Preparation and properties of porous alumina ceramics with uni-directionally oriented pores by extrusion method using a plastic substance as a pore former

Porous alumina ceramics with uni-directionally aligned pores were prepared by an extrusion method using 0–40 vol.% poly (vinyl acetate) (PVAC) as the pore former. A paste was prepared by mixing 25 mass% distilled water, 4 mass% methylcellulose, 8 mass% oleic acid and 0.8 mass% ammonium poly (carboxylic acid). This paste was molded into a 10 mm Ø body using a ram-type extruder, dried at room temperature for 24 h, calcined at 600 °C for 1 h and sintered at 1500 °C for 2 h in air. The PVAC added to the paste was homogeneously dispersed and formed particles 0.1–150 μm in size which extended in the extrusion direction and were converted to through-hole pores after sintering. The resulting pore size distribution in the samples was bimodal, centered at about 0.4 μm with a broad peak at about 70 μm dia. The resulting porous alumina ceramics showed high gas permeability because of their uni-directionally oriented through-hole pore structure.