Effect of polymer concentration on porosity and pore size characteristics of alumina membrane substrates prepared by gelcasting

The effect of urea–formaldehyde (UF) polymer concentration on porosity and average pore size of alumina membrane substrates prepared by gelcasting has been studied. The soluble UF oligomers formed in the initial stages of polymerization act as steric stabilizer for alumina particles in the suspension. The porosity and average pore size of the substrate samples decreased with both the decrease of amount of polymer in the gelcast body and the increase of sintering temperature. Membrane substrates obtained by sintering of gelcast bodies containing UF polymer concentrations from 24.3 to 15.6 wt% at temperatures from 1250 to 1450 °C showed porosity and average pore size of 62.5–27 vol% and 0.43–0.20 μm, respectively. The membrane substrates prepared by the gelcasting method had narrow pore size distribution.