Fabrication of conductive porous alumina (CPA) structurally modified with carbon nanotubes (CNT)

A novel binary porous composite nano-carbon networks (NCNs)/alumina, which is denoted as electrically conductive porous alumina (CPA), was structurally modified by carbon nanotubes (CNT) pre-treated with mixed concentrated acids at 60 °C for 6 h in this study. This conductive ceramics (CCs) was fabricated by combination of gelcasting and high temperature reductive sintering (HTRS) in novel atmosphere. CNT pre-treatment leading to the increased hydrophilicity makes it possible to make uniformly dispersed CNT/alumina slurry. And by HTRS in Ar at 1700 °C for 2 h, well-gelled polymer net-paths in green body prepared by gelcasting technology were totally converted to nano-carbon networks (NCNs) without destruction of CNT. NCN with graphitic crystal structure was evaluated by Raman spectroscopy in sintered ceramic body. Moreover, comparing with as-received CNT, the decreased surface defect of detected composite also supported the further graphitization of CNT via HTRS in Ar instead of burning out. With the aid of field-emission scanning electronic microscopy (FE-SEM) observation, the increased alumina grains in sintered ceramic body CNT/NCN/alumina was valid. Moreover, it was demonstrated that there were three components in this composite, which is carbon filler with two different forms (CNT and NCN) and alumina matrix. And these three components CNT covered with Al2O3 particles (Al2O3/CNT), NCN and alumina grains (alumina) co-exist in four different situations as follows: (a) Al2O3/CNT–alumina co-junction, (b) Al2O3/CNT–NCN co-junction, (c) Al2O3/CNT–alumina–NCN and (d) Al2O3/CNT mesh between alumina boundaries. Furthermore, by comparing with binary composite NCN/alumina (CPA), the increased flexural strength of ternary composite CNT/NCN/alumina (CNT/CPA) up to 38 MPa was attributed to the reinforcement CNT acting as elastic bridge in composite.