Preparation of AlN micro-honeycombs with high permeability via freeze-casting

Highly permeable AlN micro-honeycomb (AlN-H) ceramics with unidirectional macropore channels and porous struts were fabricated via tertiary butyl alcohol (TBA)-based freeze-casting. The effect of the AlN solid loading of the freezing slurries on the microstructure, open porosity, N₂ gas permeability, and compressive strength of the as-prepared AlN-Hs were systematically investigated. The results showed that the honeycomb structure and open porosity of the AlN-Hs can be adjusted by altering solid loading. With the increase in solid loading from 10 vol% to 30 vol%, the approximate pore channel size of the AlN-Hs decreased from 50.1 μm to 15.6 μm, strut thickness increased from 8.2 μm to 16.6 μm approximately, and the corresponding open porosity decreased from 87.6–56.6%. The as-fabricated AlN-H with an open porosity of 64.9% possessed high N₂ gas permeability and essential compressive strength and can be used as a catalyst support or filter in industries.