The combination of high strength and toughness, excellent wear resistance and moderate density makes zirconia-toughened alumina (ZTA) a favorable ceramic, and the foam version of it may also exhibit excellent properties. Here, ZTA foams were prepared by the polymer sponge replication method. We developed an immersion infiltration approach with simple equipment and operations to fill the hollow struts in as-prepared ZTA foams, and also adopted a multiple recoating method (up to four cycles) to strengthen them. The solid load of the slurry imposed a significant influence on the properties of the ZTA foams. Immersion infiltration gave ZTA foams an improvement of 1.5 MPa in compressive strength to 2.6 MPa at 87% porosity, only resulting in a moderate reduction of porosity (2-3%). The Weibull modulus of the infiltrated foams was in the range of 6-9. The recoating method generated an increase in compression strength to 3.3-11.4 MPa with the reduced porosity of 58-83%. The recoating cycle dependency of porosity and compression strength is nearly linear. The immersion infiltration strategy is comparable to the industrially-established recoating method and can be applied to other reticulated porous ceramics (RPCs).
Keywords: Weibull modulus; ZTA foams; compression strength; infiltration; recoating.