Simultaneous control of mechanical strength and hierarchical structure in freeze‐casted porous alumina by two‐step sintering

Abstract To increase mechanical strength of porous ceramics, here, an effective two‐step sintering (TSS) technique capable of producing highly porous alumina with enhanced mechanical strength is suggested. Based on the sintering theories, here, a significantly lower activation energy for densification at low temperature region allowed a beneficial temperature range for the TSS to be deduced. With a specific TSS regime ( T 1 = 1550°C and T 2 = 1400°C), significantly higher compressive strength levels (8.00–15.24 MPa) were measured with an apparent porosity of 56.49% compared to conventional sintering (1.03–1.86 MPa) with similar apparent porosity of 57.84%. Specifically, another TSS regime ( T 1 = 1550°C and T 2 = 1380°C) left submicron‐sized open pores within the lamellar walls, providing a hierarchical porous structure with enhanced mechanical strength. An evaluation of the mechanical stability by a finite element analysis indicated outstanding compressive strength even with small pores in the lamella walls.