Fabrication of homogeneous mullite-based fiber porous ceramics with high strength and porosity

Silica sol is widely used in the preparation of mullite-based fiber porous ceramics (MFPCs), but it aggregates at the top surface of MFPCs during the drying process. This leads to the decrease in mechanical strength and porosity. To overcome the problem and fabricate homogeneous MFPCs, the sodium silicate solution and glass fibers were applied in the fabrication process of MFPCs. The effects of concentrations of sodium silicate solution and silica sol, amounts of glass fibers and sintering temperatures on the properties of prepared MFPCs were studied. The sodium silicate solution consolidated the silica sol and mullite fibers, forming a homogeneous structure and ensuring the even distribution of silica sol. Compared with other reported MFPCs, this process required low sintering temperature while maintaining high compressive strength (2.14 MPa) and porosity (75.93%). This study provides an effective method for preparing MFPCs with high strength, uniformity and porosity. • Mullite-based fiber porous ceramics (MFPCs) with high performances were fabricated. • Sodium silicate solution and glass fibers were applied for the preparation of MFPCs. • Sodium silicate solution consolidated silica sol and ensured even distribution. • Interlaced mullite fibers and glass fibers formed 3D structures and improved strength. • The fabrication process in this study required a low sintering temperature.