Chiang Mai Journal of Science

This study utilized non-metallic residue by-product obtained at aluminum ingot melting plant as the main component in the fabrication of open-cell porous ceramics. The amount which could be utilized varied in the range 34-52 wt%. Alpha-alumina, a-Al2O3 was the main crystalline phase present in all sintered porous ceramic samples. Mullite, Al6Si2O13 was present as a major second phase. The increase in compressive strength in this study mainly came from thicker solid struts in the sample skeleton. Sample containing 46 wt% non-metallic residue, sintered at 1200°C for 4 hours, gave overall excellent mechanical strengths. All the synthesized samples were free from toxic ions and they can be applied for various applications such as ceramic filters and catalysts.