch as a pore-forming agent and direct incorporation of MgO into the raw materials via mechanical mixing. Furthermore, after undergoing an alkali corrosion resistance test represented by K2CO3, the residual strength retention rate is recorded at 66.74%. Additionally, through analyzing both the Kirkendall pore inhibition effect and the protective mechanism provided by magnesium aluminate spinel within these materials, this research offers novel insights for designing high-performance porous ceramics.