Texturation of model clay materials using tape casting and freezing

• Published in: Ceramics international 2013-12, Vol.39 (8), p.9047-9053
• Main Authors: Lecomte-Nana, Gisèle, Mokrani, Amina, Tessier-Doyen, Nicolas, Boussois, Kévin, Goure-Doubi, Hervé
• Format: Article
• Language: English
• Subjects: Chemical Sciences; Clay (material); Cohesion; Drying; Freezing; Kaolin; Lyophilisation; Material chemistry; Montmorillonite; Surface layer; Tape casting; Tape casting-freezing; Texturation; Texture
• ISSN: 0272-8842; 1873-3956
• DOI: 10.1016/j.ceramint.2013.04.108

The present work aimed to investigate the processing of textural clay based materials using tape casting together with freezing. Two model raw materials were used, namely: BIP kaolin from France and ABM montmorillonite from Mediterranean region. The mixtures of both clays were studied, whereby, the amount of montmorillonite was 0, 5, 10, 20 or 50mass%. After tape casting, the as-obtained green bands were frozen into liquid nitrogen, lyophilized and then fired at 1050°C or 1200°C. The amount of montmorillonite appeared as a critical parameter that controls the cohesion of the dry products. For montmorillonite content ≥20mass%, the products exhibited multiple cracks after lyophilisation. With lower montmorillonite content, the cohesion of the dry products was satisfactorily and a macroscopic cross-linked surface texturation was observed. After calcination at 1050°C or 1200°C, the texturation appeared well defined. Moreover, calcination at 1200°C increased the densification of products and the occurrence of a glassy phase was noted. The combination of both tape casting and freezing (freeze tape casting) is a promising way to develop various clay-based and composites materials exhibiting unique microstructure organization and characteristics with potential application in the field sustainable and environmentally friendly filtration, adsorption or catalysis.