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Freeze-casting

Freeze-casting is a technique that exploits the highly anisotropic solidification behavior of a solvent (generally water) in a well-dispersed slurry to template controllably a directionally porous ceramic. By subjecting an aqueous slurry to a directional temperature gradient, ice crystals will nucleate on one side of the slurry and grow along the temperature gradient. The ice crystals will redistribute the suspended ceramic particles as they grow within the slurry, effectively templating the ceramic.

Once solidification has ended, the frozen, templated ceramic is placed into a freeze-dryer to remove the ice crystals. The resulting green body contains anisotropic macropores in an replica of the sublimated ice crystals and micropores found between the ceramic particles in the walls. This structure is often sintered to consolidate the particulate walls and provide strength to the porous material. The porosity left by the sublimation of solvent crystals is typically between 2 - 200 μm.